Cabling machine for cable production and method thereof

Abstract

This invention relates to the field of cable production, specifically disclosing a cable forming machine and method for cable production. The machine includes a stranding device, which is integrally configured with a large turntable, a small turntable, and a stranding disc according to the cable's travel direction. The large turntable is equipped with several core frames and core cylinders. Cores from the core cylinders are led out and sequentially pass through perforations around the core frames, the small turntable, and the stranding disc before entering the die head. A material cylinder is installed at the end of the small turntable closest to the cable's travel direction, and a filler rope is wound around the material cylinder. The filler rope is led out from the material cylinder, passes through the stranding disc, and enters the die head. With the large turntable, small turntable, and stranding disc rotating as a whole, multiple cores and filler ropes are stranded into a cylindrical cable. An adjustment component is located at the end where the cores are led out, used to ensure that the tension of the cores led out from the multiple core cylinders is consistent.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and in particular to a cable forming machine and method for cable production. Background Technology

[0002] For outdoor high and low voltage power cables, the cable forming machine is a key piece of equipment in its manufacturing process. It is mainly used to twist multiple insulated wire cores (electrical cores) with filler materials into a tightly structured cylindrical cable core. Its core principle is to use the synchronous rotation of a large turntable, a small turntable, and a stranding disc, combined with the sizing action of the die head, to spirally twist the scattered individual wire cores according to a preset pitch. During the stranding process, a tension adjustment mechanism is used to ensure that each wire core is subjected to uniform force, thereby ensuring the roundness, stability, and electrical performance of the final cable, meeting the requirements of outdoor high and low voltage power supply.

[0003] When multiple cores are stranded together, the winding tension of the cores on each core's spool is not uniform because the winding process relies solely on rotation during core production. For example, prior art publication CN121601351A discloses a novel flexible, environmentally friendly, flame-retardant, and fire-resistant low-voltage power cable forming device. This device includes a fixed base, a wire feeding device fixedly connected to one side of the fixed base, a second feeding block fixedly connected to one end of the feeding device, a stranding turntable fixedly connected to the other end of the second feeding block, multiple sets of flame-retardant and fire-resistant material feeders rotatably connected to one side of the second feeding block, an extrusion device fixedly connected to one side of the fixed base, a drive mechanism located between the second feeding block and the stranding turntable, and a first winding mechanism located on the second feeding block. Similarly, prior art publication CN121583647A discloses a conductor surface treatment device and method for cable manufacturing, both of which disclose specific solutions for stranded cables.

[0004] The above-mentioned solutions and other existing technologies do not disclose a method for adjusting the tension of the lead-out of the battery cells. As a result, the battery cells with lower tension and those with higher tension experience different forces after stranding and during use. The tension is applied to the battery cells with higher tension, while the battery cells with lower tension are not subjected to any force. After the cable is put into use in outdoor high and low voltage power supply lines, not only does the overall tensile strength decrease significantly, but the wire cores are also prone to damage. Therefore, it is necessary to improve the equipment in the stranding process. Summary of the Invention

[0005] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0006] This invention provides a cable-forming machine and method for cable production, which can solve the problem of different stresses on multiple battery cells in the prior art. The specific solution is as follows: On one hand, the present invention provides a cable forming machine for cable production, including a stranding device. The stranding device is integrally arranged with a large turntable, a small turntable, and a stranding disc according to the cable travel direction. Several core frames and core cylinders are mounted on the large turntable. After being led out from the core cylinders, the cores pass sequentially through perforations around the core frames, the small turntable, and the stranding disc into the die head. A material cylinder is mounted on the end of the small turntable near the cable travel direction, and a filler rope is wound around the material cylinder. The filler rope is led out from the material cylinder, passes through the stranding disc, and enters the die head. With the overall rotation of the large turntable, the small turntable, and the stranding disc, multiple cores and filler ropes are stranded into a cylindrical cable. An adjustment component is located at the end where the cores are led out on the core frame. The adjustment component is used to adjust the... The battery cell tension is consistent across all battery cells. The adjustment assembly includes a rotating component with two adjusting wheels fixed to its center. These two adjusting wheels are offset at the upper and lower ends of the battery cell. When the rotating component rotates in one direction, the two adjusting wheels move closer to the battery cell, creating an offset compression that increases the battery cell tension. When the rotating component rotates in the other direction, the two adjusting wheels move away from the battery cell, restoring the battery cell tension to its normal state. At least one adjusting wheel has a pressure transmission component installed on its side closest to the battery cell. This pressure transmission component detects the pressure applied to the battery cell by the adjusting wheel, thereby calculating the battery cell tension. The rotating component adjusts its rotation angle in real time based on the tension to apply different pressures to the battery cell.

[0007] Preferably, the adjustment assembly further includes a drive arm, one end of which is hinged to the cell frame, and the other end of which is coupled to the side of the rotating component near the upper adjustment wheel of the cell. A motor for driving the drive arm to rotate is mounted on the hinge shaft of the drive arm. When the motor drives the drive arm to rotate in one direction, it can drive the rotating component to rotate in one direction, so that the two adjustment wheels squeeze the cell.

[0008] Preferably, the rotating component has two rotating holes, and the shafts at both ends of the two adjusting wheels are rotatably connected to the rotating holes. The two rotating holes have movable grooves on the side away from the battery cell. The pressure transmission component is embedded in the movable groove. A pressure sensor is fixedly connected to the end of the movable groove away from the rotating hole. One end of the pressure transmission component abuts against the pressure sensor, and the other end of the pressure transmission component abuts against the shaft of the adjusting wheel. The rotating holes are configured to allow the shaft of the adjusting wheel to make slight movements along the rotation direction of the rotating component, so that the pressure applied by the adjusting wheel to the battery cell can be transmitted to the pressure sensor.

[0009] Preferably, the two ends of the rotating component are fixedly connected to a rotating shaft, the end of the rotating shaft is rotatably connected to the battery cell frame, a sleeve is provided on the inner side of the battery cell frame, a fixed block is fixedly connected to the end of the sleeve near the rotating component, a movable block is fixedly connected to the end of the rotating shaft near the rotating component, a first spring is fixedly connected to the end of the movable block adjacent to the fixed block, the two ends of the first spring are fixedly connected to the fixed block and the movable block respectively, and the first spring is in the extended state by default, so that the two adjusting wheels on the rotating component are separated from the battery cell.

[0010] Preferably, a movable wheel and a fixed wheel are provided below the drive arm. The movable wheel and the fixed wheel are located between the battery cell and the rotating component. The fixed wheel is rotatably mounted on the battery cell frame via a rotating lug. The movable wheel is movably mounted below the drive arm via a movable frame. Several limiting rods are fixedly connected to the top of the movable frame. The limiting rods are slidably connected to the drive arm. At least one limiting rod is fitted with a second spring. The two ends of the second spring are fixedly connected to the drive arm and the movable frame, respectively. A limiting structure is provided at the top of the limiting rod so that the limiting rod cannot detach from the drive arm.

[0011] Preferably, the two ends of the battery cell frame are rotatably connected to a large turntable and a small turntable, respectively. A drive source is installed on the large turntable to drive the battery cell frame to rotate, so that the battery cell frame always maintains the same angle when rotating with the large turntable.

[0012] Preferably, a material cylinder frame is fixedly connected to one end of the small turntable near the material cylinder, and several material cylinder rods are fixedly connected to the material cylinder frame. The material cylinder is sleeved on the material cylinder rods. An annular frame is also fixedly connected to one end of the material cylinder frame near the die head. The annular frame is located between the two ends of the material cylinder. The filling rope on the material cylinder extends into the die head through the perforations around the annular frame and the twisting disc.

[0013] Preferably, the stranding disc has several perforations around it, and the number of perforations is greater than the total number of filler ropes and battery cells. The battery cells and filler ropes are evenly threaded through each perforation according to their positions.

[0014] Preferably, a central shaft is fixedly connected to the middle of the large turntable, the small turntable, and the stranding disc. The central shaft is hollow, and an electric core or filler rope is also inserted inside the central shaft. The electric core or filler rope is located at the center of the stranded cable.

[0015] On the other hand, the present invention provides a cable-forming method for cable production, comprising the following steps: S1. Install multiple battery cell cylinders on the large turntable, and lead out each battery cell from the corresponding battery cell cylinder, so that each battery cell leads out and passes through the holes around the battery cell frame, small turntable and twisting plate in sequence, and finally enters the die head. Lead out the filling rope from the material cylinder installed on the small turntable, and let the filling rope pass through the twisting plate and enter the die head. S2. Drive the large turntable, small turntable and twisting disc to rotate as a whole, so that multiple battery cells and filler ropes are twisted together at the die head to form a cylindrical cable. S3. During the stranding process, the tension of each cell passing through the cell frame is adjusted by the adjusting component to keep the tension of each cell consistent. S3.1 By rotating a rotating component, two misaligned adjusting wheels fixed to it move synchronously; S3.2 When the rotating part rotates in the first direction, it drives the two adjusting wheels to move closer to each other and squeezes the battery cell vertically to increase the tension of the battery cell. S3.3 When the rotating part rotates in a second direction opposite to the first direction, it drives the two adjusting wheels to move away from each other to reduce the pressure on the battery cell and restore the tension of the battery cell. S3.4 During the tension adjustment process, the pressure applied to the battery cell by the adjustment wheel is detected by a pressure transmission element provided on at least one adjustment wheel; S3.5 Based on the detected pressure value, the real-time tension of the battery cell is calculated. Each rotating component adjusts its rotation angle in real time according to the tension to apply different pressures to the battery cell, so that the tension of the battery cells drawn out from several battery cell cylinders is consistent.

[0016] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects: 1. This invention, by setting independent adjustment components on each core path, can perform individual and precise closed-loop control of the tension of each core. This ensures that all cores maintain consistent tension during the stranding process, avoiding uneven internal stress caused by excessive or insufficient tension in a single core. This significantly improves the structural uniformity and long-term reliability of the final cable product, achieves coordinated and precise adjustment of multi-core tension, and ensures the quality of the cable.

[0017] 2. This invention indirectly detects the pressure on the battery cell and calculates the tension by setting a pressure transmission component on the shaft of the adjusting wheel that contacts the battery cell. This avoids wear and interference caused by direct contact between the sensor and the surface of the high-speed moving battery cell. This design not only realizes real-time and sensitive monitoring of the tension state, but also places the sensing component in a relatively static and protected position, thereby improving the stability and service life of the system.

[0018] 3. This invention provides a preliminary, flexible pre-tension force to the battery cell by using a movable wheel in conjunction with a fixed wheel before the battery cell enters the adjustment wheel. This design eliminates the initial slack that may exist in the battery cell, allowing the subsequent main adjustment wheel to fine-tune the tension more accurately and efficiently. The entire adjustment process is smoother and responds faster, avoiding the damage to the wire core that may be caused by direct and rough pulling.

[0019] 4. The two ends of the battery cell frame of the present invention are connected by rotation and equipped with an independent drive source, so that while following the revolution of the large turntable, it can actively maintain its own angle without rotation. This design ensures that the direction and position of the battery cell led out from the battery cell cylinder remain constant, eliminating the wire twisting and path change caused by the rolling of the frame, and providing a crucial foundation for the stability of tension control.

[0020] 5. This invention adopts an integrated layout of large turntable, small turntable and stranding disc, and sets up a ring frame to guide the filling rope. The number of perforations is sufficient and the layout is uniform. This design allows the battery core and filling rope to be drawn out from their respective pay-out units in an orderly and separate manner, and to be neatly positioned through specific perforations before stranding, and finally smoothly converge to the die head. It is not only suitable for conventional cable types, but also provides a good equipment foundation for the parallel, stable and efficient production of complex structure cables with multiple units and high core count.

[0021] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein: Figure 1 This is a perspective view of the upper right side of the present invention; Figure 2 This is a perspective view of the upper left side of the present invention; Figure 3 This is a perspective view of the entire invention on the right side; Figure 4 This is a front view of the present invention; Figure 5 This is a top view of the present invention; Figure 6 This is a perspective view of a single cell frame, cell barrel, and adjustment assembly of the present invention; Figure 7 This is a cross-sectional view of the adjustment component and the cell frame of the present invention; Figure 8 This is a schematic diagram showing the installation of the rotating component and the pressure transmission component of the present invention; Figure 9 This is a perspective view of the overall adjustment component of the present invention; Figure 10This is a schematic diagram showing the installation of the sleeve and rotating shaft on the adjusting assembly of the present invention; Figure 11 This is an exploded view of the regulating component of the present invention; Figure 12 This is a schematic diagram of the installation of the material cylinder frame of the present invention.

[0023] The accompanying figure is labeled as follows: 1. Stranding equipment; 2. Cable; 3. Large turntable; 4. Small turntable; 5. Stranding disc; 6. Cell frame; 7. Cell cylinder; 8. Cell; 9. Perforation; 11. Barrel; 12. Filler rope; 13. Adjusting assembly; 14. Rotating component; 15. Adjusting wheel; 16. Pressure transmission component; 17. Rotating hole; 18. Movable groove; 19. Pressure sensor; 20. Drive arm; 21. Motor; 22. Shaft; 23. Sleeve; 24. Fixed 25. Fixed block; 26. Movable block; 27. First spring; 28. Movable wheel; 29. ​​Fixed wheel; 30. Rotating ear; 31. Movable frame; 32. Limiting rod; 33. Second spring; 34. Material cylinder frame; 35. Material cylinder rod; 36. Ring frame; 37. Central shaft; 38. First guide wire; 39. Controller; 40. Second guide wire; 41. Third guide wire; 42. Second slip ring; 43. Fourth guide wire; 44. Bus; 45. First slip ring. Detailed Implementation

[0024] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form part of the present invention and, together with the embodiments of the present invention, serve to illustrate the principles of the present invention.

[0025] Example 1: As Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 As shown, this embodiment provides a cable forming machine for cable production, including a stranding device 1. The stranding device 1 is integrally arranged with a large turntable 3, a small turntable 4 and a stranding disc 5 according to the direction of cable 2 travel. Several core frames 6 and core cylinders 7 are installed on the large turntable 3. After the core 8 on the core cylinder 7 is led out, it passes through the perforations 9 around the core frames 6, the small turntable 4 and the stranding disc 5 in sequence and enters the die head 10.

[0026] A material cylinder 11 is installed at one end of the small turntable 4 near the direction of cable travel. A filler rope 12 is wound on the material cylinder 11. The filler rope 12 is led out from the material cylinder 11 and passes through the perforations 9 around the twisting disc 5 into the die head 10. Under the overall rotation of the large turntable 3, the small turntable 4 and the twisting disc 5, multiple battery cells 8 and the filler rope 12 are twisted into a cylindrical cable 2.

[0027] like Figure 6 , Figure 7As shown, the battery cell frame 6 has an adjustment component 13 at one end where the battery cell 8 is led out. The adjustment component 13 is used to make the tension of the battery cells 8 led out by several battery cell cylinders 7 consistent. The adjustment component 13 includes a rotating part 14. Two adjusting wheels 15 are installed in the middle of the rotating part 14. The two adjusting wheels 15 are staggered at the upper and lower ends of the battery cell 8. When the rotating part 14 rotates in one direction, the two adjusting wheels 15 can move closer to the battery cell 8, and exert vertically misaligned pressure on the battery cell 8, which increases the tension of the battery cell 8. When the rotating part 14 rotates in the other direction, the two adjusting wheels 15 move away from the battery cell, so that the tension of the battery cell 8 returns to the normal state.

[0028] like Figure 8 As shown, at least one adjusting wheel 15 is equipped with a pressure transmission element 16 on the side near the battery cell. The pressure transmission element 16 is used to detect the pressure applied by the adjusting wheel 15 to the battery cell 8, thereby calculating the tension of the battery cell 8 at this time. The rotating element 14 adjusts the rotation angle in real time according to the tension, thereby applying different pressures to the battery cell 8.

[0029] Two rotating holes 17 are provided on the rotating component 14. The shafts at both ends of the two adjusting wheels 15 are rotatably connected to the rotating holes 17. A movable groove 18 is provided on the side of the two rotating holes 17 away from the battery cell 8. The pressure transmitting component 16 is embedded in the movable groove 18. A pressure sensor 19 is fixedly connected to the end of the movable groove 18 away from the rotating holes 17. One end of the pressure transmitting component 16 abuts against the pressure sensor 19, and the other end of the pressure transmitting component 16 abuts against the outer wall of the shaft of the adjusting wheel 15. The rotating holes 17 are configured to allow the shaft of the adjusting wheel 15 to make a slight movement along the rotation direction of the rotating component 14, so that the pressure applied by the adjusting wheel 15 to the battery cell 8 can be transmitted to the pressure sensor 19.

[0030] like Figure 9 As shown, the adjustment assembly 13 also includes a drive arm 20. One end of the drive arm 20 is hinged to the cell frame 6, and the other end of the drive arm 20 is coupled to the side of the rotating member 14 near the upper adjustment wheel 15 of the cell 8. Specifically, the drive arm 20 has a pin, and the rotating member 14 has a groove. The pin and the groove fit together, and the groove is arc-shaped to adapt to the movement changes of the drive arm 20 and prevent the drive arm 20 from locking when it drives the rotating member 14 to rotate. A motor 21 for driving the drive arm 20 to rotate is installed on the hinge shaft of the drive arm 20. When the motor 21 drives the drive arm 20 to rotate in one direction, it can drive the rotating member 14 to rotate in one direction, so that the two adjustment wheels 15 squeeze the cell 8. Conversely, when the motor 21 drives the drive arm 20 to rotate in another direction, it can drive the rotating member 14 to rotate in another direction, so that the two adjustment wheels 15 leave the cell 8.

[0031] like Figure 10As shown, rotating shafts 22 are fixedly connected to both ends of rotating component 14. The ends of rotating shafts 22 are rotatably connected to battery cell frame 6. A sleeve 23 is provided on the inner side of battery cell frame 6. A fixed block 24 is fixedly connected to one end of sleeve 23 near rotating component 14. A movable block 25 is fixedly connected to one end of rotating shaft 22 near rotating component 14. A first spring 26 is fixedly connected to one end of movable block 25 adjacent to fixed block 24. The two ends of the first spring 26 are fixedly connected to fixed block 24 and movable block 25 respectively. The first spring 26 is in the extended state by default, so that the two adjusting wheels 15 on rotating component 14 are away from battery cell 8.

[0032] like Figure 6 , Figure 10 , Figure 11 As shown, a movable wheel 27 and a fixed wheel 28 are provided below the drive arm 20. The movable wheel 27 and the fixed wheel 28 are located between the battery cell 7 and the rotating component 14. The fixed wheel 28 is rotatably mounted on the battery cell frame 6 via a rotating lug 29. The movable wheel 27 is movably mounted below the drive arm 20 via a movable frame 30. Several limiting rods 31 are fixedly connected to the top of the movable frame 30. The limiting rods 31 are movably connected to the drive arm 20. At least one limiting rod 31 is fitted with a second spring 32. The two ends of the second spring 32 are fixedly connected to the drive arm 20 and the movable frame 30, respectively. The top of the limiting rod 31 is provided with a limiting structure, so that the limiting rod 31 cannot be disengaged from the drive arm 20.

[0033] With the above scheme, when the drive arm 20 applies pressure to the rotating part 14, the two adjusting wheels 15 on the rotating part 14 can squeeze the battery cell 8. At this time, the movable wheel 27 can approach the fixed wheel 28, so that the battery cell 8 can generate resistance before entering the adjusting wheel 15, which facilitates the battery cell 8 to generate pre-tension force. Furthermore, the second spring 32 keeps the movable wheel 27 and the fixed wheel 28 in a relatively stationary state, so that the adjusting wheel 15 on the rotating part 14 can continue to increase the pressure on the battery cell 8.

[0034] like Figure 2 As shown, the two ends of the battery cell frame 6 are rotatably connected to the large turntable 3 and the small turntable 4 respectively. A drive source (not shown in the figure, usually a servo motor or stepper motor) is installed on the large turntable 3. The drive source is used to drive the battery cell frame 6 to rotate, so that the battery cell frame 6 always maintains the same angle when rotating with the large turntable 3.

[0035] like Figure 12As shown, a material cylinder frame 33 is fixedly connected to one end of the small turntable 4 near the material cylinder 11. Several material cylinder rods 34 are fixedly connected to the material cylinder frame 33. The material cylinder 11 is sleeved on the material cylinder rods 34. The number of material cylinders 11 can be freely set according to the actual filling requirements. An annular frame 35 is also fixedly connected to one end of the material cylinder frame 33 near the die head 10. The annular frame 35 is located in the plane formed by the two end faces of the material cylinder 11. The filling rope 12 on the material cylinder 11 extends into the die head 10 through the perforations 9 around the annular frame 35 and the twisting disc 5.

[0036] There are several perforations 9 around the stranding disc 5. The number of perforations 9 is greater than the total number of filler ropes 12 and battery cells 8. The battery cells 8 and filler ropes 12 are evenly threaded into each perforation 9 according to their positions.

[0037] A central shaft 36 is fixedly connected to the middle of the large turntable 3, the small turntable 4 and the stranding disc 5. The central shaft 36 is hollow and a central filling rope is also inserted inside the central shaft 36. The central filling rope is located at the center of the stranded cable 2, providing central support for the final cable 2, so that the cross-section of the cable 2 forms a circle.

[0038] Example 2: The technical solution of this example differs from that of Example 1 in that this example describes the connection method of each electrical component in Example 1: like Figure 1 , Figure 2 , Figure 6 , Figure 9 As shown, pressure sensor 19 is led out through first wire 37. Controller 38 is installed on battery cell frame 6. Motor 21 is connected to controller 38 through second wire 39. Controller 38 is led out through third wire 40. First slip ring 44 is installed on large turntable 3 near the rotating position of battery cell frame 6. Third wire 40 is connected to first slip ring 44. Second slip ring 41 is installed in the middle of large turntable 3. Fourth wire 42 connects second slip ring 41 and first slip ring 44. Second slip ring 41 is connected to external power supply through bus 43.

[0039] Example 3: This example provides a cable-forming method for cable production, using a cable-forming machine as described in Examples 1 and 2. The method includes the following steps: S1. System initialization and tension benchmark establishment: Before the equipment is started, the battery cells 8 on each battery cell cylinder 7 and the filling rope 12 on the material cylinder 11 are sequentially threaded through the battery cell frame 6 and the small turntable 4, and pass through the specific perforation 9 on the twisting plate 5, and finally converge at the entrance of the die head 10.

[0040] S1.1 Initial state of preload: When there is no control signal, the drive arm 20 is in the initial position. At this time, the rotating part 14, under the action of the first spring 26 at both ends (in the extended state), keeps the two adjusting wheels 15 above and below it separated, and does not apply pressure to the battery cell 8 passing between them. At the same time, the movable frame 30 connected to the drive arm 20 is lifted under the support of the second spring 32, so that the movable wheel 27 is separated from the fixed wheel 28. The battery cell 8 can pass freely in this stage, with only very small running resistance. At this time, the tension of each battery cell 8 is determined only by its wire feeding resistance, which is usually small and inconsistent.

[0041] S1.2 Tension Target Setting and Monitoring Start-up: When the controller 38 (usually a PLC or dedicated controller) is powered on, the pressure sensor 19 monitors the signal transmitted from the pressure transmission component 16 in real time. The initial value of this signal is extremely small (close to zero), corresponding to the low tension state of the battery cell 8. The controller 38 has preset the standard tension target value required for the production of this type of cable.

[0042] S2. Dynamic Twisting and Single-Core Tension Closed-Loop Control: When the main drive starts, the large turntable 3, small turntable 4, and twisting disc 5 begin to rotate synchronously, and the battery cell 8 and filler rope 12 are pulled forward and begin to twist. At this time, the tension control system immediately starts working.

[0043] S2.1 Deviation detection and command issuance: The pressure sensor 19 continuously transmits the detected analog signal corresponding to the pressure of the adjusting wheel 15 on the cell 8 to the controller 38 through the first wire 37.

[0044] The S2.2 controller 38 compares the received pressure feedback value (which can be linearly calculated as the tension of cell 8) with the preset tension target value. If the feedback value is less than the target value, the controller 38 determines that the tension of cell 8 is "insufficient" and then generates a control command to "increase tension".

[0045] S2.3 Actuator action (increase tension): Pre-tensioning stage: Controller 38 sends a signal to motor 21 via second wire 39, driving it to rotate forward. Motor 21 drives drive arm 20 to rotate downward around its hinge point. When drive arm 20 presses down, it first overcomes the elastic force of second spring 32 through movable frame 30 at its bottom, pushing movable wheel 27 closer to fixed wheel 28, forming a gentle clamp on the battery cell 8 passing between them. This provides a preliminary, buffered pre-tensioning force for battery cell 8, eliminating the absolute slack state of the battery cell, laying the foundation for subsequent precise adjustment, and avoiding sudden impact on the battery cell.

[0046] Main adjustment phase: The drive arm 20 continues to press down, and its end begins to contact the rotating member 14 and apply a thrust. This thrust overcomes the tension of the first spring 26, causing the rotating member 14 to rotate around its axis 22 in a specific direction (such as clockwise). The rotation of the rotating member 14 causes the two vertically staggered adjusting wheels 15 fixed on it to move closer to each other, forming a "V" or "X" shaped staggered compression on the passing battery cell 8 from both vertical and horizontal directions. This compression significantly increases the frictional resistance between the battery cell 8 and the adjusting wheels 15, thereby significantly increasing the tension of the battery cell 8.

[0047] S2.4 Real-time Feedback and Balance Maintenance: As the pressure exerted by the adjusting wheel 15 on the battery cell 8 increases, this force is transmitted through the shaft of the adjusting wheel 15, causing the shaft to have a slight displacement tendency in the rotating hole 17, opposite to the direction of pressure. This displacement tendency forces the pressure transmission element 16 to move within the movable groove 18 and press against the sensing surface of the pressure sensor 19.

[0048] The pressure value detected by the S2.5 pressure sensor 19 increases accordingly and is fed back to the controller 38 in real time.

[0049] The controller 38 continuously compares the feedback value with the target value. When the feedback value reaches the target value, the controller 38 immediately stops the motor 21 from rotating. At this time, the drive arm 20, the rotating part 14, and the adjusting wheel 15 are all kept in a precise balance position, so that the tension on the battery cell 8 is just stable at the target value.

[0050] S2.6 Tension Release (Tension Reduction): If, during production, for some reason (such as smoother wire feeding on the battery cell 7), the tension feedback value of the battery cell 8 exceeds the target value, the controller 38 will issue a reverse command. The motor 21 reverses, driving the drive arm 20 to swing upwards. On one hand, the movable wheel 27 returns to its original position under the action of the second spring 32, reducing the preload. On the other hand, the pressure on the rotating part 14 is released, and the rotating part 14 rotates in the opposite direction under the strong reset pull of the first spring 26, causing the two adjusting wheels 15 to separate from each other, thereby reducing the squeezing force on the battery cell 8 and causing its tension to drop back to the target value.

[0051] S3, Multi-system collaboration and stable molding: S3.1 Spatial Attitude Locking: During the entire stranding process, each cell frame 6 does not passively roll with the large turntable 3. The independent drive source installed on the large turntable 3 will work continuously to precisely drive each cell frame 6 to rotate in the opposite direction around its own axis, so that its azimuth angle in space remains unchanged. This ensures that the path of the cell 8 led out from the cell cylinder 7 is stable and will not be twisted additionally due to the rolling of the frame. This is the premise for achieving stable tension control of a single core.

[0052] S3.2 Synchronous introduction of filler rope: After the filler rope 12 is unwound from the barrel 11, it is guided and regulated by the annular frame 35 on the barrel frame 33, and passes through the designated perforation 9 on the stranding disc 5 with constant tension and position. The function of the annular frame 35 is to restrain the swing of the filler rope 12, so that it enters the stranding area smoothly.

[0053] S3.3 Final Stranding: All the battery cores 8 with precisely controlled tension, together with the filler rope 12, are tightly and uniformly stranded into a cylindrical cable 2 with a preset pitch and structure under the rotational torque of the stranding disc 5 and the convergence and constraint of the die head 10. The central shaft 36 can be used to pass through additional reinforcing members (such as steel wire rope) to improve the overall tensile strength of the cable.

[0054] S4. Control signal transmission path: The equipment is in a continuous rotation state, and the controller 38 is mounted on the rotating battery cell frame 6. The transmission of control commands and sensor signals is achieved through a slip ring system to achieve a non-tangle connection. S4.1 Sensor signal uplink: The signals from the pressure sensors 19 on each cell rack 6 are collected by the third wire 40 and sent to the first slip ring 44 mounted on the rotating shaft of the large turntable 3.

[0055] S4.2 Power and Command Downlink: The external power supply and main control system are connected to the second slip ring 41 via bus 43, and then to the first slip ring 44 via the fourth wire 42. In this way, external power can be supplied to the rotating system, and data from each controller on the rotating system can also be transmitted, forming a complete closed-loop control system in the rotating state.

[0056] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0057] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the present application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0058] The devices or elements referred to in the embodiments of this application or implied herein must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as limiting the embodiments of this application. In the description of the embodiments of this application, "a plurality of" means two or more, unless otherwise precisely specified.

[0059] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A cable forming machine for cable production, comprising a stranding device, wherein the stranding device is integrally arranged with a large turntable, a small turntable, and a stranding disc according to the cable travel direction, and a plurality of core frames and core cylinders are mounted on the large turntable, wherein the cores on the core cylinders are led out and sequentially pass through the perforations around the core frames, the small turntable, and the stranding disc into the die head, characterized in that: An adjustment component is located at the end of the battery cell holder where the battery cell leads out. The adjustment component is used to ensure that the tension of the battery cells led out from several battery cell cylinders is consistent. The adjustment component includes a rotating part, and two adjusting wheels are fixedly connected to the middle of the rotating part. The two adjusting wheels are staggered at the upper and lower ends of the battery cell. When the rotating part rotates in one direction, it can bring the two adjusting wheels closer to the battery cell, creating a vertically offset compression on the battery cell, which increases the tension of the battery cell. When the rotating part rotates in the other direction, the two adjusting wheels move away from the battery cell, and the tension of the battery cell returns to the normal state. At least one adjusting wheel is equipped with a pressure transmission component on the side close to the battery cell. The pressure transmission component is used to detect the pressure applied to the battery cell by the adjusting wheel, thereby calculating the tension of the battery cell at this time. The rotating part adjusts the rotation angle in real time according to the tension to apply different pressures to the battery cell.

2. The cable forming machine for cable production as described in claim 1, characterized in that: The adjustment assembly also includes a drive arm, one end of which is hinged to the cell frame, and the other end of which is coupled to the side of the rotating component near the upper adjustment wheel of the cell. A motor is mounted on the hinge shaft of the drive arm to drive the drive arm to rotate. When the motor drives the drive arm to rotate in one direction, it can drive the rotating component to rotate in one direction, so that the two adjustment wheels squeeze the cell.

3. A cable-forming machine for cable production as described in claim 1, characterized in that: Two rotating holes are provided on the rotating component. The shafts at both ends of the two adjusting wheels are rotatably connected to the rotating holes. Movable grooves are provided on the side of the two rotating holes away from the battery cell. Pressure transmission components are embedded in the movable grooves. A pressure sensor is fixedly connected to the end of the movable groove away from the rotating holes. One end of the pressure transmission component abuts against the pressure sensor, and the other end of the pressure transmission component abuts against the shaft of the adjusting wheel. The rotating holes are configured to allow the shaft of the adjusting wheel to make slight movements along the rotation direction of the rotating component, so that the pressure applied by the adjusting wheel to the battery cell can be transmitted to the pressure sensor.

4. A cable-forming machine for cable production as described in claim 1, characterized in that: The rotating part has a rotating shaft fixedly connected to both ends. The ends of the rotating shaft are rotatably connected to the battery cell frame. A sleeve is provided on the inner side of the battery cell frame. A fixed block is fixedly connected to one end of the sleeve near the rotating part. A movable block is fixedly connected to one end of the rotating shaft near the rotating part. A first spring is fixedly connected to one end of the movable block adjacent to the fixed block. The two ends of the first spring are fixedly connected to the fixed block and the movable block respectively. The first spring is in the extended state by default, so that the two adjusting wheels on the rotating part are separated from the battery cell.

5. A cable-forming machine for cable production as described in claim 2, characterized in that: The drive arm is equipped with movable wheels and fixed wheels, which are located between the battery cell and the rotating component. The fixed wheels are rotatably mounted on the battery cell frame via rotating lugs, and the movable wheels are movably mounted below the drive arm via a movable frame. Several limit rods are fixedly connected to the top of the movable frame, and the limit rods are slidably connected to the drive arm. At least one limit rod is fitted with a second spring, and the two ends of the second spring are fixedly connected to the drive arm and the movable frame, respectively. The top of the limit rod is provided with a limit structure, which prevents the limit rod from detaching from the drive arm.

6. A cable-forming machine for cable production as described in claim 1, characterized in that: The two ends of the battery cell frame are rotatably connected to a large turntable and a small turntable, respectively. A drive source is installed on the large turntable to drive the battery cell frame to rotate, so that the battery cell frame always maintains the same angle when rotating with the large turntable.

7. A cable-forming machine for cable production as described in claim 1, characterized in that: A material cylinder is installed at the end of the small turntable near the direction of cable travel. A filler rope is wound on the material cylinder. After the filler rope is led out from the material cylinder, it passes through the twisting plate and enters the die head. With the overall rotation of the large turntable, small turntable and twisting plate, multiple battery cells and filler ropes are twisted into a cylindrical cable. A material cylinder frame is fixedly connected to the end of the small turntable near the material cylinder. Several material cylinder rods are fixedly connected to the material cylinder frame. The material cylinder is sleeved on the material cylinder rods. An annular frame is also fixedly connected to the end of the material cylinder frame near the die head. The annular frame is located between the two ends of the material cylinder. The filler rope on the material cylinder extends into the die head through the perforations around the annular frame and the twisting plate.

8. A cable-forming machine for cable production as described in claim 1, characterized in that: There are several perforations around the stranding disc, and the number of perforations is greater than the total number of filler ropes and battery cells. The battery cells and filler ropes are evenly threaded through each perforation according to their positions.

9. A cable-forming machine for cable production as described in claim 1, characterized in that: A central shaft is fixed to the middle of the large turntable, small turntable, and stranding turntable. The central shaft is hollow and contains a battery core or filler rope. The battery core or filler rope is located at the center of the stranded cable.

10. A cable-forming method for cable production, employing a cable-forming machine for cable production as described in any one of claims 1-9, characterized in that, The method includes the following steps: S1. Install multiple battery cell cylinders on the large turntable, and lead out each battery cell from the corresponding battery cell cylinder, so that each battery cell leads out and passes through the holes around the battery cell frame, small turntable and twisting plate in sequence, and finally enters the die head. Lead out the filling rope from the material cylinder installed on the small turntable, and let the filling rope pass through the twisting plate and enter the die head. S2. Drive the large turntable, small turntable and twisting disc to rotate as a whole, so that multiple battery cells and filler ropes are twisted together at the die head to form a cylindrical cable. S3. During the stranding process, the tension of each cell passing through the cell frame is adjusted by the adjusting component to keep the tension of each cell consistent. S3.1 By rotating a rotating component, two misaligned adjusting wheels fixed to it move synchronously; S3.2 When the rotating part rotates in the first direction, it drives the two adjusting wheels to move closer to each other and squeezes the battery cell vertically to increase the tension of the battery cell. S3.3 When the rotating part rotates in a second direction opposite to the first direction, it drives the two adjusting wheels to move away from each other to reduce the pressure on the battery cell and restore the tension of the battery cell. S3.4 During the tension adjustment process, the pressure applied to the battery cell by the adjustment wheel is detected by a pressure transmission element provided on at least one adjustment wheel; S3.5 Based on the detected pressure value, the real-time tension of the battery cell is calculated. Each rotating component adjusts its rotation angle in real time according to the tension to apply different pressures to the battery cell, so that the tension of the battery cells drawn out from several battery cell cylinders is consistent.

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