Universal anti-blocking die holder for cable production

Abstract

This invention provides a universal anti-clogging mold base for cable production. The mold base includes a fixed base, a movable mold base, an elastic element, and a position sensor. The elastic element is located between the fixed base and the movable mold base, and its preload is set to a mechanical threshold greater than the normal production axial force but less than the minimum impact force for mold clogging. The movable mold base has a standardized cavity with a replaceable mold core sleeve inside. The position sensor is electrically connected to the production line control system. When mold clogging occurs, the axial thrust pushes the movable mold base to move, triggering the sensor and achieving automatic emergency stop. This invention also includes a preload adjustment structure, and the contact surface between the mold base and the cable core is rounded. It achieves real-time, direct, and automated monitoring of mold clogging, significantly reducing material waste and equipment wear. It is adaptable to the production of multiple cable specifications, has strong versatility, reduces reliance on manual labor, and ensures cable product quality and production line operation safety.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and in particular to a universal anti-clogging mold base for cable manufacturing. Background Technology

[0002] In the continuous cable production process, the stabilizing die is the core guiding device that ensures the stability of conductor or cable core transport. Most existing stabilizing dies are designed with a half-and-half structure, and their inner diameter is 3-10mm larger than the conductor core. As the first guiding component as the cable core passes through the production line, its normal operation is crucial to the continuity and stability of cable production. However, in actual production, die blockage is a typical production anomaly with a high incidence and significant hazards. The core cause is that during production or when changing specifications, the pull head and temporary connector of the traction cable are often improperly manufactured, resulting in oversized or oddly shaped parts that easily become stuck when passing through the stabilizing die.

[0003] Not only does die blockage cause serious damage to the cable itself, but for multi-strand stranded conductors, it can also cause excessive twisting, disrupting their inherent pitch and structural stability. Furthermore, since cable production is a continuous operation, even if the operator stops the machine within seconds of the blockage, tens or even hundreds of meters of cable can still be scrapped, resulting in significant material losses. Simultaneously, the enormous, continuous tension generated by the blockage acts in the opposite direction on various equipment on the production line. This can easily damage the stabilizing die holder itself, cause slippage and wear on the traction wheels, and create impact loads on the front-end wire feeding equipment and the rear-end wire take-up equipment. Over time, this accelerates equipment wear throughout the entire production line, creating potential safety hazards.

[0004] Currently, there is no dedicated automated monitoring and shutdown device to address the problem of mold blockage. Production line operators rely solely on manual methods, such as listening to equipment operation sounds and observing the appearance of conductors / cable cores, to determine if blockage has occurred and then manually pressing the emergency stop button to halt production. This monitoring method is indirect and depends entirely on the operator's personal experience, attention, and physical condition. This leads to inconsistent judgment standards and susceptibility to misjudgments or omissions due to fatigue or lack of concentration. Furthermore, by the time a blockage is manually detected and a shutdown is initiated, the blockage has already occurred, resulting in irreparable quality problems in the conductor or cable core, making it impossible to prevent losses at the source. Additionally, the hidden costs of manual monitoring are high, and the product scrapping and equipment damage caused by blockage remain unresolved. Against this industry backdrop, there is an urgent need for a universal anti-blockage mold holder that can achieve real-time direct monitoring of blockage and automatically trigger an emergency shutdown to overcome the many shortcomings of existing technologies and ensure product quality and equipment safety in cable production. Summary of the Invention

[0005] This invention provides a universal anti-clogging mold base for cable production, which addresses the deficiencies in the prior art.

[0006] This invention provides a universal anti-clogging mold base for cable production, comprising a fixed base, a movable mold base, an elastic element, and a position sensor; The elastic element is disposed between the fixed base and the movable mold base. The elastic element is configured to provide a preload to hold the movable mold base in its initial working position. The preload is greater than the sum of the axial forces generated by the cable core during cable production and less than the minimum impact force generated when the mold is blocked. The movable mold base has a standardized cavity, which is used to place the mold core sleeve that is adapted to the half-stabilized mold. The position sensor is electrically connected to the control system of the cable production line. When the axial thrust generated by the mold blockage pushes the movable mold seat to produce a slight displacement, the position sensor is triggered and sends a signal to the control system to control the emergency shutdown of the cable production line.

[0007] According to the present invention, a universal anti-clogging mold base for cable production is provided, wherein the elastic element is a compression spring, the number of the compression springs is 3-4, and each of the compression springs is evenly distributed between the fixed base and the movable mold base.

[0008] According to the present invention, a general-purpose anti-clogging mold base for cable production further includes a preload adjustment structure, wherein the preload adjustment structure is an adjustment screw, the adjustment screw cooperates with the elastic element, and the magnitude of the preload is adjusted by changing the initial compression of the elastic element.

[0009] According to the present invention, a universal anti-clogging mold base for cable production is provided, wherein the mold core sleeve is a replaceable structure, which can be adapted to different specifications of half-stabilizing molds to meet the production needs of different specifications of cables.

[0010] According to the present invention, a universal anti-clogging mold base for cable production is provided, wherein all surfaces of the movable mold base that come into contact with the cable core, as well as the inner edge of the mold core sleeve, are rounded and smoothed.

[0011] According to the present invention, a universal anti-clogging mold base for cable production is provided, wherein the initial working position of the movable mold base is towards the upstream direction of the cable production line.

[0012] According to the present invention, a universal anti-clogging mold base for cable production is provided, wherein the initial state of the elastic element is a compressed state, and the preload is the elastic force generated after the elastic element is compressed.

[0013] According to the present invention, a universal anti-clogging mold base for cable production is provided, wherein the position sensor is a displacement sensor, and the detection end of the displacement sensor abuts against the outer wall of the movable mold base to detect the axial displacement of the movable mold base.

[0014] The present invention provides a universal anti-clogging mold base for cable production, which has the following beneficial effects: (1) Realize real-time, direct and automated monitoring and shutdown of mold blockage, and transform the axial thrust of mold blockage that cannot be directly detected into a mold seat displacement signal that can be accurately captured. When the axial force generated by mold blockage exceeds the preset pre-tightening force threshold of the elastic element, the small displacement of the mold seat will immediately trigger the position sensor, and send a signal to the production line control system simultaneously to achieve emergency shutdown. This changes the traditional "passive shutdown after manual discovery of abnormality" to "automatic active shutdown at the moment of abnormality", and completely solves the problem of lag in the existing indirect monitoring method.

[0015] (2) Minimize material waste and equipment wear. The production line can be stopped instantly when the mold blockage occurs, which greatly shortens the duration of the mold blockage and effectively reduces the length of scrapped cables and reduces raw material loss. At the same time, it avoids the huge tension generated by the mold blockage from acting on the production line equipment for a long time, reduces the impact load on the stabilizing mold base, traction wheel, and wire feeding / receiving equipment, slows down the overall wear rate of the equipment, eliminates the production safety hazards caused by the mold blockage, and improves the operation safety and service life of the cable production line.

[0016] (3) It has high versatility and process adaptability. The movable mold seat is equipped with a standardized cavity. The half-stabilizing mold is installed in the cavity through the mold core sleeve. When changing the cable specification, only the small and lightweight mold core sleeve needs to be replaced. There is no need to replace the entire movable mold seat, which greatly reduces the cost of accessories and the complexity of operation when changing specifications. At the same time, the preload of the elastic element can be flexibly adjusted by adjusting the screw. Different trigger force thresholds can be accurately set to adapt to the production needs of cable products with different weights, materials and process tensions. It can be used on various cable production lines and has a wide range of applications.

[0017] (4) It significantly reduces the reliance on manual labor in production, improves production efficiency and stability, replaces the traditional manual listening and observation method for judging blockage, eliminates the production risks caused by human factors such as different judgment standards of different operators and fatigue omissions, and reduces the workload of operators; at the same time, the specification switching operation is simple and quick, reduces the downtime adjustment time of the production line, ensures the continuity of cable production, and improves the overall production efficiency.

[0018] (5) Effectively protect the surface quality of the cable core and ensure product quality. The edges of the mold and all surfaces in contact with the cable core are rounded and smoothed. Even during the process of mold jamming and mold base reset and release, the scratches and wear on the surface of the cable core can be minimized, avoiding the introduction of new product quality defects due to mold base structure problems, and ensuring the structural and surface integrity of the cable conductor / cable core.

[0019] (6) The monitoring trigger is accurate and there are no invalid false triggers. The preload of the elastic element is precisely calculated and calibrated by experiments. It is set to be greater than the sum of the axial forces generated by the cable core due to friction and vibration during normal production, and significantly less than the minimum impact force when the mold is blocked. This forms an accurate mechanical trigger threshold, ensuring that the mold base always maintains the initial working position during normal production. It will not cause the sensor to be falsely triggered by the slight force of the cable core during normal transportation, thus ensuring the normal and continuous operation of the production line and improving the reliability and accuracy of the monitoring system. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the overall structure of a universal anti-clogging mold base for cable production provided in an embodiment of the present invention.

[0022] Figure label: 1. Fixed base; 2. Movable mold base; 3. Elastic element; 4. Position sensor; 5. Adjusting screw. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0024] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0025] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0026] In the description of the embodiments of the present invention, it should be noted that the terms "inner", "outer", "upper", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention 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. Therefore, they should not be construed as limiting the present invention.

[0027] This application provides a general-purpose anti-clogging mold base for cable production, including a fixed base 1, a movable mold base 2, an elastic element 3, and a position sensor 4; The elastic element 3 is disposed between the fixed base 1 and the movable mold base 2. The elastic element 3 is configured to provide a preload to hold the movable mold base 2 in its initial working position. The preload is greater than the sum of the axial forces generated by the cable core during cable production and less than the minimum impact force generated when the mold is blocked. The movable mold base 2 has a standardized cavity, which is used to place the mold core sleeve that is adapted to the half-stabilized mold. The position sensor 4 is electrically connected to the control system of the cable production line. When the axial thrust generated by the mold blockage pushes the movable mold seat to produce a small displacement, the position sensor 4 is triggered and sends a signal to the control system to control the emergency shutdown of the cable production line.

[0028] The elastic element 3 is a compression spring, and there are 3-4 compression springs, which are evenly distributed between the fixed base 1 and the movable mold base 2.

[0029] It also includes a preload adjustment structure, which is an adjustment screw 5. The adjustment screw 5 cooperates with the elastic element 3 to adjust the magnitude of the preload by changing the initial compression of the elastic element 3.

[0030] The mold core sleeve is a replaceable structure, adaptable to different specifications of half-stabilized molds, to meet the production needs of cables of different specifications.

[0031] All surfaces of the movable mold base 2 that come into contact with the cable core, as well as the inner edge of the mold core sleeve, are rounded and smoothed.

[0032] The initial working position of the movable mold base 2 is facing upstream of the cable production line.

[0033] The initial state of the elastic element 3 is a compressed state, and the preload is the elastic force generated after the elastic element 3 is compressed.

[0034] The position sensor 4 is a displacement sensor. The detection end of the displacement sensor abuts against the outer wall of the movable mold base 2 and is used to detect the axial displacement of the movable mold base 2.

[0035] Working Principle: This universal anti-clogging mold holder for cable production is designed based on the core principles of mechanical threshold recognition and mechanical displacement sensing. It utilizes the difference in magnitude between the axial force exerted by the cable core on the stable mold during mold clogging faults and normal production. Through the elastic element 3, a precise mechanical trigger threshold is constructed, converting the axial thrust of the mold clogging, which cannot be directly detected, into a precisely captured mechanical displacement signal. Then, through the position sensor 4, the mechanical signal is converted into an electrical signal, realizing real-time monitoring of mold clogging anomalies and automatic emergency shutdown of the production line. At the same time, through the standardized and replaceable mold core sleeve and the adjustable elastic preload design, the mold holder can be adapted to the production of cables with different specifications and process requirements, achieving universal application.

[0036] An elastic element 3 is set between the fixed base 1 and the movable mold base 2. The elastic element 3 generates an adjustable pre-tightening force through pre-compression. This pre-tightening force is precisely calculated and experimentally calibrated to be greater than the sum of the axial forces generated by the cable core due to friction and vibration during normal production, and significantly less than the minimum axial impact force generated when the mold is blocked. This forms a natural mechanical identification threshold, enabling the differentiation between the mechanical signals of normal production and abnormal mold blockage.

[0037] During normal production, the preload of the elastic element 2 can stabilize the movable mold seat 2 in the initial working position, and the position sensor 4 is not triggered. When mold blockage occurs, the huge axial thrust transmitted by the cable core breaks through the mechanical threshold and pushes the movable mold seat 2 to produce a small axial displacement. This displacement directly triggers the position sensor 4, which then sends an electrical signal to the production line control system. After receiving the signal, the control system immediately issues an emergency stop command to realize an automated response to the mold blockage abnormality.

[0038] The movable mold base 2 has a standardized cavity. The half-stabilizing mold is installed in the cavity through a special mold core sleeve. When changing the cable production specifications, only the mold core sleeve that adapts to the new specifications needs to be replaced, without replacing the entire movable mold base. At the same time, by adjusting the structure to change the initial compression of the elastic element, the preload can be flexibly adjusted to adapt to the production needs of cables with different weights, materials, and process tensions, thus realizing the universal design of the mold base.

[0039] All surfaces and edges of the movable mold base 2 and mold core sleeve that come into contact with the cable core are rounded and smoothed. During the mold base displacement and mold block release process, the hard friction and scratching between the components and the cable core are minimized, and new cable core quality defects are avoided due to the movement of the mold base structure.

[0040] Working Process: The working process of this anti-clogging mold holder is mainly divided into three stages: normal production condition, mold clogging abnormality triggering condition, and shutdown reset and specification change condition. Each component works in coordination during each stage to ensure stable cable production and rapid handling of mold clogging abnormalities. Normal production conditions: First, according to the specifications, material, and process tension requirements of the cable to be produced, adjust the initial compression of the elastic element 3 (3-4 evenly distributed compression springs) by adjusting the screw 5, set the appropriate pre-tightening force threshold, install the half-stabilizing mold that is suitable for the cable specification into the mold core sleeve, and then embed the mold core sleeve into the standardized cavity of the movable mold base 2 to complete the pre-production debugging of the mold base.

[0041] After debugging, the movable mold seat 2 is stabilized in the initial working position facing upstream of the incoming line by the pre-tightening force of the elastic element 3. The position sensor 4 maintains the initial engagement state with the movable mold seat 2 and there is no signal output. The production line starts and the cable core is conveyed forward through the half-stabilizing mold. During normal production, the cable core only generates slight friction and vibration-like axial force on the movable mold seat. This force is less than the pre-tightening force of the elastic element 3. The movable mold seat 2 always remains stationary and the production line continues to operate stably.

[0042] Mold blockage abnormality triggering condition: When mold blockage occurs, the cable core pull head / temporary joint gets stuck at the half stabilizing mold due to specifications or other problems. The traction force at the back end of the production line is directly transmitted to the movable mold seat 2 through the cable core, forming a huge axial thrust opposite to the direction of cable core movement.

[0043] When the value of the axial thrust exceeds the preset preload threshold of the elastic element 3, the elastic element 3 is further compressed, and the movable mold seat 2 overcomes the preload to generate a small axial displacement, deviating from the initial working position.

[0044] The displacement of the movable mold base 2 immediately triggers the position sensor 4. The sensor quickly converts the mechanical displacement signal into an electrical signal and transmits the abnormal signal to the control system of the cable production line in real time.

[0045] After receiving the abnormal signal of mold blockage, the control system immediately executes the emergency shutdown procedure, cutting off the power sources of the production line such as traction, wire feeding, and wire take-up. The production line stops operating in a very short time to prevent the huge tension generated by the mold blockage from continuing to act on the cable core and production equipment.

[0046] The entire process from mold blockage triggering to production line shutdown is automated, requiring no manual intervention. The response time from the occurrence of the abnormality to the shutdown is extremely short, minimizing the duration of the mold blockage abnormality.

[0047] Shutdown Reset and Specification Change Operation: Mold Blockage Handling and Mold Base Reset: After the production line stops, the operator handles the mold blockage point, removes the pull head / temporary connector stuck at the stabilizing mold, and checks the integrity of the cable core, mold core sleeve and half stabilizing mold; after handling, manually push the movable mold base 2 back to the initial working position facing upstream of the incoming line, the elastic element 3 returns to the preset pre-tightened compression state, the position sensor 4 resets, and the abnormal signal output is released.

[0048] Production line restart: After confirming that there are no abnormalities in the mold base, cable core, and all equipment on the production line, the production line is started. The movable mold base 2 returns to its initial working position, and the mold base resumes normal production monitoring and assurance status.

[0049] Cable specification change: When it is necessary to switch to producing cables of different specifications, the operator does not need to disassemble the main structure such as the fixed base 1 and the movable mold base 2. The operator only needs to take out the original specification mold core sleeve from the standardized cavity of the movable mold base 2 and replace it with a mold core sleeve that is compatible with the new specification cable (and install the corresponding half stabilizer). Then, according to the material and process tension requirements of the new cable, the operator can adjust the preload of the elastic element 3 by adjusting the screw 5 to reset the threshold and start the production of the new specification cable. The entire specification change process is simple to operate and short in time, which greatly reduces the downtime adjustment time of the production line.

[0050] This invention provides a universal anti-clogging mold holder for cable production, enabling real-time, direct, and automated monitoring and shutdown of mold blockage. It transforms the axial thrust of the mold blockage, which cannot be directly detected, into a mold displacement signal that can be accurately captured. When the axial force generated by the mold blockage exceeds the preset preload threshold of the elastic element, the slight displacement of the mold holder will immediately trigger the position sensor, simultaneously sending a signal to the production line control system and achieving an emergency shutdown. This transforms the traditional "passive shutdown after manual discovery of abnormalities" into "automatic active shutdown the instant an abnormality occurs," completely solving the problem of lag in existing indirect monitoring methods.

[0051] By minimizing material waste and equipment wear, the production line can be stopped instantly when mold blockage occurs, significantly shortening the duration of the blockage and effectively reducing the length of scrapped cables, thus reducing raw material loss. At the same time, it avoids the enormous tension generated by the blockage acting on the production line equipment for a long time, reducing the impact load on the stabilizing mold base, traction wheel, and wire feeding / receiving equipment, slowing down the overall wear rate of the equipment, eliminating the production safety hazards caused by the blockage, and improving the operational safety and service life of the cable production line.

[0052] With high versatility and process adaptability, the movable mold base has a standardized cavity, and the half-stabilizing mold is installed in the cavity through the mold core sleeve. When changing cable specifications, only the small and lightweight mold core sleeve needs to be replaced, without replacing the entire movable mold base, which greatly reduces the accessory cost and operational complexity of specification switching. At the same time, the preload of the elastic element can be flexibly adjusted by adjusting the screw, and different trigger force thresholds can be precisely set to adapt to the production needs of cable products with different weights, materials and process tensions. It can be used on various cable production lines and has a wide range of applications.

[0053] It significantly reduces the reliance on manual labor in production, improves production efficiency and stability, and replaces the traditional method of judging blockages by listening and observing. It eliminates the production risks caused by human factors such as inconsistent judgment standards among different operators and missed judgments due to fatigue, and reduces the workload of operators. At the same time, the specification switching operation is simple and quick, reducing the downtime of the production line for adjustment, ensuring the continuity of cable production, and improving overall production efficiency.

[0054] Effectively protects the surface quality of the cable core and ensures product quality. The edges of the mold and all surfaces in contact with the cable core are rounded and smoothed. Even during the process of mold jamming and mold base reset and release, it can minimize scratches and wear on the surface of the cable core, avoid introducing new product quality defects due to mold base structure problems, and ensure the structural and surface integrity of the cable conductor / core.

[0055] The monitoring trigger is accurate, with no invalid false triggers. The preload of the elastic element is precisely calculated and calibrated experimentally. It is set to be greater than the sum of the axial forces generated by the cable core due to friction and vibration during normal production, and significantly less than the minimum impact force when the mold is blocked. This forms a precise mechanical trigger threshold, ensuring that the mold base always maintains its initial working position during normal production. It will not cause false triggering of the sensor due to the slight force of normal cable core transmission, thus ensuring the normal and continuous operation of the production line and improving the reliability and accuracy of the monitoring system.

[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A universal anti-clogging mold base for cable production, characterized in that, Includes a fixed base, a movable mold base, elastic elements, and a position sensor; The elastic element is disposed between the fixed base and the movable mold base. The elastic element is configured to provide a preload to hold the movable mold base in its initial working position. The preload is greater than the sum of the axial forces generated by the cable core during cable production and less than the minimum impact force generated when the mold is blocked. The movable mold base has a standardized cavity, which is used to place the mold core sleeve that is adapted to the half-stabilized mold. The position sensor is electrically connected to the control system of the cable production line. When the axial thrust generated by the mold blockage pushes the movable mold seat to produce a slight displacement, the position sensor is triggered and sends a signal to the control system to control the emergency shutdown of the cable production line.

2. The universal anti-clogging mold base for cable production according to claim 1, characterized in that, The elastic element is a compression spring, and there are 3-4 compression springs, which are evenly distributed between the fixed base and the movable mold base.

3. The universal anti-clogging mold base for cable production according to claim 2, characterized in that, It also includes a preload adjustment structure, which is an adjustment screw that cooperates with the elastic element to adjust the magnitude of the preload by changing the initial compression of the elastic element.

4. The universal anti-clogging mold base for cable production according to claim 1, characterized in that, The mold core sleeve is a replaceable structure, adaptable to different specifications of half-stabilized molds, to meet the production needs of cables of different specifications.

5. A universal anti-clogging mold base for cable production according to claim 1, characterized in that, All surfaces of the movable mold base that come into contact with the cable core, as well as the inner edge of the mold core sleeve, are rounded and smoothed.

6. A universal anti-clogging mold base for cable production according to claim 1, characterized in that, The initial working position of the movable mold base is facing upstream of the cable production line.

7. A universal anti-clogging mold base for cable production according to claim 1, characterized in that, The initial state of the elastic element is a compressed state, and the preload is the elastic force generated after the elastic element is compressed.

8. A universal anti-clogging mold base for cable production according to claim 1, characterized in that, The position sensor is a displacement sensor, and the detection end of the displacement sensor abuts against the outer wall of the movable mold base to detect the axial displacement of the movable mold base.

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