A wire stranding device for wire core production

Abstract

This application relates to a wire stranding device, which comprises a first, second, and third wire separating reel arranged sequentially along the wire inlet direction, each reel being an array of concentric through holes. A first and second wire die are located at the center of the second and third reels, respectively, and a third wire die is located at the wire inlet. A single wire passes through the first reel, and a first predetermined number of wires are stranded into a first bundle between the first and second reels and then limited in diameter by the first wire die. The remaining wires form a second bundle between the second and third reels and are limited in diameter by the second wire die. Finally, the remaining wires form a third bundle between the third reel and the third wire die and enter the main body through the third wire die. This stranding device employs a combination of segmented bundling and cascaded diameter limiting, and a design that matches the number of strands / tension in the axial free sections between the reels and the wire dies, resulting in a denser wire core, better roundness, adaptability to high-speed, long-pitch extrusion, and improved concentricity and electrical and mechanical performance consistency.

Description

Technical Field

[0001] This invention relates to a wire core production apparatus, and more particularly to a wire stranding apparatus for wire core production. Background Technology

[0002] In cable manufacturing, multiple metal filaments need to be converged into concentric, layered cores in the stranding section to meet the requirements of geometric stability and dimensional consistency in subsequent processes such as extrusion, cabling, and coiling. Typical applications include power cables, electronic conductors, wiring harnesses for automotive and rail transportation, and communication signal lines. Production lines commonly feature high-speed winding, long pitch, and multi-strand parallel operation, placing higher demands on filament path control, tension balance, and pre-forming quality. Simultaneously, the density (small gaps between filaments), roundness (close to a perfect circle), and surface smoothness of the core cross-section directly affect the conductor's electrical properties, mechanical fatigue life, and the concentricity and appearance of the subsequent extruded layers.

[0003] Existing technologies typically involve setting one or two perforated wire separating plates (or guide plates) on the wire inlet side of the stranding machine. These plates utilize a concentric array of holes to guide multiple strands of monofilament in a one-to-one correspondence. Additionally, a single wire mold is usually installed at the wire inlet for sizing and pressing.

[0004] However, in actual production, the above-mentioned structure generally suffers from the problem that the individual filaments are not fully positioned and rearranged within or between layers before entering the single or a small number of filaments. This results in the strands springing back and migrating laterally after a single strong compression, leading to larger gaps between the filaments in the cross-section. Furthermore, because the axial "free section" length before and after the filament changes asynchronously with the number of strands and tension, the interlayer stress is uneven, causing the outer ring to be easily stretched or flattened, resulting in a large deviation in the roundness of the finished product. Therefore, the cores produced by existing stranding devices often exhibit problems such as insufficient core tightness, large gaps between filaments, and insufficient roundness of the outer ring profile. Summary of the Invention

[0005] The purpose of this invention is to provide a stranding device for wire core production that has multiple wire splitters arranged coaxially on the wire inlet side and corresponding wire molds configured at different bundling stages with matching axial free section lengths. This device allows each layer of monofilaments to be stably positioned in the corresponding bundling area and then its cross-sectional shape to be locked by a diameter limit, thereby effectively reducing the gap between wires, improving the roundness and surface density of the wire core, and taking into account tension balance and process stability under high-speed production.

[0006] The technical solution adopted by the present invention to solve the above problems is: a metal wire stranding device for core production, comprising a main body and an inlet provided on one side of the main body along the direction of wire entry; the stranding device further comprises a first wire separating disc, a second wire separating disc, and a third wire separating disc arranged coaxially along the direction of wire entry; each of the first wire separating disc, the second wire separating disc, and the third wire separating disc is provided with an array of through holes formed by a plurality of through holes on multiple concentric circles with their respective geometric centers as centers; a first wire mold and a second wire mold for passing through and bundling metal wires are respectively provided at the geometric centers of the second wire separating disc and the third wire separating disc, and a third wire mold is provided at the inlet;

[0007] The stranding device is configured such that: after the metal wires from the pay-off end pass through the through holes of the first splitter in a one-to-one correspondence manner, a first predetermined number of metal wires are guided to a first bundling area located between the first and second splitter, where they are stranded to form a first bundle, which then passes through the first wire mold and is limited in diameter; after the remaining metal wires pass through the through holes of the second splitter in a one-to-one correspondence manner, a second predetermined number of metal wires are guided to a second bundling area located between the second and third splitter, where they are stranded outside the first bundle to form a second bundle, which then passes through the second wire mold and is limited in diameter; after the remaining metal wires pass through the through holes of the third splitter in a one-to-one correspondence manner, they are guided to a third bundling area located between the third splitter and the third wire mold, where they are stranded outside the second bundle to form a third bundle, which then passes through the third wire mold and enters the main body through the inlet, completing the stranding of the wire cores.

[0008] Preferably, the first preset quantity is 7 wires, the second preset quantity is 12 wires, and after forming the second bundle, there are 18 remaining metal wires, which are twisted together with the second bundle to form the third bundle.

[0009] Preferably, the number of through holes in the through hole array along each concentric circle is evenly distributed according to a 6n rule, where n is a positive integer.

[0010] Preferably, the through-hole array is composed of three concentric circle arrays, and the number of through holes in the three concentric circle arrays is respectively matched with the number of strands of metal wires forming the first bundle, the second bundle, and the third bundle. In addition, another through hole is provided at the geometric center of the first wire divider and is coaxially arranged with the first wire mold.

[0011] Preferably, the first die, the second die, and the third die are all replaceable sizing dies. The first die, the second die, and the third die are provided with an inlet fillet section and a sizing section in sequence along the wire feeding direction, wherein the fillet radius R of the inlet fillet section is 0.3mm to 1.0mm.

[0012] Preferably, the first splitter, the second splitter, and the third splitter are all connected to the main body via the adjustable mounting assembly, the adjustable mounting assembly comprising:

[0013] An adjustment shaft with a scale is provided on the inlet side of the main body. The axis of the adjustment shaft is parallel to the inlet direction. Slots are provided on the first splitter plate, the second splitter plate, and the third splitter plate. The adjustment shaft passes through the slots of the first splitter plate, the second splitter plate, and the third splitter plate.

[0014] Three locking mechanisms are provided, each of which is connected to the first, second, and third splitter discs in a one-to-one correspondence, to adjust the relative motion state of the first, second, and third splitter discs with respect to the adjusting shaft.

[0015] Preferably, each of the through holes of the first, second, and third splitter discs is provided with a low-friction bushing, and the entrance of each through hole is provided with a chamfer or a slightly rounded corner.

[0016] Preferably, the stranding device further includes a fourth wire die, disposed between the third splitter and the third wire die. The fourth wire die is located on the infeed path between the third splitter and the third wire die, and is used to pre-compress and limit the diameter of the third bundle before it enters the third wire die. The fourth wire die is a replaceable sizing die, and the fourth wire die is provided with an inlet fillet section and a sizing section in sequence along the infeed direction, wherein the fillet radius R of the inlet fillet section is 0.3mm to 1.0mm.

[0017] Preferably, the axial distance between the fourth wire mold and the third wire mold is 3cm to 4cm, the axial distance between the fourth wire mold and the third wire divider is 25cm to 27cm, the axial distance between the third wire divider and the second wire divider is 14cm to 16cm, and the axial distance between the second wire divider and the first wire divider is 13cm to 15cm.

[0018] Preferably, the sizing aperture of the fourth die is larger than that of the third die, and the fourth die is coaxially arranged with the third die.

[0019] The beneficial effects of the embodiments of the present invention are as follows:

[0020] 1. Due to the adoption of a first, second, and third branching reels arranged coaxially along the wire inlet direction, along with a concentric array of through holes on each reel, and the sequential placement of the first, second, and third wire molds at the second, third, and inlet reels, the metal wires are first twisted into place in the first, second, and third bundling areas, and then bound together in segments by the corresponding wire mold diameter limiting and locking mechanism. Furthermore, an axial free section matching the number of strands / tension at each layer is formed between each branching reel and the wire mold. Therefore, each layer of monofilament can achieve adaptive helix angle and intra-layer / inter-layer contact before entering the corresponding wire mold. Once in place and entering the die, only geometric locking and micro-compression are performed, effectively solving the problems in existing technologies such as springback and lateral migration caused by one-time strong pressure before the single filament is fully in place, uneven interlayer stress caused by asynchronous changes in the free section before and after the die and the number of strands / tension, insufficient core density and insufficient outer circumference. This results in a significant reduction in the average gap between filaments in the cross-section of the finished core under the same diameter and tension conditions, a significant decrease in the outer ellipticity, a denser surface, and stable production that can adapt to high-speed wire feeding and long pitch conditions. At the same time, it is beneficial to the subsequent improvement of the concentricity and appearance consistency of the extruded layer, as well as the consistency of conductor electrical properties and fatigue life.

[0021] 2. Based on the structure of segmented bundling and cascaded diameter limiting, a 7 / 12 / 18 layered strand arrangement is further adopted, and the through-hole array of each splitter disc is evenly distributed according to a 6n pattern and consists of three concentric circles of holes. The number of holes in the three circles matches the number of strands in the three layers of bundling. A through-hole coaxial with the first wire mold is added at the geometric center of the first splitter disc to provide an axial reference and straight-through guidance. At the same time, a fourth wire mold is added between the third splitter disc and the third wire mold. The fourth wire mold is a replaceable sizing structure with an inlet fillet radius of 0.3mm to 1.0mm. The axial distances between the fourth and third wire molds, the third and fourth wire molds, the second and third splitter discs, and the first and second splitter discs are limited to 3cm to 4cm, 25cm to 27cm, and 14cm to 16cm, respectively. By employing techniques such as 13cm to 15cm spacing and ensuring the fourth die has a larger aperture than the third die and is coaxial with it, uniform circumferential distribution and full positioning of each layer of strands can be achieved before entering the corresponding die. A free section is left between pre-compression and final compression to match the number of strands and tension evolution, and to share the sizing load. This effectively solves the problems in existing technologies, such as springback and lateral migration caused by one-time strong pressure, uneven interlayer stress due to asynchronous free sections and strand / tension at the front and rear of the die, large gaps between wires and insufficient outer circle roundness, and concentrated friction and surface scratches at path intersections. This results in a more compact and dense core cross-section, significantly improved outer circle roundness, more balanced tension and contact pressure along the circumference, better surface quality and coaxiality, and stable forming under high-speed feeding and long-pitch conditions, which is beneficial for the consistency of subsequent extrusion and reliable improvement of the conductor's electromechanical properties. Attached Figure Description

[0022] Figure 1 A schematic structural diagram of a twisting device proposed in one embodiment of the present invention is shown.

[0023] Figure 2 This diagram illustrates a schematic structure in one embodiment of the present invention, showing a first splitter, a second splitter, and a third splitter mounted on an adjustable mounting assembly.

[0024] Figure 3 A schematic structural diagram of the first distribution plate proposed in one embodiment of the present invention is shown.

[0025] Figure 4 A schematic structural diagram of the second distribution plate proposed in one embodiment of the present invention is shown.

[0026] Figure 5 A schematic structural diagram of the third distribution plate proposed in one embodiment of the present invention is shown.

[0027] The components are as follows: 10, main body; 110, inlet; 20, adjustable mounting component; 210, adjusting shaft; 220, locking mechanism; 30, first dividing plate; 40, second dividing plate; 50, third dividing plate; 60, first wire mold; 70, second wire mold; 80, third wire mold; 90, fourth wire mold. Detailed Implementation

[0028] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0029] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this application. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0030] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0031] See Figures 1 to 5A preferred embodiment of this application provides a stranding device for stranding multiple metal wires in wire core production. The stranding device includes a main body 10 and an inlet 110 disposed on one side of the main body 10 along the wire infeed direction. The stranding device also includes a first wire distributor 30, a second wire distributor 40, and a third wire distributor 50 arranged coaxially along the wire infeed direction. Each of the first wire distributor 30, the second wire distributor 40, and the third wire distributor 50 has an array of through holes formed by multiple concentric circles with their respective geometric centers as centers. The second wire distributor 40 and the third wire distributor 50 are respectively provided with a first wire mold 60 and a second wire mold 70 for the metal wires to pass through and bundle together, and a third wire mold 80 is provided at the inlet 110. The stranding device is configured such that: after the wires from the pay-off end pass through the through holes of the first splitter 30 in a one-to-one correspondence manner, a first predetermined number of wires are guided to a first bundling area located between the first splitter 30 and the second splitter 40, where they are stranded to form a first bundle, which then passes through the first wire mold 60 and is diameter-limited; after the remaining wires pass through the through holes of the second splitter 40 in a one-to-one correspondence manner, a second predetermined number of wires are guided to a section located between the second splitter 40 and the third splitter 40. The second bundled area between 50 and the first bundle is formed by twisting the wires together outside the second bundle. The second bundle then passes through the second wire mold 70 and is limited in diameter. The remaining metal wires pass through the through holes of the third wire distributor 50 in a one-to-one correspondence manner and are guided to the third bundled area located between the third wire distributor 50 and the third wire mold 80. The wires are twisted together outside the second bundle in the third bundled area to form a third bundle. The third bundle passes through the third wire mold 80 in sequence and enters the main body 10 through the inlet 110 to complete the wire core twisting.

[0032] Specifically:

[0033] Each wire distributor has an array of through holes arranged in multiple concentric circles centered on its geometric center. These through holes guide the metal wires from the pay-off end in a specific path. The second and third wire distributors 40 and 50 have a first wire mold 60 and a second wire mold 70 at their respective geometric centers, and a third wire mold 80 at the wire inlet 110. Each wire mold is coaxial with its geometric center, forming a continuous guiding and sizing path together with the array of through holes. Each wire distributor can be made of sheet metal or engineering plastic, and its surface can be polished or hardened. The wire molds can be made of wear-resistant material, and the inlet can have a smooth transition to reduce guide resistance. Each wire distributor is fixedly connected to the main body 10 via a mounting base or support, ensuring that the wire distributors, wire molds, and the wire inlet 110 are on the same axis, forming a wire passage from the pay-off end to the main body 10.

[0034] During operation, the metal wires from the pay-off end first pass through the through holes of the first distributor 30, completing the initial sorting and alignment. A first predetermined number of wires are guided to the first bundling area between the first distributor 30 and the second distributor 40, where they intertwine and twist to form a first bundle. This first bundle then passes through the first wire die 60 located at the geometric center of the second distributor 40 for diameter limiting and cross-sectional stabilization. The remaining metal wires continue to pass through the through holes of the second distributor 40 and are guided to the second bundling area between the second distributor 40 and the third distributor 50. In this area, they twist outside the first bundle to form a second bundle, which then passes through the second wire die 70 located at the geometric center of the third distributor 50 for diameter limiting. The remaining metal wires pass through the through holes of the third splitter 50 and are guided to the third bundling area between the third splitter 50 and the third wire mold 80 located at the inlet 110. In this area, they are twisted together outside the second bundling to form a third bundling. The third bundling then passes through the third wire mold 80 and enters the main body 10 through the inlet 110, completing the subsequent stranding process of the wire core. In the above process, the through hole array provides stable radial position constraints, each bundling area provides positioning space within and between layers, and each wire mold limits the diameter and locks the cross-section of the positioned bundling, thereby ensuring the continuity and coaxiality of the stranding path.

[0035] Before starting the device, the coaxiality of each wire distribution plate and the wire mold is corrected, the through holes are checked for unobstructedness and surface cleanliness, and the relative position of the wire inlet 110 and the third wire mold 80 is confirmed to be accurate. During the wire guiding stage, low tension is used to guide the wires, allowing each strand to pass smoothly through the corresponding through holes and enter the corresponding bundling area. After entering stable operation, the strands in each bundling area maintain a predetermined spiral relationship under tension and form stable contact with adjacent strands. If individual strand tension fluctuations or path disturbances occur, the through hole array restricts their radial displacement, the bundling area provides space for repositioning, and the wire mold completes cross-sectional correction, thus restoring overall shape stability. When stopping the machine or changing specifications, the tension can be released sequentially and the wires can be unwound in the reverse direction along the guide path to avoid scratching the hole edges and the wire mold.

[0036] This device is suitable for producing wire cores with metal wire conductors, and is adapted to conditions such as multi-strand parallel operation, long pitch, and high wire speed. The device should ideally be installed on the inlet side of the stranding machine, with sufficient assembly space along the inlet direction to ensure the coaxial layout of the distributor and each die. The device can operate in a dry or low-lubrication environment; it is advisable to maintain the cleanliness and smoothness of the through holes and die surfaces to achieve stable guiding and sizing effects.

[0037] The cross-sectional shape of the through holes can be circular or rounded polygonal; the number of turns and the density of the through hole array can be adjusted according to the strand ratio and target pitch. The splitter can be a single plate or a segmented modular structure for easy maintenance and cleaning. The wire mold can be a single piece or a sleeve type, and different inner surface characteristics can be changed according to the material and wire diameter. Without changing the segmented bundling and cascaded diameter limiting relationship, guide covers or protective components can be installed to reduce external disturbances and the risk of wire breakage.

[0038] In this embodiment, due to the use of a first splitting disc 30, a second splitting disc 40, and a third splitting disc 50 arranged coaxially along the wire inlet direction, along with an array of concentric through holes on each splitting disc, and a first wire mold 60, a second wire mold 70, and a third wire mold 80 arranged sequentially at the second splitting disc 40, the third splitting disc 50, and the wire inlet 110, the metal wires are first twisted into place in the first bundling area, the second bundling area, and the third bundling area, respectively, and then bound together in a segmented bundling and cascaded diameter-limiting structure by the corresponding wire mold diameter-limiting locking. Furthermore, an axial free section matching the number of strands / tension of each layer is formed between each splitting disc and the wire mold. Therefore, the helix angle of each layer of monofilament can be completed before entering the corresponding wire mold. Adaptive and interlayer / interlayer contact positioning, after entering the wire mold, only geometric locking and micro-compression are performed, thus effectively solving the problems of springback and lateral migration caused by one-time strong pressure when the single filament is not fully positioned in the existing technology, uneven interlayer stress caused by asynchronous changes in the free section before and after the wire mold and the number of strands / tension, insufficient core density and insufficient outer circumference. As a result, under the conditions of equal diameter single filaments and the same tension, the average gap between filaments in the cross-section of the finished wire core is significantly reduced, the outer ellipticity is significantly reduced, the surface is more dense, and it can adapt to stable production under high-speed wire feeding and long pitch conditions. At the same time, it is conducive to the subsequent improvement of the concentricity and appearance consistency of the extruded layer, as well as the consistency of conductor electrical properties and fatigue life.

[0039] Furthermore, in some embodiments, the first preset quantity is 7 wires, the second preset quantity is 12 wires, and after forming the second bundle, there are 18 remaining metal wires, which are twisted together with the second bundle to form the third bundle. The number of through holes in the through hole array along each concentric circle is evenly distributed according to a 6n rule, where n is a positive integer. Further, the through hole array consists of three concentric circle arrays, and the number of through holes in the three concentric circle arrays matches the number of strands of metal wires forming the first bundle, the second bundle, and the third bundle, respectively. Additionally, a through hole is provided at the geometric center of the first wire divider 30 and is coaxially arranged with the first wire mold 60.

[0040] Specifically:

[0041] The through holes on the first dividing plate 30, the second dividing plate 40, and the third dividing plate 50 are evenly distributed along their respective concentric circles. The hole positions follow a positive integer multiple rule with 6 as the base, ensuring consistent circumferential spacing and balanced angular distribution. The three concentric circles of through holes correspond to the target strand allocation of the inner, middle, and outer layers, respectively: the number of holes in the inner circle matches the number of strands in the first bundle, the number of holes in the middle circle matches the number of strands in the second bundle, and the number of holes in the outer circle matches the number of strands in the third bundle. An additional through hole is provided at the geometric center of the first dividing plate 30, which coincides with the axis of the first wire mold 60. This through hole serves as a guide and threading reference, facilitating rapid centering and coaxial feeding under multi-strand parallel conditions. Each through hole and the hole ring maintains a concentric relationship and is arranged at equal angles, ensuring that each metal wire obtains an independent and non-intersecting fixed channel, thereby completing circumferential position locking and radial layer pre-allocation during the dividing stage.

[0042] After the wire feeding begins, all metal wires pass through the corresponding through holes of the first splitting reel 30 to complete the initial splitting; a first preset number of wires are guided as inner layer strands, forming the first bundle in subsequent stages. The remaining metal wires continue through the through holes of the second splitting reel 40 to complete the second splitting, with a second preset number guided as middle layer strands, forming the second bundle in subsequent stages. The remaining metal wires pass through the through holes of the third splitting reel 50 to complete the third splitting, participating as outer layer strands to form the third bundle. Since the number of holes in the three rings corresponds one-to-one with the number of strands in the inner, middle, and outer layers, each wire is bound to its target layer during the splitting stage, reducing subsequent positioning time and minimizing lateral positioning and interference within the bundle area. The coaxial geometric relationship between the central through hole of the first splitting reel 30 and the first wire mold 60 provides a unified axial reference for the entire channel, making the inner layer strand inflow path short and straight, improving the concentric stability of the inner layer formation.

[0043] During the guide wire stage, the alignment of the strands can be checked by observing the occupancy status of each loop of holes. If an individual strand is misaligned, it can be individually retracted and corrected without disturbing other strands. During operation, if local tension fluctuations cause a slight radial shift in a strand, the concentric hole arrangement and equal-angle distribution will disperse this disturbance in the circumferential direction, avoiding concentrated compression and local gaps during the bundling stage. The axial reference of the central through hole of the first dividing plate 30 helps the inner strands quickly regain alignment, reducing uneven outer layer coverage caused by accumulated deviations.

[0044] In some optional embodiments, the radius, aperture, and spacing of the concentric circles can be optimized in groups according to the conductor wire diameter and target pitch to ensure that each layer of strands completes a reasonable wrap angle before entering the bundling region. The cross-section of the through hole can be circular or rounded polygonal to balance manufacturability and guiding stability. For ease of maintenance, the distributor can be designed as a detachable structure, allowing for individual replacement of distributors with different numbers and apertures to adapt to different product stranding schemes. Without changing the one-to-one correspondence between the three rings of holes and the three layers of strands, the starting position of the polar angle of the aperture rings can be slightly misaligned to reduce path ghosting and friction peaks when multiple layers are stacked.

[0045] In this embodiment, by employing three concentric circular through holes evenly distributed in positive integer multiples of six, matching the number of holes in the three rings with the inner, middle, and outer layers of strands, and setting through holes coaxial with the first wire mold 60 at the geometric center of the first splitting plate 30, the present invention effectively solves the problems of unclear layer binding, uneven circumferential distribution, and accumulation of inner layer centering errors in the prior art, which lead to difficulties in subsequent positioning and local gaps. Thus, it achieves the technical effects of completing layer locking and axial centering by self-splitting of single filaments, significantly reducing the positioning amount in the bundling stage, more uniform interlayer stress, tighter cross-section, and better outer circumference.

[0046] In some embodiments, the first wire mold 60, the second wire mold 70, and the third wire mold 80 are all replaceable sizing wire molds. The first wire mold 60, the second wire mold 70, and the third wire mold 80 are provided with an inlet fillet section and a sizing section in sequence along the wire feeding direction, wherein the fillet radius R of the inlet fillet section is 0.3mm to 1.0mm.

[0047] Specifically;

[0048] The wire die assembly provided in this embodiment consists of an inlet-side wire die (first wire die 60), an intermediate wire die (second wire die 70), and an inlet-port 110-side wire die (third wire die 80), all of which are replaceable sizing dies. Each die includes an inlet fillet section and a sizing section. The inlet fillet section is located at the front end in the wire feeding direction, has a smooth transition surface, and is continuously connected to the straight cylindrical hole of the sizing section. The fillet radius of the inlet fillet section is preferably 0.3mm to 1mm. The outer periphery of each die is provided with a positioning step and a conical positioning surface, which, through a quick-change pressure cap or pressure cover, mates with the corresponding center seat of the wire distributor or the inlet-port 110 seat to form reliable axial preload and coaxial positioning.

[0049] To reduce wear and friction, the wire mold body can be made of hard alloy, ceramic, or hardened stainless steel, with the hole walls polished to a mirror finish. The inlet can be equipped with a micro-bevel and a lubrication reservoir. Temperature-resistant and wear-resistant washers can be added between each wire mold and its mounting base to absorb minor assembly tolerances and prevent cold welding of metal contacts.

[0050] For ease of maintenance, the line mold is assembled with a pull-out or split structure, and disassembly and assembly can be completed without moving the main body of the line divider.

[0051] The incoming wire first enters the guide fillet section of the inlet die, where it is smoothly guided to the inner circumference of the sizing section, completing the initial constraint and micro-compression of the preceding bundle cross-section. It then enters the intermediate die and repeats the above process to further stabilize interlayer contact and circumferential stress distribution. Finally, the final cross-sectional dimensions are locked and coaxiality is corrected through the inlet 110 side die. The guide fillet section serves to set the attitude and reduce friction, while the sizing section serves to lock the dimensions and correct roundness. When changing specifications, simply release the pressure cap, remove the existing die, insert the target die according to the markings, tighten the pressure cap again, and after resetting and checking coaxiality, production can resume.

[0052] During the wire guiding stage, low tension and slow speed are employed to ensure a smooth transition of the strands within the guide rounded section and into the sizing section. When fluctuations in the contact pressure of the outer strands are detected, appropriately extending the dwell time in the guide section or increasing lubrication supply can prevent scratches and burrs. If slight ellipticity of the cross-section occurs during operation, moderately increasing the axial preload of the intermediate die or repolishing the sizing section wall can quickly restore roundness. When excessive temperature rise is detected, appropriately reducing the wire feed speed or increasing lubrication supply will effectively disperse frictional heat and suppress scratches due to the curvature and smoothness of the guide rounded section.

[0053] In some optional embodiments, the fillet section can adopt a circular arc, a compound circular arc, or a circular arc with a micro-cone transition surface scheme; the sizing section can be a constant diameter section or a combination of a short constant diameter section and a micro-diffusion outlet to balance the limiting force and springback. The die body can adopt an integral, sleeve, or embedded structure, and accuracy can be restored by simply replacing the inner liner after wear. To adapt to different wire diameters and materials, multiple die libraries can be configured, and the fillet radius and sizing section length can be switched according to the product. The installation method can use a quick-change mechanism such as a pressure cap, clamp, or self-centering wedge to shorten downtime.

[0054] In this embodiment, by employing replaceable sizing die and sequentially setting the guide fillet section and sizing section in the wire feeding direction, using a small to medium millimeter-level fillet radius for the guide fillet section, and combining it with coaxial quick-change positioning and high-gloss hole wall technology, the technical problems of sharp wire feeding, concentrated friction, scratches and burrs, unstable cross-section locking, and long downtime for tooling changes in the prior art are effectively solved. Thus, the technical effects of smooth wire feeding and low friction sizing, stable cross-section roundness and coaxiality, more uniform wire contact, better surface quality, and rapid dimensional reproduction during shape change are achieved.

[0055] In some embodiments, an adjustable mounting assembly 20 is also included. The first splitter 30, the second splitter 40, and the third splitter 50 are all connected to the main body 10 via the adjustable mounting assembly 20. The adjustable mounting assembly 20 includes a graduated adjustment shaft 210 and three locking mechanisms 220. The graduated adjustment shaft 210 is disposed on the cable inlet 110 side of the main body 10, and the axial direction of the adjustment shaft 210 is parallel to the cable inlet direction. The first splitter 30, the second splitter 40, and the third splitter 50 are all connected to the main body 10 via the adjustable mounting assembly 20. Slots are provided on both the first distributor 30 and the third distributor 50. The adjusting shaft 210 passes through the slots of the first distributor 30, the second distributor 40, and the third distributor 50. Each locking mechanism 220 is connected to the first distributor 30, the second distributor 40, and the third distributor 50 in a one-to-one correspondence to adjust the relative movement of the first distributor 30, the second distributor 40, the third distributor 50, and the adjusting shaft 210.

[0056] Specifically:

[0057] The adjustable mounting assembly 20 is used to connect the first splitter 30, the second splitter 40, and the third splitter 50 to the main body 10 and achieve precise positioning. The adjustable mounting assembly 20 includes a graduated adjustment shaft 210 located on the side of the cable inlet 110 of the main body 10 and several locking mechanisms 220 corresponding to the splitter 10.

[0058] The adjusting shaft 210 is arranged along the cable inlet direction, and its outer circumference is provided with equidistant engravings and reference marks to indicate the axial position of each distributor plate. Each distributor plate has an elongated slot that mates with the adjusting shaft 210. The length of the slot is aligned with the cable inlet direction, and wear-resistant strips can be inlaid on the slot walls to reduce sliding friction. The adjusting shaft 210 passes through the slots of each distributor plate to form a guiding relationship. The distributor plates achieve smooth movement along the cable inlet direction through the cooperation between the slots and the adjusting shaft 210, and are positioned at the target position by their respective locking mechanisms 220.

[0059] The locking mechanism 220 may include a pressure plate, a locking element, and an anti-loosening element. The pressure plate is connected to the distributor plate, and the locking element spans the slot to press the distributor plate onto the outer circular surface of the adjusting shaft 210, so that it can slide when released and be positioned when tightened.

[0060] A support base or vibration isolation pad can also be installed between the distribution panel and the main body 10 to provide additional rigidity and vibration reduction.

[0061] Each distribution panel is coaxially aligned with its corresponding wire mold. The distribution panel can be installed relative to the main body 10 using locating pins or stepped shoulders to ensure coaxiality and repeatability. The distribution panel can be made of high-strength aluminum alloy or stainless steel, and its surface can be hardened or anodized. The adjusting shaft 210 can be made of wear-resistant alloy steel and undergo surface polishing and rust prevention treatment.

[0062] During installation and alignment, first fix the adjusting shaft 210 to the inlet 110 side of the main body 10, aligning its axis with the inlet direction. Each distributor plate is fitted onto the adjusting shaft 210 via a slot. After loosening the corresponding locking mechanism 220, move it horizontally along the slot direction to the preset position. Quantitatively set the distributor plate spacing and the position of the wire mold by reading the scale lines on the adjusting shaft 210 and the frame reference line. After positioning, sequentially tighten each locking mechanism 220 to ensure reliable clamping and vibration-resistant support for the distributor plates on the adjusting shaft 210. During production, if fine-tuning of the distributor plate spacing is required, simply release the corresponding distributor plate's locking mechanism 220, move it slightly to the target position according to the scale lines, and then tighten it again. Other distributor plates and wire molds remain stationary, thus achieving rapid local correction. During maintenance shutdown, sequentially loosen the locking mechanisms 220, remove the distributor plates along the slot direction for cleaning and replacement, and then reset them according to the scale lines.

[0063] During the wire guiding stage, the initial position of the splitter disc is set using the etched readings to ensure that the through-hole array and the subsequent wire mold are on the same axis. When strand tension fluctuations or path deviations occur, a small axial adjustment can be made to a specific splitter disc to change the effective length of the bundling area and the guide wrap angle, stabilizing the strand positioning. If a deviation in outer circumference or uneven spacing between strands is detected during operation, the relative position of adjacent splitter discs can be finely adjusted using the etched lines on the adjusting shaft 210. The locking mechanism 220 provides stable clamping force after re-clamping, preventing secondary displacement caused by vibration. To improve the reliability of anti-loosening, the locking mechanism 220 can be used in conjunction with elastic washers or anti-reverse structures.

[0064] In some optional embodiments, the adjusting shaft 210 may have a hollow structure to reduce weight or provide lubrication channels; the slot may be a straight elongated hole or a guide hole with a slight curvature to match different process wrap angle requirements; the locking mechanism 220 may be an eccentric pressing type, a wedge self-centering type, or a quick cam type to shorten the switching time and improve the consistency of repeatable positioning; without changing the guiding and locking positioning relationship between the adjusting shaft 210 and the slot, a radial fine-tuning mechanism may be added between the dividing plate and the main body 10 for fine correction of coaxiality; the engraving lines may be combined with visual marks or pointer windows to improve reading recognition and oil resistance.

[0065] In this embodiment, the use of an adjustable mounting assembly 20 with a graduated adjustment shaft 210 passing through each distributor slot and supplemented by a corresponding locking mechanism 220 effectively solves the technical problems in the prior art, such as fixed distributor spacing, time-consuming alignment, large repeated positioning errors, and secondary offset caused by running vibration. This achieves the technical effects of rapid and controllable distributor position, intuitive reading, reliable locking, and stable and reproducible coaxiality and spacing accuracy, thus providing a more stable and consistent foundation for subsequent channel guidance, bundle positioning, and diameter limiting forming.

[0066] In some embodiments, each of the through holes of the first splitter plate 30, the second splitter plate 40 and the third splitter plate 50 is provided with a low-friction bushing, and the entrance of each through hole is provided with a chamfer or a micro-rounded corner.

[0067] Specifically;

[0068] Low-friction bushings can be sleeve-type structures, with the outer diameter interfering with the bore wall or having a locating shoulder fit. Axial movement can be limited by pressure rings, snap rings, or end face steps to prevent slippage and rotation. The bushing's inner bore has a smooth guide surface, with the inlet end machined for a smooth transition to meet the bore chamfer or micro-rounded corner, and the outlet end maintaining a stable guide straight section. Bushing materials can include polytetrafluoroethylene, ultra-high molecular weight polyethylene, polyetheretherketone, alumina ceramic, zirconia ceramic, or wear-resistant metals with a solid lubricating coating. The inner bore is finely polished to reduce friction and wear. For ease of maintenance, the bushing can be quick-change installed, allowing individual replacement of worn parts without disassembling the distributor plate body. Each distributor plate can be made of metal or engineering plastic sheet, with the bore edge concentrically fitted to the outer surface of the bushing to ensure continuous and consistent guide axis.

[0069] During wire guiding and operation, the incoming wire enters each through-hole inlet separately. Chamfered or slightly rounded corners gently guide the wire into the bushing's inner bore, preventing sharp edge engagement and impact. The bushing provides a low-friction guiding channel, stabilizing the radial position of the wire and reducing contact shearing and wear against the hole wall. The straight exit section ensures the incoming wire leaves the hole in a stable direction, preventing secondary scratches at the exit point. If a specification change or cleaning is required, simply release the limiting element, remove the bushing for replacement or cleaning, and then reinstall it in its original position to restore guiding accuracy.

[0070] During the wire guiding stage, slow piercing with low tension and chamfering or micro-rounding can significantly reduce the risk of wire snagging and burrs. When local tension fluctuations or increased friction are detected, check the cleanliness and lubrication of the bushing inner hole, and perform quick replacement or repolishing if necessary. During long-term operation, if wear of individual holes is found to cause guide misalignment, only the corresponding bushing can be replaced to restore concentricity and smoothness, without adjusting the overall tray position.

[0071] In this embodiment, by employing a low-friction bushing in each through hole and forming a chamfer or micro-rounded corner at the hole opening, the technical problems of easy scratching at the wire entry point, high dry friction on the hole wall, and rapid wear and tear during long-term operation leading to guide deviation and surface scratches in the prior art are effectively solved. This results in smoother wire entry guidance, significantly reduced guide friction, more stable wire surface quality, higher guide concentricity and lifespan, and more convenient maintenance.

[0072] In some embodiments, the stranding device further includes a fourth wire die 90 disposed between the third wire distributor 50 and the third wire die 80. The fourth wire die 90 is located on the wire inlet path between the third wire distributor 50 and the third wire die 80, and is used to pre-compress and limit the diameter of the third bundle before it enters the third wire die 80. The fourth wire die 90 is a replaceable sizing die, and the fourth wire die 90 is provided with an inlet fillet section and a sizing section in sequence along the wire inlet direction, wherein the fillet radius R of the inlet fillet section is 0.3mm to 1.0mm.

[0073] Specifically:

[0074] This stranding device includes a fourth die 90 located between the third splitter spool 50 and the third die 80. The fourth die 90 is situated on the inlet path between the third splitter spool 50 and the third die 80, coaxial with the device axis, and is used for pre-compression and diameter limiting before the third bundle enters the third die 80. The fourth die 90 is a replaceable sizing die. The die body features an inlet fillet section and a sizing section. The inlet fillet section is located on the side facing the incoming wire direction and smoothly transitions to the straight cylindrical hole of the sizing section. The fillet radius of the inlet fillet section is 0.3 to 1 mm. The outer circumference of the die is provided with positioning steps and a conical positioning surface. Quick assembly / disassembly and reliable pre-tightening are achieved via a pressure cap or clamp and mounting base. The mounting base is fixed to the frame or a special bracket and is concentric with the axis. To reduce friction and wear, the die can be made of hard alloy, engineering ceramics, or surface-hardened stainless steel, with the sizing hole wall polished to a mirror finish. To extend service life, a micro-lubricant reservoir or a solid lubricant layer can be applied to the inlet end. To suppress the transfer of assembly tolerances, elastic washers can be added between the wire mold and the mounting base to achieve micro-compensation and prevent rotational loosening.

[0075] After being led out from the third splitter 50, the third bundle enters the inlet rounded section of the fourth die 90. This smooth transition guides the strands to the sizing section without causing damage, completing pre-compression and shape stabilization of the cross-section. After leaving the fourth die 90, the third bundle travels a short distance along the inlet path before entering the third die 80 for final compression and sizing. The fourth die 90 performs pre-compression and attitude setting, while the third die 80 performs final locking and coaxial correction. Their cascaded operation distributes the sizing load and suppresses springback and lateral migration caused by a single strong pressure. During changeover, releasing the pressure cap allows the fourth die 90 to be removed. After replacing with the appropriate specification, re-tightening and checking coaxiality resumes production.

[0076] During the initial stage of guide wire operation and startup, a lower tension and lower linear speed are used to ensure a smooth transition of the third bundle within the fillet section of the fourth die 90 and into the sizing section. When fluctuations in peripheral contact pressure or increased temperature are detected, lubrication can be appropriately increased or the relative position between the fourth die 90 and the third die 80 can be finely adjusted to optimize the free section length. If slight ellipticity or surface scratches appear, the sizing hole wall of the fourth die 90 can be repolished or replaced with a more suitable hole diameter and fillet radius specification to ensure that the pre-compressed cross-section remains stable before entering the third die 80.

[0077] In this embodiment, by employing a fourth die 90 with a fillet section and a sizing section that can be quickly replaced between the third die 50 and the third die 80, and by implementing pre-compression and diameter limiting at the fourth die 90, the technical problems of large cross-sectional springback, excessive lateral migration, concentrated friction and heat generation, and easy surface scratches caused by one-time strong compression before final compression in the prior art are effectively solved. This achieves the technical effects of diameter limiting load sharing, cross-sectional stability before entering the final compression die, improved roundness and coaxiality, more uniform contact between wires, and improved surface quality and forming stability under high-speed conditions.

[0078] Furthermore, in some embodiments, the axial distance between the fourth die 90 and the third die 80 is 3cm to 4cm, the axial distance between the fourth die 90 and the third dividing plate 50 is 25cm to 27cm, the axial distance between the third dividing plate 50 and the second dividing plate 40 is 14cm to 16cm, and the axial distance between the second dividing plate 40 and the first dividing plate 30 is 13cm to 15cm. The sizing bore of the fourth die 90 is larger than that of the third die 80, and the fourth die 90 and the third die 80 are coaxially arranged.

[0079] Specifically:

[0080] The fourth die 90 is coaxially arranged with the third die 80 along the wire inlet direction, and the sizing bore of the fourth die 90 is larger than that of the third die 80. The fourth die 90 is mounted on a dedicated die holder, which is fixed to the frame or an independent support, sharing the same axis as the holder containing the third die 80. A short axial distance of 3 to 4 cm is maintained between the fourth die 90 and the third die 80, and a free axial distance of 25 to 27 cm is maintained between the fourth die 90 and the third splitter disc 50. To coordinate with the pre-stage bundling rhythm, a axial distance of 14 to 16 cm is maintained between the third splitter disc 50 and the second splitter disc 40, and a axial distance of 13 to 15 cm is maintained between the second splitter disc 40 and the first splitter disc 30. The fourth die 90 consists of an inlet fillet section and a sizing section. The inlet fillet section is a smooth transition surface that connects seamlessly with the straight cylindrical hole of the sizing section. The fillet radius of the inlet fillet section is 0.3 to 1 mm. Each die holder can be equipped with a micro-aligning structure and a positioning shoulder to ensure coaxiality and repeatability after assembly.

[0081] After being led out by the third splitter plate 50, the third bundle completes helix angle adaptation and interlayer stress redistribution within a 25-27 cm free section. It then enters the inlet fillet section of the fourth die 90 and is guided to the sizing section for pre-compression and sizing. After leaving the fourth die 90, the third bundle maintains its cross-sectional geometry and stress state within a 3-4 cm short distance before entering the third die 80 for final compression and final sizing. The two axial distances between the preceding splitter plates provide the necessary positioning and stabilization zones for the first and second bundles, ensuring that each layer has a stable layer sequence and contact relationship before entering the fourth die 90, thus forming a sequential pre-compression and final compression fit with the fourth die 90 and the third die 80.

[0082] During the start-up and guide wire stages, lower tension and wire speed are used to allow the third bundle to naturally settle within the free section before entering the fourth die 90, avoiding surface scratches caused by premature diameter limitation. If fluctuations in outer circumference or uneven contact pressure are detected during operation, the short distance between the fourth die 90 and the third die 80, or the length of the free section between the third splitter 50 and the fourth die 90, can be finely adjusted while maintaining coaxiality to suppress springback and lateral migration while maintaining pre-compression. When temperature rises or friction increases, lubrication can be appropriately increased or the smoothness of the die inlet radius can be re-inspected to restore smooth feed.

[0083] In this embodiment, by employing the technical means of setting the fourth wire die 90 between the third wire divider 50 and the third wire die 80 and being coaxial with the third wire die 80, and by using the fourth wire die 90 having a larger aperture than the third wire die 80 and matching the axial distance between the free section and the short-pitch section, the technical problems of large cross-sectional springback, excessive lateral migration, uneven force distribution, and easy surface scratches caused by the one-time strong pressure before final compression in the prior art are effectively solved. This achieves the technical effects of load sharing and shape memory transfer between pre-compression and final compression, more stable cross-section before entering the final compression wire die, better roundness and coaxiality, more uniform contact between wires, and adaptability to high linear speed and long pitch working conditions.

[0084] The above description is merely illustrative of the invention. Those skilled in the art can make various modifications or additions to the described specific embodiments or use similar methods to replace them, as long as they do not depart from the content of this specification or exceed the scope defined by the claims, all of which should fall within the protection scope of this invention.

Claims

1. A wire stranding device for core production, comprising a main body and an inlet disposed on one side of the main body and opened along the wire feeding direction, characterized in that, The stranding device further includes a first wire distributor, a second wire distributor, and a third wire distributor arranged coaxially along the wire inlet direction; each of the first wire distributor, the second wire distributor, and the third wire distributor has an array of through holes formed by several through holes on multiple concentric circles with their respective geometric centers as centers; the second wire distributor and the third wire distributor have a first wire mold and a second wire mold for passing through and bundling metal wires at their geometric centers, and a third wire mold is provided at the wire inlet; The stranding device is configured such that: after the metal wires from the pay-off end pass through the through holes of the first splitter in a one-to-one correspondence manner, a first predetermined number of metal wires are guided to a first bundling area located between the first and second splitter, where they are stranded to form a first bundle, which then passes through the first wire mold and is limited in diameter; after the remaining metal wires pass through the through holes of the second splitter in a one-to-one correspondence manner, a second predetermined number of metal wires are guided to a second bundling area located between the second and third splitter, where they are stranded outside the first bundle to form a second bundle, which then passes through the second wire mold and is limited in diameter; after the remaining metal wires pass through the through holes of the third splitter in a one-to-one correspondence manner, they are guided to a third bundling area located between the third splitter and the third wire mold, where they are stranded outside the second bundle to form a third bundle, which then passes through the third wire mold and enters the main body through the inlet, completing the stranding of the wire cores.

2. The stranding device according to claim 1, characterized in that, The first preset quantity is 7 wires, the second preset quantity is 12 wires, and after forming the second bundle, there are 18 remaining metal wires, which are twisted together with the second bundle to form the third bundle.

3. The stranding device according to claim 1, characterized in that, The number of through holes in the array of through holes along each concentric circle is evenly distributed according to a 6n rule, where n is a positive integer.

4. The stranding device according to claim 3, characterized in that, The through-hole array consists of three concentric circle arrays. The number of through holes in the three concentric circle arrays is respectively matched with the number of strands of metal wires forming the first bundle, the second bundle, and the third bundle. In addition, another through hole is provided at the geometric center of the first wire divider and is coaxially arranged with the first wire mold.

5. The stranding device according to claim 1, characterized in that, The first, second, and third die are all replaceable sizing dies. The first, second, and third dies are provided with an inlet fillet section and a sizing section in sequence along the wire feeding direction. The fillet radius R of the inlet fillet section is 0.3mm to 1.0mm.

6. The stranding device according to claim 1, characterized in that, It also includes an adjustable mounting component, wherein the first splitter, the second splitter, and the third splitter are all connected to the main body via the adjustable mounting component, and the adjustable mounting component includes: An adjustment shaft with a scale is provided on the inlet side of the main body. The axis of the adjustment shaft is parallel to the inlet direction. Slots are provided on the first splitter plate, the second splitter plate, and the third splitter plate. The adjustment shaft passes through the slots of the first splitter plate, the second splitter plate, and the third splitter plate. Three locking mechanisms are provided, each of which is connected to the first, second, and third splitter discs in a one-to-one correspondence, to adjust the relative motion state of the first, second, and third splitter discs with respect to the adjusting shaft.

7. The stranding device according to claim 1, characterized in that, Each of the through holes in the first, second, and third splitter discs is provided with a low-friction bushing, and the entrance of each through hole is provided with a chamfer or a slight rounded corner.

8. The stranding device according to claim 1, characterized in that, It also includes a fourth wire mold, which is disposed between the third wire splitter and the third wire mold. The fourth wire mold is located on the wire inlet path between the third wire splitter and the third wire mold, and is used to pre-compress and limit the diameter of the third bundle before it enters the third wire mold. The fourth wire mold is a replaceable sizing wire mold, and the fourth wire mold is provided with an inlet fillet section and a sizing section in sequence along the wire inlet direction, wherein the fillet radius R of the inlet fillet section is 0.3mm to 1.0mm.

9. The stranding device according to claim 8, characterized in that, The axial distance between the fourth wire mold and the third wire mold is 3cm to 4cm, the axial distance between the fourth wire mold and the third wire divider is 25cm to 27cm, the axial distance between the third wire divider and the second wire divider is 14cm to 16cm, and the axial distance between the second wire divider and the first wire divider is 13cm to 15cm.

10. The stranding device according to claim 8 or 9, characterized in that: The sizing aperture of the fourth die is larger than that of the third die, and the fourth die is coaxial with the third die.

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