A method and system for untwisting pairs of a cable

Abstract

The present application belongs to the technical field of cable processing, and provides a cable untwisted pair method and system, a plurality of shielded wires are twisted into a cable core in an untwisted manner; a braiding device is used to cross-braid metal wires outside the cable core to form a mesh-shaped metal wire braided shielding layer, and then a plastic liquid is extruded by an extruder to coat the cable core, and a shaped cable is obtained after cooling, which can directly reduce the torsional stress of each single shielded wire, thereby indirectly acting on the tension of the shielded wire between the clamping traction device and the twisting machine, reducing the residual torsional internal stress of the cable, reducing problems such as uneven twisting pitch, core eccentricity, local hardening, serpentine deformation and lamp-shaped bulging, and improving the service life of the cable and the stability and communication performance of the communication signal.

Description

Technical Field

[0001] This invention belongs to the field of cable processing technology, specifically relating to a method and system for cable twisting without twisting. Background Technology

[0002] There are two stranding methods for the conductive cores of cables: untwisted stranding and non-untwisted stranding. Untwisted stranding refers to reversing the pre-twisted cable during the cabling process after manufacturing, eliminating or reducing the internal stress caused by pre-twisting. The process involves a special device (untwisting device) on a reel frame with a pay-off spool keeping the pay-off spool horizontal as the machine rotates. During stranding, the individual wires only experience flexing, not twisting. This process is usually performed on a cable stranding machine, returning the cable to a stress-free state by reversing the twist. Untwisting reduces stress concentration during transportation and installation, improving cable reliability and lifespan. This process is often used for loosely twisted cables to prevent them from breaking apart due to internal stress in the event of a single wire breakage.

[0003] Non-twist stranding is often used for compacted cores (compacted cores are a type of cable conductor structure where the stranded core geometry is made more compact through mechanical compaction, typically changing from a round shape to a compacted round or fan-shaped shape to improve the overall performance of the cable). This is because the residual stress generated by self-twist is elastic deformation, while compression is plastic deformation, and the pay-off reel is fixed in non-twist cases. The process involves fixing a reel frame with the pay-off reel to the winch. Each time the winch rotates 360°, the pay-off reel rotates, and the individual wires or insulated cores also twist 360°. Therefore, non-twist stranding is often used for loosely compacted stranded cores, where the individual wires have no torsional internal stress, resulting in a stable stranded structure. Non-twist stranding, on the other hand, is often used for compacted round and fan-shaped cores. Compacted cable cores allow for smaller gaps between conductors, effectively reducing the cable's outer diameter.

[0004] Because untwisting stranding can lead to the multi-wire effect (a phenomenon where the electric field distribution on the surface of the conductor is uneven due to the inverse relationship between the radius of a single wire and its surface electric field strength when multiple single wires are twisted together), many cable types must use non-untwisting stranding to produce compacted conductors to reduce this effect. Its functions include smoothing the conductor surface to avoid electric field concentration, preventing semiconductive materials from entering the conductor, preventing moisture penetration, and improving bending performance. However, non-untwisting stranding leaves residual torsional stress in the cable, which accumulates plastic deformation and fatigue damage, manifesting as twisting. Uneven spacing, eccentric cores, localized hardening, cracking, and even broken cores can lead to serious problems such as serpentine deformation (after the cable is uncoiled or cut, it will automatically curl and knot due to the release of internal stress, twisting like a snake, making construction difficult), lantern-shaped bulges (when bending or compressing the cable, due to the torsional stress on the individual wires, they tend to spread out, causing the insulation layer or sheath to bulge, forming a "lantern" shape); and structural instability: the pitch between wire pairs may change slightly due to stress release, affecting high-frequency signal transmission (such as crosstalk and impedance fluctuations). Summary of the Invention

[0005] The purpose of this invention is to provide a method and system for cable twisting without twisting, in order to solve one or more technical problems existing in the prior art, and at least provide a beneficial option or create conditions.

[0006] To achieve the above objectives, according to one aspect of the present invention, a method for twistless cable pairing is provided, the method comprising the following steps: S100 uses a wire drawing machine to draw copper wire, and then anneals the copper wire to obtain annealed copper wire; S200 involves stranding multiple annealed copper wires into a core, and then simultaneously extruding the surface of the core using an extruder to form an insulation layer, thus obtaining an insulated core. S300 is a shielded wire formed by fully covering the surface of the insulated wire core with a metal shielding layer. S400 uses multiple shielding wires twisted together into cable cores using a non-untwisting method; In the process of stranding the wire into cable cores without unwinding, the shielding wire before stranding is clamped and pulled by a clamping and pulling device; tension monitoring is performed between the clamping and pulling device and the stranding machine. In particular, when stranding in the non-untwisting method, the tension signal fed back by the shielding wire is used to determine in real time whether the shielding wire is generating a tendency of combined stress. If so, the spindle speed of the stranding machine is automatically adjusted. The S500 uses a braiding machine to cross-braid metal wires on the outside of the cable core to form a mesh-like metal wire braided shielding layer. Then, a plastic liquid is extruded from the extruder to cover the cable core, and after cooling, a shaped cable is obtained.

[0007] Furthermore, in S100, the method of drawing copper wire using a wire drawing machine includes: drawing an oxygen-free copper rod with a diameter of 8mm into a copper wire with a diameter of 1-5mm using a wire drawing machine.

[0008] Furthermore, in S100, the method for annealing copper wire to obtain annealed copper wire includes: continuously annealing the copper wire in a heat treatment chamber, wherein two annealing zones are set in the heat treatment chamber; the copper wire is heated to 260-300°C in the first annealing zone, and the atmosphere in the first annealing zone is not controlled; the single-wire copper wire is heated to 600-650°C in the second annealing zone, and the oxygen content in the air in the second annealing zone is controlled to be less than 1%.

[0009] Furthermore, in S200, the method of twisting multiple annealed copper wires into a core includes: twisting multiple annealed copper wires into a core using a single twisting machine.

[0010] Furthermore, in S200, the method for obtaining an insulated wire core by simultaneously extruding an insulating layer onto the surface of the wire core using an extruder specifically includes: The method of co-extruding molten plastic and nitrogen onto the surface of the wire core to obtain an insulated wire core involves: plasticizing and melting polyolefin plastic particles in an extruder, causing the polyolefin plastic particles to melt under heat in the extruder to obtain molten plastic, at a flow rate of 0.1–0.25 m... 3 Nitrogen is introduced into the screw chamber of the extruder at a nitrogen filling rate of / h until the atmospheric pressure inside the screw chamber reaches the range of 1.5 to 2.5 kPa. The molten plastic and nitrogen are then extruded together and coated onto the surface of the wire core to obtain an insulated wire core.

[0011] Preferably, the surface of the insulated wire core also needs to be corona treated.

[0012] Furthermore, in S300, the method of forming a shielded wire by fully covering the surface of the insulated wire core with a metal shielding layer specifically includes: using a wrapping machine to fully cover the insulated wire core with any one of aluminum foil, soft copper strip or loosely wound copper wire to form a metal shielding layer and thus form a shielded wire.

[0013] The wrapping machine is any one of the following: HD-630D vertical tower tray automatic wrapping machine, HD-800D vertical tower tray automatic wrapping machine, cage stranding high-speed wrapping machine, or TRB400 speed-regulating wrapping machine. Furthermore, in S400, the method for monitoring tension between the clamping traction device and the stranding machine is as follows: when the shielded wire is clamped between the clamping traction device and the stranding machine and tension is generated, the tension sensor located between the clamping traction device and the stranding machine detects the real-time pressure of the shielded wire section and collects the real-time tension of the clamped shielded wire.

[0014] The clamping and traction device includes an upper clamping part and a lower clamping part. Each clamping part includes a clamping belt. Each clamping belt is covered with multiple clamping rollers, which clamp and pull the cable through the clamping belt.

[0015] Each clamping belt moves synchronously with the traction belt via a synchronous belt and synchronous belt gears (such as the clamping roller synchronous belt gear, the synchronous belt intermediate gear, and the synchronous belt gear), and the traction belt is driven by a servo motor.

[0016] In this configuration, when the shielding wire between the tension sensor, clamping traction device, and stranding machine is clamped and tension is generated, the tension sensor detects a force vector, and the real-time tension vector of the cable tensioned along the shielding wire towards the stranding machine on both sides forms a parallelogram. Based on the parallelogram principle, the tension detected by the tension sensor can be converted into the real-time tension of the shielding wire.

[0017] The clamping and traction device includes an upper clamping part and a lower clamping part. Each clamping part includes a clamping belt. Each clamping belt is covered with multiple clamping rollers, which clamp and pull the shielding wire through the clamping belt.

[0018] Each clamping belt moves synchronously with the traction belt via a timing belt and timing belt gear, and the traction belt is driven by a servo motor.

[0019] The traction belt and clamping belt are synchronous gear belts.

[0020] The clamping and traction device introduces a synchronization signal for the stranding machine's linear speed. When the clamping belt is not tightened, the linear speed of the traction belt and the surface of the clamping belt is set to be consistent with the speed of the stranding machine.

[0021] In S500, the weaving equipment is any one of a 24-spindle rope weaving machine, a 16-spindle high-speed weaving machine, or a 32-spindle high-speed weaving machine.

[0022] Furthermore, in S500, the metal wire is a non-ferrous metal wire made of any one of copper wire, aluminum wire, copper-clad steel wire, or copper-clad aluminum wire.

[0023] Furthermore, after the shielding wire is twisted into the cable core in a non-untwisting manner, it needs to be bundled and filled.

[0024] The filling process is to ensure the roundness and stability of the cable core; the binding process is to ensure that the cable core does not become loose.

[0025] The filler is glass fiber.

[0026] Preferably, the weaving equipment is a 24-spindle rope weaving machine, and the plastic is a polyolefin plastic.

[0027] One method for forming the cable core using a non-untwisting twisting method involves using the rotation of a rigid stranding machine (maximum traction speed 66.45 m / min) to complete the stranding process, thus creating the cable core from the stranded wire of the shielding wire. The support structure of the rigid stranding machine can be any one of the following: fork type, star type, tube type, or frame type.

[0028] Because the shielding wire between the clamping traction device and the stranding machine moves synchronously with the stranding process, non-unwinding stranding will leave residual torsional internal stress in the cable, thus accumulating plastic deformation and fatigue damage, resulting in uneven mechanical stress distribution in the cable core (such as problems caused by excessively small bending radius, improper crimping points, or external extrusion). This, in turn, leads to a multi-wire effect, causing non-ideal distribution of current or signal transmission in the cable core. For example, when the spiral structure of the shielding wire bends during stranding, the outer shielding wire bears tensile stress, while the inner shielding wire bears compressive stress. Long-term dynamic bending causes micro-plastic deformation in the outer shielding wire, gradually decoupling it from the original stranding pitch and disrupting the balanced current distribution. Under high-frequency signals, stress deformation causes an increase in resistance within the surface area of ​​the shielding wire. According to the skin effect, this problem leads to increased insertion loss and deteriorated return loss in the cable. External electromagnetic noise (such as RFI) is more easily coupled into the differential signal line. In existing technologies, for example, a method using Chinese Patent Publication No. CN116206823B to avoid... Methods and devices for preventing twisting of cable cores generally involve monitoring stress change trends to identify local stress concentrations during the untwisting process, thereby reducing uneven mechanical stress distribution. While this method avoids core twisting, it relies on a rotating untwisting machine to eliminate internal stress after conductor stranding, potentially leading to a "snake-like bend" phenomenon in the cable after cabling. (In untwisting stranding: the torsional stress of individual wires is eliminated during stranding using a mechanical device, keeping the individual wires in their original straight state; i.e., stress exists before untwisting. In non-untwisting stranding: the torsional stress of individual wires is not eliminated during stranding, and each individual wire remains twisted after stranding. This results in residual stress within the individual wires; i.e., stress exists after the non-untwisting process.) In non-untwisting stranding production scenarios, the torsional stress of individual wires is difficult to eliminate because it is not eliminated during stranding. Stress sensors monitor the overall cable product stress and cannot detect the torsional stress of the shielding wires that make up the cable. Therefore, this application reduces this torsional stress problem through the following method: Furthermore, the specific method for determining in real time whether the shielding wire is prone to generating a resultant stress is as follows: After the stranding machine starts, (because multiple shielding wires are stranded during the stranding process, each shielding wire remains in a twisted state after stranding. Since there is no untwisting step, the torsional stress of the individual shielding wires is not eliminated during stranding. Therefore, the stress after stranding is the resultant force of each individual wire. Because there are cases where the torsional stress of the individual shielding wires is relatively large and the torsional stress of the individual wires is relatively small at the same position in the stranded cable, the resultant force of the torsional stress may be relatively balanced. Therefore, it is impossible to accurately measure the total cable stress. Therefore, it is necessary to estimate the magnitude of the torsional stress based on the peak value of the tension of the individual wires that have not yet been stranded at the front end); all tension values ​​collected at time intervals (TimeF) for each shielding wire before stranding are compiled into a sequence and recorded as a tension sequence; (the default time interval TimeF is set to 100 to 800 milliseconds). The maximum tension value in each tension sequence is the peak tension of a single wire, the minimum tension value is the trough tension of a single wire, and the average value is the mean tension of a single wire. (Note: During the stranding process, due to annealing, micro-cracks, material properties, etc., the mechanical stress deformation of the shielding wire is different, resulting in different possible torsional stresses in each shielding wire. Therefore, the tension acting on the unstrung shielding wire is different, so the tension of each shielding wire will vary. Since the reaction force of the torsional stress of the stranded shielding wire on the unstrung shielding wire is a process of increasing from small to large, under normal circumstances, the tensions in each tension sequence generally show a gradual increase over time between the trough tension value and the peak tension value. However, if the shielding wire is affected by the torsional stress of other shielding wires, the increase is not gradual. Therefore, the resultant force of the torsional stress generated by the two shielding wires is monitored.) The time period between the trough tension value and the peak tension value of a single wire in each tension sequence is the stress-bearing period. The time intervals obtained by taking the intersection of all load-bearing time intervals are recorded as resultant force time intervals; the maximum value among all single-line tension averages is taken as the average disturbance tension. The disturbance force value is marked for each tension value in each tension sequence in turn. The specific method is as follows: if there exists a tension value M1 before any current tension value that is greater than the average disturbance tension value, and the current tension value is less than M1, and the tension value before M1 is less than M1, then the current tension value is marked as a disturbance force value. If there is no disturbance force value, it is determined that the shielding wire does not have a tendency to generate resultant stress; otherwise, it is determined that the shielding wire has generated a tendency to generate resultant stress.

[0029] The disturbance force value is the tension that suddenly increases due to the reaction force of the torsional stress of other shielding wires.

[0030] The above method uses the intersection method to obtain the resultant force period and roughly locate the tension of each shielding wire affected by the resultant force generated by the torsional stress during twisting. However, if the difference between the torsional stresses of two shielding wires is small, and the tension generated by the reaction force of the torsional stresses of the two shielding wires on the shielding wires is lower than the average disturbance tension, it is impossible to locate whether the two shielding wires have a resultant stress trend. Therefore, the present invention proposes the following preferred solution: Preferably, the specific method for determining in real time whether the shielding wire is generating a tendency for combined stress is as follows: After the stranding machine starts, all tension values ​​collected at time intervals (TimeF) for each shielded wire before stranding are compiled into a sequence and recorded as a tension sequence; (the default time interval (TimeF) is set to 100 to 800 milliseconds). The maximum tension value in each tension sequence is the peak tension value of a single line, the minimum tension value is the valley tension value of a single line, and the average value is the mean tension value of a single line; the time period between the valley tension value and the peak tension value of a single line in each tension sequence is the stress-bearing period. The time intervals obtained by taking the intersection of all load-bearing time intervals are recorded as resultant force time intervals; the maximum value among all single-line tension averages is taken as the average disturbance tension. The disturbance force value is marked for each tension value in each tension sequence in turn. The specific method is as follows: if there exists a tension value M1 before any current tension value that is greater than the average disturbance tension value, and the current tension value is less than M1, and the tension value before M1 is less than M1, then the current tension value is marked as a disturbance force value. All disturbance force values ​​collected during the resultant force period are constructed into a sequence according to time order, which is the resultant force sequence. Let the arithmetic mean of all disturbance force values ​​in the resultant force sequence be the equilibrium reference value; The number of disturbance force values ​​in the resultant force sequence that are greater than the equilibrium reference value is defined as the total positive offset, and the number of disturbance force values ​​that are less than the equilibrium reference value is defined as the total negative offset. The sum of the absolute values ​​of the differences between all tension values ​​that are less than the equilibrium reference value of the resultant force sequence and the equilibrium reference value in the tension value of each tension sequence during the resultant force period is the macroscopic cumulative tension base value; The sum of the absolute values ​​of the differences between all tension values ​​in each tension sequence that are less than the minimum disturbance force value in the resultant force sequence and the minimum disturbance force value in the resultant force sequence is the micro-accumulated tension base value. When the total positive offset is greater than the total negative offset, the maximum disturbance force value in the resultant force sequence is taken as the critical tension. If the macroscopic cumulative tension base value is greater than or equal to the critical tension, it is determined that the shielding wire has generated a resultant stress trend. When the total positive offset is less than or equal to the total negative offset, if the micro-accumulated tension base value is greater than or equal to the macro-accumulated tension base value, it is determined that the shielding wire does not have a tendency to generate a combined stress.

[0031] In this case, if there are many disturbance values ​​in the resultant force sequence that are greater than the equilibrium reference value, it indicates that the resultant force was generated within a short period of shielding wire twisting. Otherwise, it indicates that the resultant stress trend was generated over a longer period of shielding wire twisting, which is not easy to detect directly. Therefore, it is necessary to judge by the above two accumulated values: macroscopic accumulated tension base value and microscopic accumulated tension base value. By accumulating the difference within the resultant force period and judging accordingly, it is possible to indirectly determine whether a resultant stress trend has been generated. This solves the problem that the subtle stress changes generated during a long period of shielding wire twisting cannot be judged by the tension obtained by the sensor.

[0032] Furthermore, the method for automatically adjusting the spindle speed of the stranding machine specifically includes: The longest duration of the resultant force period is taken as the adjustment duration; the spindle speed of the stranding machine is reduced within one adjustment duration, and the original spindle speed of the stranding machine is restored after the adjustment duration ends.

[0033] Preferably, the method for reducing the spindle speed of the stranding machine is to reduce the current spindle speed of the stranding machine by a factor of 10 to 20%.

[0034] Therefore, by reducing the spindle speed of the stranding machine, the torsional stress of each individual shielded wire can be directly reduced, which in turn indirectly affects the tension of the shielded wire between the clamping and traction device and the stranding machine. This reduces the residual torsional internal stress of the cable, and reduces problems such as uneven stranding, wire core eccentricity, local hardening, serpentine deformation, and lantern-shaped bulges, thereby improving the cable's lifespan and the stability and performance of the communication signal.

[0035] This invention also provides a cable twist-free system, comprising: a processor, a memory, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the cable twist-free method. The cable twist-free system can run on computing devices such as desktop computers, laptops, handheld computers, and cloud data centers. The executable device may include, but is not limited to, a processor, a memory, and a server cluster. The processor executes the computer program within the following unit: The stress monitoring unit monitors the tension between the clamping and traction devices and monitors the stress value of the stranded cable core. The traction adjustment unit, when stranding in the non-twist mode, judges in real time whether the shielding wire is generating a tendency for combined stress based on the tension signal fed back by the shielding wire. If so, it automatically adjusts the spindle speed of the stranding machine.

[0036] The beneficial effects of this invention are as follows: This invention provides a method and system for cable twisting without twisting, which can directly reduce the torsional stress of each individual shield wire, thereby indirectly acting on the tension of the shield wire between the clamping and traction device and the twisting machine, reducing the residual torsional internal stress of the cable, reducing problems such as uneven twist pitch, wire core eccentricity, local hardening, serpentine deformation and lantern-shaped bulges, and improving the life of the cable and the stability and performance of the communication signal. Attached Figure Description

[0037] The above and other features of the present invention will become more apparent from the detailed description of the embodiments shown in conjunction with the accompanying drawings. In the accompanying drawings, the same reference numerals denote the same or similar elements. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without any creative effort. In the drawings: Figure 1 The diagram shows a flowchart of a cable twisting method. Figure 2 The diagram shows a structural diagram of a cable twisted-pair system. Detailed Implementation

[0038] The following will provide a clear and complete description of the concept, specific structure, and technical effects of the present invention in conjunction with the embodiments and accompanying drawings, so as to fully understand the purpose, solution, and effects of the present invention. It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0039] like Figure 1 The diagram shows a flowchart of a cable twisting method without twisting. The following section will combine... Figure 1 This invention describes a method for non-twisted cable twisting according to an embodiment of the present invention, the method comprising the following steps: Example 1: S100 uses a wire drawing machine to draw copper wire, and then anneals the copper wire to obtain annealed copper wire; S200 involves stranding multiple annealed copper wires into a core, and then simultaneously extruding the surface of the core using an extruder to form an insulation layer, thus obtaining an insulated core. S300 is a shielded wire formed by fully covering the surface of the insulated wire core with a metal shielding layer. S400 uses multiple shielding wires twisted together into cable cores using a non-untwisting method; In the process of stranding the wire into cable cores without unwinding, the shielding wire before stranding is clamped and pulled by a clamping and pulling device; tension monitoring is performed between the clamping and pulling device and the stranding machine. In particular, when stranding in the non-untwisting method, the tension signal fed back by the shielding wire is used to determine in real time whether the shielding wire is generating a tendency of combined stress. If so, the spindle speed of the stranding machine is automatically adjusted. The S500 uses a braiding machine to cross-braid metal wires on the outside of the cable core to form a mesh-like metal wire braided shielding layer. Then, a plastic liquid is extruded from the extruder to cover the cable core, and after cooling, a shaped cable is obtained.

[0040] Furthermore, in S100, the method of drawing copper wire using a wire drawing machine includes: drawing an oxygen-free copper rod with a diameter of 8mm into a copper wire with a diameter of 1mm using a wire drawing machine.

[0041] Furthermore, in S100, the method for annealing copper wire to obtain annealed copper wire includes: continuously annealing copper wire in a heat treatment chamber, wherein two annealing zones are set in the heat treatment chamber, the copper wire is heated to 300°C in the first annealing zone, and the atmosphere in the first annealing zone is not controlled; the single-wire copper wire is heated to 600°C in the second annealing zone, and the oxygen content in the air in the second annealing zone is controlled to be less than 1%.

[0042] Furthermore, in S200, the method of twisting multiple annealed copper wires into a core includes: twisting multiple annealed copper wires into a core using a single twisting machine.

[0043] Furthermore, in S200, the method for obtaining an insulated wire core by simultaneously extruding an insulating layer onto the surface of the wire core using an extruder specifically includes: The method of co-extruding molten plastic and nitrogen onto the surface of the wire core to obtain an insulated wire core involves: plasticizing and melting polyolefin plastic particles in an extruder, causing the polyolefin plastic particles to melt under heat in the extruder to obtain molten plastic, at a concentration of 0.25m... 3 Nitrogen is introduced into the screw chamber of the extruder at a nitrogen filling rate of / h until the atmospheric pressure inside the screw chamber reaches 1.5kPa. The molten plastic and nitrogen are then extruded together and coated onto the surface of the wire core to obtain an insulated wire core.

[0044] Preferably, the surface of the insulated wire core also needs to be corona treated.

[0045] Furthermore, in S300, the method of forming a shielded wire by fully covering the surface of the insulated wire core with a metal shielding layer specifically includes: using a wrapping machine to fully cover the insulated wire core with aluminum foil to form a metal shielding layer and thus form a shielded wire.

[0046] The wrapping machine is an HD-630D vertical tower tray automatic wrapping machine. Furthermore, in S400, the method for monitoring tension between the clamping traction device and the stranding machine is as follows: when the shielded wire is clamped between the clamping traction device and the stranding machine and tension is generated, a tension sensor is installed between the clamping traction device and the stranding machine, and the real-time tension of the clamped shielded wire is collected by the tension sensor.

[0047] The clamping and traction device includes an upper clamping part and a lower clamping part. Each clamping part includes a clamping belt. Each clamping belt is covered with multiple clamping rollers, which clamp and pull the cable through the clamping belt.

[0048] Each clamping belt moves synchronously with the traction belt via a timing belt and timing belt gear, and the traction belt is driven by a servo motor.

[0049] In this configuration, when the shielding wire between the tension sensor, clamping traction device, and stranding machine is clamped and tension is generated, the tension sensor detects a force vector, and the real-time tension vector of the cable tensioned along the shielding wire towards the stranding machine on both sides forms a parallelogram. Based on the parallelogram principle, the tension detected by the tension sensor can be converted into the real-time tension of the shielding wire.

[0050] The clamping and traction device includes an upper clamping part and a lower clamping part. Each clamping part includes a clamping belt. Each clamping belt is covered with multiple clamping rollers, which clamp and pull the shielding wire through the clamping belt.

[0051] Each clamping belt moves synchronously with the traction belt via a timing belt and timing belt gear, and the traction belt is driven by a servo motor.

[0052] The traction belt and clamping belt are synchronous gear belts.

[0053] The clamping and traction device introduces a synchronization signal for the stranding machine's linear speed. When the clamping belt is not tightened, the linear speed of the traction belt and the surface of the clamping belt is set to be consistent with the speed of the stranding machine.

[0054] In S500, the weaving equipment is a 24-spindle rope weaving machine.

[0055] Furthermore, in S500, the metal wire is a copper wire.

[0056] Furthermore, after the shielding wire is twisted into the cable core in a non-untwisting manner, it needs to be bundled and filled.

[0057] The filling process is to ensure the roundness and stability of the cable core; the binding process is to ensure that the cable core does not become loose.

[0058] The filler consists of 30 parts glass fiber, 23 parts elastomer, 37 parts carbon black, 5 parts polyphosphazene, and 5 parts antioxidant.

[0059] Preferably, the weaving equipment is a 24-spindle rope weaving machine, and the plastic is a polyolefin plastic.

[0060] The method of twisting the shielding wire into cable cores using a non-untwisting method involves using the rotation of a rigid cage of a rigid-frame stranding machine (maximum traction speed 66.45 m / min) to complete the stranding process, thus creating the cable core from the stranded wire of the shielding wire. The rigid-frame stranding machine is a frame type.

[0061] Furthermore, the specific method for determining in real time whether the shielding wire is prone to generating a resultant stress is as follows: After the stranding machine is started, all tension values ​​collected at time intervals (TimeF) for each shielded wire before stranding are compiled into a sequence and recorded as a tension sequence; where the time interval (TimeF) is set to 100 milliseconds. The maximum tension value in each tension sequence is the peak tension value of a single line, the minimum tension value is the valley tension value of a single line, and the average value is the mean tension value of a single line; the time period between the valley tension value and the peak tension value of a single line in each tension sequence is the stress-bearing period. The time intervals obtained by taking the intersection of all load-bearing time intervals are recorded as resultant force time intervals; the maximum value among all single-line tension averages is taken as the average disturbance tension. The disturbance force value is marked for each tension value in each tension sequence in turn. The specific method is as follows: if there exists a tension value M1 before any current tension value that is greater than the average disturbance tension value, and the current tension value is less than M1, and the tension value before M1 is less than M1, then the current tension value is marked as a disturbance force value. If there is no disturbance force value, it is determined that the shielding wire does not have a tendency to generate resultant stress; otherwise, it is determined that the shielding wire has generated a tendency to generate resultant stress.

[0062] Furthermore, the method for automatically adjusting the spindle speed of the stranding machine specifically includes: The longest duration of the resultant force period is taken as the adjustment duration; the spindle speed of the stranding machine is reduced within one adjustment duration, and the original spindle speed of the stranding machine is restored after the adjustment duration ends.

[0063] Example 2: Example 2 is based on Example 1, but replaces the method of real-time determination of whether the shielding wire generates a tendency for combined stress with the following method: Preferably, the specific method for determining in real time whether the shielding wire is generating a tendency for combined stress is as follows: After the stranding machine is started, all tension values ​​collected at time intervals (TimeF) for each shielded wire before stranding are compiled into a sequence and recorded as a tension sequence; where the time interval (TimeF) is set to 100 milliseconds. The maximum tension value in each tension sequence is the peak tension value of a single line, the minimum tension value is the valley tension value of a single line, and the average value is the mean tension value of a single line; the time period between the valley tension value and the peak tension value of a single line in each tension sequence is the stress-bearing period. The time intervals obtained by taking the intersection of all load-bearing time intervals are recorded as resultant force time intervals; the maximum value among all single-line tension averages is taken as the average disturbance tension. The disturbance force value is marked for each tension value in each tension sequence in turn. The specific method is as follows: if there exists a tension value M1 before any current tension value that is greater than the average disturbance tension value, and the current tension value is less than M1, and the tension value before M1 is less than M1, then the current tension value is marked as a disturbance force value. All disturbance force values ​​collected during the resultant force period are constructed into a sequence according to time order, which is the resultant force sequence. Let the arithmetic mean of all disturbance force values ​​in the resultant force sequence be the equilibrium reference value; The number of disturbance force values ​​in the resultant force sequence that are greater than the equilibrium reference value is defined as the total positive offset, and the number of disturbance force values ​​that are less than the equilibrium reference value is defined as the total negative offset. The sum of the absolute values ​​of the differences between all tension values ​​that are less than the equilibrium reference value of the resultant force sequence and the equilibrium reference value in the tension value of each tension sequence during the resultant force period is the macroscopic cumulative tension base value; The sum of the absolute values ​​of the differences between all tension values ​​in each tension sequence that are less than the minimum disturbance force value in the resultant force sequence and the minimum disturbance force value in the resultant force sequence is the micro-accumulated tension base value. When the total positive offset is greater than the total negative offset, the maximum disturbance force value in the resultant force sequence is taken as the critical tension. If the macroscopic cumulative tension base value is greater than or equal to the critical tension, it is determined that the shielding wire has generated a resultant stress trend. When the total positive offset is less than or equal to the total negative offset, if the micro-accumulated tension base value is greater than or equal to the macro-accumulated tension base value, it is determined that the shielding wire does not have a tendency to generate a combined stress.

[0064] Comparative example: A method for manufacturing a twisted-pair cable includes the following steps: S1. Wire drawing: Select copper wire and use a wire drawing mechanism to form core conductors. Each single conductor is wrapped with an insulation layer. S2. Twisted pair: Two core wires form a twisted pair, which are twisted together using a twisted structure; S3. Cable Formation: Cables are formed using a rigid frame stranding machine; S4. Sheath: The glass fiber, elastomer, carbon black, polyphosphazene and antioxidant are mixed in the specified mass ratio, and mechanically stirred to obtain a mixture. The mixture is then extruded and granulated to obtain a sheath. A layer of sheath is wrapped around the cable to obtain the finished cable. The mass ratio of the components in the mixture is: 30 parts glass fiber, 23 parts elastomer, 37 parts carbon black, 5 parts polyphosphazene, and 5 parts antioxidant.

[0065] 1000-meter lengths of the finished cables prepared in Examples 1, 2, and the comparative example were cut and coiled onto cable reels. The cables from Examples 1, 2, and the comparative example were subjected to mechanical property testing using a CMT4204 plastic bending tester. The diameter was measured using a laser diameter gauge (ISO / IEC 11801: specifies that the average outer diameter range of Category 5e / 6 twisted pair cables is 5.0±0.2mm, with an allowable error of ±0.1mm (based on YD / T 1019-2013 "Polyolefin Insulated Horizontal Twisted Pair Cables for Digital Communication")). The mechanical property test data obtained from the tests are as follows: The test data for Example 1 are as follows: elongation at break is 208%, tensile strength is 15.7 MPa, outer diameter is 5.0±0.15 mm, and there is no serpentine deformation after the cable is unwound from the cable reel. The test data for Example 2 are as follows: elongation at break is 232%, tensile strength is 16.1 MPa, outer diameter is 5.0 ± 0.11 mm, and there is no serpentine deformation after the cable is unwound from the cable reel. The comparative test data are as follows: elongation at break is 177%, tensile strength is 15.1 MPa, outer diameter is 5.0 ± 0.18 mm, and slight serpentine deformation occurs after the cable is unwound from the cable reel.

[0066] Note: The serpentine deformation phenomenon occurs when cables are uncoiled or cut, and due to the release of internal stress, they will automatically curl and knot, twisting like a snake, which makes construction difficult.

[0067] Based on the above test results, it can be seen that the elongation at break and tensile strength of the finished cable products prepared according to Examples 1 and 2 are better than those of the comparative example, and they have good mechanical properties, no serpentine deformation, low residual torsional internal stress, and stable structure compared with the comparative example.

[0068] An embodiment of the present invention provides a cable twist-free pair system, such as... Figure 2The diagram shown is a structural diagram of a cable twistless pair system according to the present invention. The cable twistless pair system of this embodiment includes: a processor, a memory, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the above-described cable twistless pair system embodiment.

[0069] The stress monitoring unit monitors the tension between the clamping and traction devices and monitors the stress value of the stranded cable core. The traction adjustment unit compares the stress value difference based on the feedback tension signal of the shielded wire when twisting in the non-unwinding mode. When the difference exceeds the peak value, it automatically adjusts the traction speed of the shielded wire.

[0070] The described cable twistless pair system can operate in computing devices such as desktop computers, laptops, handheld computers, and cloud servers. The devices that can run in the described cable twistless pair system may include, but are not limited to, processors and memory. Those skilled in the art will understand that the examples described are merely illustrations of a cable twistless pair system and do not constitute a limitation on such a system. It may include more or fewer components, combinations of certain components, or different components. For example, the described cable twistless pair system may also include input / output devices, network access devices, buses, etc.

[0071] The processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor. The processor is the control center of the cable twistless pair system operating device, connecting all parts of the entire cable twistless pair system operating device via various interfaces and lines.

[0072] The memory can be used to store the computer program and / or modules. The processor implements various functions of the cable twistless pair system by running or executing the computer program and / or modules stored in the memory and calling the data stored in the memory. The memory may mainly include a program storage area and a data storage area. The program storage area may store the operating device and the application program required for at least one function (such as sound playback function, image playback function, etc.). The data storage area may store data created according to the use of the mobile phone (such as audio data, phonebook, etc.). In addition, the memory may include high-speed random access memory and non-volatile memory, such as hard disk, memory, plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, at least one disk storage device, flash memory device, or other volatile solid-state storage device.

[0073] Although the invention has been described in considerable detail and particularly with regard to several of the described embodiments, it is not intended to limit itself to any of these details or embodiments or any particular embodiment, thereby effectively covering the intended scope of the invention. Furthermore, the invention has been described above with respect to embodiments foreseeable by the inventors in order to provide a useful description, and non-substantial modifications to the invention that have not yet been foreseen may still represent equivalent modifications.

Claims

1. A method for twisting cables without twisting, characterized in that, The method includes the following steps: S100 uses a wire drawing machine to draw copper wire, and then anneals the copper wire to obtain annealed copper wire; S200 involves stranding multiple annealed copper wires into a core, and then simultaneously extruding the surface of the core using an extruder to form an insulation layer, thus obtaining an insulated core. S300 is a shielded wire formed by fully covering the surface of the insulated wire core with a metal shielding layer. S400 uses multiple shielding wires twisted together into cable cores using a non-untwisting method; In the process of stranding the wire into cable cores without unwinding, the shielding wire before stranding is clamped and pulled by a clamping and pulling device; tension monitoring is performed between the clamping and pulling device and the stranding machine. In particular, when stranding in the non-untwisting method, the tension signal fed back by the shielding wire is used to determine in real time whether the shielding wire is generating a tendency of combined stress. If so, the spindle speed of the stranding machine is automatically adjusted. S500 uses braiding equipment to cross-braid metal wires on the outside of the cable core to form a mesh-like metal wire braided shielding layer. Then, it uses an extruder to extrude liquid plastic to cover the cable core and obtains a shaped cable after cooling. The specific method for determining in real time whether the shielding wire is prone to generating a combined stress is as follows: After the stranding machine is started, all tension values ​​collected at time intervals (TimeF) for each shielded wire before stranding are compiled into a sequence, which is called the tension sequence. The maximum tension value in each tension sequence is the single-wire tension peak value, the minimum tension value is the single-wire tension valley value, and the average value is the single-wire tension mean value. The time interval between the single-wire tension valley value and the single-wire tension peak value in each tension sequence is the stress-bearing period. The time intervals obtained by taking the intersection of all load-bearing time intervals are recorded as resultant force time intervals; the maximum value among all single-line tension averages is taken as the disturbance tension average; the disturbance force value is marked for each tension value in each tension sequence in turn. The specific method is as follows: if there exists a tension value M1 before any current tension value that is greater than the disturbance tension average, and the current tension value is less than M1, and the tension value before M1 is less than M1, then the current tension value is marked as the disturbance force value. If there is no disturbance force value, it is determined that the shielding wire does not have a tendency to generate resultant stress; otherwise, it is determined that the shielding wire has generated a tendency to generate resultant stress.

2. A method for twisting cables without twisting, characterized in that, The method includes the following steps: S100 uses a wire drawing machine to draw copper wire, and then anneals the copper wire to obtain annealed copper wire; S200 involves stranding multiple annealed copper wires into a core, and then simultaneously extruding the surface of the core using an extruder to form an insulation layer, thus obtaining an insulated core. S300 is a shielded wire formed by fully covering the surface of the insulated wire core with a metal shielding layer. S400 uses multiple shielding wires twisted together into cable cores using a non-untwisting method; In the process of stranding the wire into cable cores without unwinding, the shielding wire before stranding is clamped and pulled by a clamping and pulling device; tension monitoring is performed between the clamping and pulling device and the stranding machine. In particular, when stranding in the non-untwisting method, the tension signal fed back by the shielding wire is used to determine in real time whether the shielding wire is generating a tendency of combined stress. If so, the spindle speed of the stranding machine is automatically adjusted. S500 uses braiding equipment to cross-braid metal wires on the outside of the cable core to form a mesh-like metal wire braided shielding layer. Then, it uses an extruder to extrude liquid plastic to cover the cable core and obtains a shaped cable after cooling. The specific method for determining in real time whether the shielding wire is generating a tendency for combined stress is as follows: After the stranding machine is started, all tension values ​​collected at time intervals (TimeF) for each shielded wire before stranding are compiled into a sequence, which is recorded as the tension sequence. The maximum tension value in each tension sequence is the peak tension value of a single line, the minimum tension value is the valley tension value of a single line, and the average value is the mean tension value of a single line; the time period between the valley tension value and the peak tension value of a single line in each tension sequence is the stress-bearing period. The time intervals obtained by taking the intersection of all load-bearing time intervals are recorded as resultant force time intervals; the maximum value among all single-line tension averages is taken as the disturbance tension average; the disturbance force value is marked for each tension value in each tension sequence in turn. The specific method is as follows: if there exists a tension value M1 before any current tension value that is greater than the disturbance tension average, and the current tension value is less than M1, and the tension value before M1 is less than M1, then the current tension value is marked as the disturbance force value. All disturbance force values ​​collected during the resultant force period are constructed into a sequence according to time order, which is the resultant force sequence. Let the arithmetic mean of all disturbance force values ​​in the resultant force sequence be the equilibrium reference value; The number of disturbance force values ​​in the resultant force sequence that are greater than the equilibrium reference value is defined as the total positive offset, and the number of disturbance force values ​​that are less than the equilibrium reference value is defined as the total negative offset. The sum of the absolute values ​​of the differences between all tension values ​​that are less than the equilibrium reference value of the resultant force sequence and the equilibrium reference value in the tension value of each tension sequence during the resultant force period is the macroscopic cumulative tension base value; The sum of the absolute values ​​of the differences between all tension values ​​in each tension sequence that are less than the minimum disturbance force value in the resultant force sequence and the minimum disturbance force value in the resultant force sequence is the micro-accumulated tension base value. When the total positive offset is greater than the total negative offset, the maximum disturbance force value in the resultant force sequence is taken as the critical tension. If the macroscopic cumulative tension base value is greater than or equal to the critical tension, it is determined that the shielding wire has generated a resultant stress trend. When the total positive offset is less than or equal to the total negative offset, if the micro-accumulated tension base value is greater than or equal to the macro-accumulated tension base value, it is determined that the shielding wire does not have a tendency to generate a combined stress.

3. A method for twisting cables without twisting according to claim 1 or 2, characterized in that, The method for monitoring tension between the clamping traction device and the stranding machine is as follows: when the shielded wire is clamped between the clamping traction device and the stranding machine and tension is generated, the tension sensor located between the clamping traction device and the stranding machine collects the real-time tension of the clamped shielded wire.

4. A method for twisting cables without twisting according to claim 1 or 2, characterized in that, The specific methods for automatically adjusting the spindle speed of a stranding machine include: The longest duration of the resultant force period is taken as the adjustment duration; the spindle speed of the stranding machine is reduced within one adjustment duration, and the original spindle speed of the stranding machine is restored after the adjustment duration ends.

5. A cable twist-free pair system, characterized in that, The cable twistless pair system includes: a processor, a memory, and a computer program stored in the memory and running on the processor. When the processor executes the computer program, it implements the steps of the cable twistless pair method according to any one of claims 1 to 2.

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