Torsion arm assembly for cord manufacturing machine for merging plurality of threads and cord manufacturing machine for merging plurality of threads

Abstract

A torsion arm assembly for a cord manufacturing machine for merging a plurality of threads and a cord manufacturing machine for merging a plurality of threads are disclosed. A torsion arm assembly (100) for a cord manufacturing machine (16) merging a plurality of threads (11, 12), the torsion arm assembly (100) comprising: at least one torsion arm for rotationally guiding at least one thread (11, 12) of the plurality of threads (11, 12) about a main axis (101) of the cord manufacturing machine (16), characterized in that the torsion arm comprises a groove (112, 116) embedded in the torsion arm, the groove is adapted to receive said at least one wire (11, 12) for said guiding.

Description

Technical Field

[0001] This disclosure relates to the field of cord manufacturing machines. More specifically, this disclosure relates to a torsion arm assembly for a cord manufacturing machine and a method for manufacturing the torsion arm assembly. Background Technology

[0002] Cord-making machines (e.g., cabling machines, bundling machines, or twisting machines) can be used to combine multiple threads (e.g., metal wires or yarns) to form cords. The characteristics of the cords formed by cord-making machines depend on the material and diameter of the threads, as well as the configuration in which they are combined.

[0003] In the prior art, a cord manufacturing machine may include a flywheel ring, or sometimes a torsion disc or torsion arm, for guiding at least one of a plurality of cords to be combined to rotate about the main axis of the cord manufacturing machine. This rotation can twist the cord about its own axis, and / or, when the plurality of cords to be combined are guided by the flywheel ring, torsion disc, or torsion arm, this rotation can twist the cords together to form a cord. The specific configuration of the cord twisting affects the cord's properties, such as flexibility and breaking load.

[0004] A flywheel ring is a bow-shaped blade that physically guides filaments or cords through perforations mounted on thin, aerodynamically shaped blades from one rotating disc to another. The filaments can enter the flywheel ring at one disc and be guided through it to the opposite disc, where the resulting cords exit the flywheel ring. The flywheel ring rotates at high speeds within the machine, generating air turbulence. Energy is thus lost as heat. Furthermore, flywheel rings are prone to wear and breakage and have a limited lifespan. Additionally, the sharp blades remain a safety hazard to the operator. Numerous examples of flywheel ring systems exist, such as US2006 / 0000197A1, JP05247861; JP2010106392, and US6289661B1.

[0005] To overcome the problems associated with using flywheel rings, torsion discs have been introduced. In machines with torsion discs, filaments or cords are guided to the outside of a rotatable disc equipped with guides. The filaments or cords travel from a first guide on a first torsion disc to a second guide on a second torsion disc without guidance. Energy consumption is significantly lower due to the smaller mass rotating and the lower air resistance of the cords or filaments compared to flywheel rings. However, tension control of the filaments or cords becomes more critical because they can become "ballooned," meaning they rotate outwards under centrifugal force. Any tension drop below a threshold will cause the balloon to burst, followed by breakage of the filaments and cords. When air contacts the disc, air resistance during high-speed rotation causes turbulence, resulting in heat loss. An example of an embodiment using a disc instead of a flywheel ring is described in US4335571.

[0006] The final option is to use a "torsion arm." That is, the entire disc is replaced by a single arm. The furthest end of the torsion arm is not mechanically supported or held, whereas the flywheel ring is held at both ends. Therefore, this torsion arm is used in slow-running, heavy-duty wire-making machinery because its use eliminates the need for heavy flywheel rings or very large torsion discs. Prior art example DE3943032A1... Figure 1 Cited in this application Figure 1 A cord manufacturing machine, particularly a double-twist twisting machine, is disclosed, comprising a pair of torsion arm assemblies 10 and 10' for merging multiple cords 1. The first torsion arm assembly 10 includes a first torsion arm 4, and the second torsion arm assembly 10' includes a second torsion arm 7, for rotatably guiding at least one cord 1 about a main axis 9 (also referred to as a rotation axis 9) of the cord manufacturing machine. Each torsion arm 4, 7 includes rollers 5, 8 located at the distal end of the torsion arm 4, 7 away from the main axis 9, for guiding at least one cord 1. Furthermore, each torsion arm assembly 10, 10' includes counterweights 13, 14 for counteracting centrifugal forces acting on the torsion arms 4, 7 during rotation of the torsion arm assemblies 10, 10'.

[0007] Each wire 1, which is combined with other wires, is typically obtained from and continuously unwound from a dewinding spool (not shown). The torsion arms 4 and 7 rotate continuously and synchronously during use, guiding at least one wire 1 from the guide pulley 17 located on the main axis 9 on one side of the cord manufacturing machine, through the roller 5 of the first torsion arm 4 to the roller 8 of the second torsion arm 7, and then back to the guide pulley 18 located on the main axis 9 on the other side of the machine.

[0008] However, this type of torsion arm is unsuitable for high-speed, low linear mass density steel cord manufacturing machines. The flywheel rings or torsion discs in steel cord manufacturing machines can rotate at speeds up to 6000 revolutions per minute, corresponding to a circumferential speed of 500 to 600 km / h for the flywheel rings, cords, or filaments. At such high speeds, the aerodynamics of the torsion arm significantly impacts the air resistance it experiences, thus greatly affecting the power consumption of the cord manufacturing machine. Furthermore, the high speed places high demands on the strength of the materials used in the torsion arm.

[0009] To reduce the power consumption of the cord manufacturing machine, the aerodynamics of the torsion arm needs continuous optimization. Simultaneously, the torsion arm is preferably designed so that its manufacturing and assembly, as well as the replacement of worn parts, can be performed directly and quickly without the need for specialized tools or expert assistance. Furthermore, the torsion arm is preferably lightweight yet robust.

[0010] Therefore, there is still a need in the art for apparatuses and methods to solve at least some of the aforementioned problems. Utility Model Content

[0011] The purpose of this disclosure is to provide a good torsion arm assembly. Another purpose of this disclosure is to provide a good cord manufacturing machine including the torsion arm assembly.

[0012] The purpose of this disclosure is to provide an efficient method for manufacturing the torsion arm assembly.

[0013] The above objectives are achieved by methods and apparatus according to embodiments of the present disclosure.

[0014] The advantage of the embodiments of this disclosure is that a torsion arm assembly incorporating a torsion arm with a well-designed aerodynamic shape can be obtained. Therefore, the advantage of the embodiments of this disclosure is that the air resistance experienced by the rotating torsion arm can be very small. Therefore, the advantage of the embodiments of this disclosure is that the power consumption of the cord manufacturing machine including this torsion arm assembly can be very low, and thus the environmental impact can also be very low.

[0015] In a first aspect, this disclosure relates to a torsion arm assembly for a cord manufacturing machine for merging multiple cords. The torsion arm assembly includes at least one torsion arm, also referred to as a cord guide arm, for rotatably guiding at least one of multiple cords about the main axis of the cord manufacturing machine. The torsion arm includes a groove embedded therein adapted to receive at least one cord for the guidance.

[0016] The main axis is the axis around which the torsion arm rotates when it is coupled to the bearings of the cord manufacturing machine; in other words, it is the axis of rotation of the torsion arm. The torsion arm assembly has an unsupported end away from the axis of rotation of the torsion arm. The main axis may alternatively be referred to as the axis of rotation, torque axis, or torsion axis. Although in principle, a cord manufacturing machine may contain a physical axis (i.e., a solid axis) that coincides with the main axis, this is not usually the case.

[0017] In embodiments, the cord manufacturing machine can be a cabling machine, a bundling machine, or a twisting machine. The cord can be of any type, such as metal wire or yarn (the yarn can be formed from synthetic or natural fibers). In embodiments, the cord can include cables, bundles, or strands. However, this design is most preferably used for steel cord manufacturing machines.

[0018] Typically, the groove is embedded on the side of the torsion arm opposite to the main axis (in other words, opposite to the middle of the main axis, i.e., opposite to the center of the machine). In some embodiments, the torsion arm may be integrally formed, i.e., it may be formed from a single piece. The groove serves to shield, conceal, cover, or guide one or more lines outside the airflow field when the torsion arm assembly is operating at high speed. Preferably, at least the one or more lines are covered, shielded, or concealed at least along those lengths experiencing the highest circumferential speed, i.e., at the distal end of the torsion arm assembly. Preferably, the groove has a straight section along at least half of its length.

[0019] In a preferred embodiment, the torsion arm may include a body component and a wear component. In some embodiments, the groove may be entirely contained within the wear component. In a particular embodiment, the torsion arm includes: a body component including a first section of the groove; and a wear component attachable to or attached to the body component, the wear component including a second section of the groove. The wear component further contributes to reduced air resistance because it does not protrude from the end of the torsion arm assembly and can be fully engaged in the distal end of the torsion arm assembly. Preferably, the groove in the wear component has a curved path, while the groove in the body component has a straight section. Preferably, the first section of the groove (i.e., the groove in the body component) is straight.

[0020] Preferably, the wear component is located at the distal end of the torsion arm, away from the main axis, when attached to the main component. Preferably, the wear component is the part of the torsion arm that suffers the most wear due to friction caused by at least one wire sliding along its surface as it is guided through the second portion of the groove. Therefore, the wear component may need to be replaced periodically. The advantage of these embodiments is that the wear component can be replaced without replacing the entire torsion arm.

[0021] In embodiments, the material of the body component is selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, carbon-reinforced composites, glass fiber-reinforced composites, laminated wood, ferroalloys (such as isothermally hardened ductile iron), or steel (such as medium-carbon or high-carbon steel), or combinations thereof. These materials can combine sufficient strength with light weight. Preferably, the body comprises aluminum or an aluminum alloy, for example, AlZnMgCu1.5. Aluminum is particularly lightweight, thus producing a lightweight torsion arm assembly. Alternatively, the body component may comprise a polymer, such as a carbon fiber-reinforced polymer.

[0022] In embodiments, the wear component comprises a polycrystalline diamond composite (PDC), ceramic (such as silicon nitride, e.g., Si3N4), or a metal carbide (such as titanium carbide, tantalum carbide, or tungsten carbide). An advantage of these embodiments is that these materials are resistant to wear caused by at least one wire sliding along the material surface. In a preferred embodiment for handling steel wire, the wear component comprises a cermet, such as tungsten carbide. The advantage of these materials is that they are particularly resistant to this type of wear. The material of the wear component is selected based on the material of the at least one wire.

[0023] In one embodiment, the main body includes a cavity for receiving a worn component. The main body and the worn component may be mating components. In another embodiment, the worn component may have a shape substantially complementary to the shape of the cavity. In these embodiments, the worn component and the cavity can be adapted such that the worn component can easily slide and subsequently be secured within the cavity. In another embodiment, means for securing the worn component within the cavity, such as fasteners, may be applied. In a particular embodiment, the worn component is curved, and the cavity is correspondingly curved. The advantage of these embodiments is that it facilitates holding the worn component securely within the cavity. In fact, due to the curvature, it is more difficult for the worn component to leave the cavity. An advantage is that forming the torsion arm may require less raw material.

[0024] In this embodiment, the main body component and the wear component are configured such that the wear component can be inserted into the distal end of the main body component, away from the central portion of the torsion arm assembly, thereby inserting the wear component into the cavity. The main body component includes a slit for exposing a second portion of the groove of the wear component when it is inserted into the cavity. Hereinafter, the central portion of the torsion arm assembly is typically the location where the torsion arm assembly is coupled to the bearing of the cord manufacturing machine, i.e., at the main axis. The advantage of these embodiments is that they enable easy manufacturing and assembly of the torsion arm assembly, wherein the wear component can be held securely within the main body component without special assistance in securing it to the main body component.

[0025] In an embodiment, the slit that exposes a second portion of the groove of the wear member when it is inserted into the cavity extends across a surface of the body component that is away from the main axis (more specifically, away from the middle of the main axis, i.e., away from the center of the machine). Preferably, the width of the slit is smaller than the width of the wear member, such that the wear member cannot be moved out of the slit. In an embodiment, the body component includes at least one retaining ridge for holding the wear member in place within the cavity. The advantage of these embodiments is that the retaining ridge prevents the wear member from moving outward in a direction away from the main axis due to the centrifugal force acting on the wear member as the torsion arm rotates about the main axis.

[0026] In one embodiment, the torsion arm assembly includes means for coupling the torsion arm to a bearing of a cord manufacturing machine. The coupling means can be any suitable means for coupling the torsion arm assembly to the bearing, and thus can depend on the type of coupling means for the bearing. For example, the coupling means for the torsion arm assembly may include: an orifice for receiving a protruding portion or shaft of the bearing; and / or an opening for receiving fasteners (such as bolts or pins) to secure the torsion arm assembly to the bearing.

[0027] In embodiments, the area of ​​the cross-section of the torsion arm perpendicular to its axis decreases from the central portion of the torsion arm assembly toward the ends (such as the distal ends) of the torsion arm away from the central portion. An advantage of these embodiments is that the torsion arm may be particularly robust near the location where the torsion arm assembly is fixed to the bearing, which is typically where the centrifugal force exerted on the torsion arm due to rotation is greatest, while the torsion arm can have a lighter weight away from this location, thereby reducing or even minimizing the centrifugal force exerted on the torsion arm during rotation.

[0028] In the embodiments, the angle between the straight section of the groove and the main axis is 40° to 70°, preferably 50° to 60°, and more preferably 50° to 55°. This angle range provides an optimal volume-to-axial-length ratio for the desired speed and tension. This angle is smaller than the angle desired for a rotating rope when the maximum volume is limited to 71.0°, an angle typically used when the line guide is a reel. Axial length refers to the distance along the main axis between the torsion arm assemblies.

[0029] In an embodiment, when viewed in a vertical cross-section, the torsion arm includes, on at least a portion thereof: a first convex surface having a first radius of curvature, which faces away from the main axis when the torsion arm is coupled to a bearing of the cord manufacturing machine; and a second convex surface having a second radius of curvature, which faces the main axis when the torsion arm is coupled to the bearing, wherein the second radius of curvature is greater than the first radius of curvature. The ratio of the second radius to the first radius is greater than one and less than two, more preferably between 1.2 and 1.7, for example, 1.5. When mounted on and used on the cord manufacturing machine, the torsion arm does not move in a straight line but rotates about the main axis of the cord manufacturing machine. Therefore, when the first and second radii of curvature are equal, lift is applied radially toward the main axis to the torsion arm. When the second radius of curvature is greater than the first radius of curvature, the lift can be reduced. Preferably, the first and second radii are selected such that the lift applied to the torsion arm during rotation is substantially zero. Preferably, the at least portion of the torsion arm is at least the distal end of the torsion arm, for example, extending from the distal end, because this is the part of the torsion arm with the highest rotational speed, and therefore the lift may become particularly large.

[0030] In one embodiment, the torsion arm assembly may include two torsion arms, which, when installed in a cord manufacturing machine, are typically located on opposite diameter sides of the main axis of the cord manufacturing machine. In a different embodiment, the torsion arm assembly may include one torsion arm and one or more counterweights, wherein the torsion arm assembly and the one or more counterweights, when installed in the cord manufacturing machine, are typically located on opposite diameter sides of the main axis of the cord manufacturing machine. In another embodiment, the torsion arm assembly may include more than two torsion arms, such as three, four, or more torsion arms, which, when installed in the cord manufacturing machine, may be evenly distributed around the main axis of the cord manufacturing machine.

[0031] In a second aspect, this disclosure relates to a cord manufacturing machine for merging multiple cords. The cord manufacturing machine includes: at least a first bearing, coaxial with the main axis of the cord manufacturing machine; a first torsion arm assembly according to an embodiment of the first aspect of this disclosure, coupled to the first bearing; and a drive device for driving the first torsion arm assembly.

[0032] In an embodiment, the cord manufacturing machine includes: a second bearing coaxial with the main axis of the cord manufacturing machine; a second torsion arm assembly according to an embodiment of the first aspect of the present disclosure, connected to the second bearing; and a drive device for driving the second torsion arm assembly.

[0033] Typically, the torsion arms of the first and second torsion arm assemblies are located in the same plane, with the distal ends of the torsion arms of the first and second torsion arm assemblies facing each other, i.e., within each other's extension range. A drive mechanism for driving the first torsion arm assembly is preferably coupled to a drive mechanism for driving the second torsion arm assembly, such that the first and second torsion arm assemblies are configured to rotate synchronously at the same rotational rate.

[0034] Typically, the torsion arms of the first and second torsion arm assemblies are not located in the same field, but are offset from each other at a small angle relative to the plane passing through the first torsion arm and the main axis. The offset is greater than 0°, greater than 1°, or even 2°, but preferably less than 20°, or less than 15°, or less than 10°. The offset compensates for the air resistance and Coriolis force acting on the filaments and cords as they travel in the rotational reference frame from the first torsion arm to the second torsion arm. By offsetting the torsion arms at an angle, the circumferential force on the filaments or cords is smaller when they reach the second torsion arm assembly. The direction of the offset is determined by the rotational direction of the torsion arm assembly, which in turn is determined by the twist direction of the produced cords. In any case, the second torsion arm lags behind the first torsion arm, following it at the small angle when the rotational direction of the first torsion arm is taken into account. In the case of this embodiment, the first torsion arm is where the filaments or cords leave, and the second torsion arm is where the filaments or cords arrive.

[0035] In a third aspect, this disclosure relates to a method of manufacturing a torsion arm assembly including a cavity according to an embodiment of the first aspect, the method comprising: providing a body part and a wear part of the torsion arm; and forming a cavity in the body part suitable for receiving the wear part using a conical cutter.

[0036] The advantage of these embodiments is that the conical cutter can accurately form cavities, even if the cavity is a curved cavity for receiving bent, worn parts, which is difficult or impossible to achieve through different techniques.

[0037] Specific and preferred aspects of this disclosure are set forth in the appended independent and dependent claims. Features in the dependent claims may be appropriately combined with features of the independent and other dependent claims, and are not limited to those expressly set forth in the claims.

[0038] The above and other features, characteristics, and advantages of this disclosure will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which illustrate the principles of this disclosure by way of example. This description is for illustrative purposes only and does not limit the scope of this disclosure. The references to the drawings cited below refer to the accompanying drawings. Attached Figure Description

[0039] Figure 1 This is a side view of a conventional cord manufacturing machine.

[0040] Figure 2A and Figure 2B These are schematic diagrams of different perspective views of a torsion arm assembly according to embodiments of the present disclosure.

[0041] Figure 3A yes Figure 2A A magnified view of a portion of it.

[0042] Figure 3B This is a schematic perspective view of a wear component according to an embodiment of the present disclosure.

[0043] Figure 3C This is a schematic front view of a plate for closing the opening of a cavity in the distal end of the main body component of a torsion arm, according to an embodiment of the present disclosure.

[0044] Figure 4A This is a schematic diagram of a front view of the distal end of the main body component of a torsion arm according to an embodiment of the present disclosure.

[0045] Figure 4B This is a schematic diagram of a front view of the distal end of the main body component of a torsion arm according to an embodiment of the present disclosure, wherein the wear part is received in the cavity.

[0046] Figure 5A This is a schematic side view of a torsion arm assembly that has been vertically bisected according to an embodiment of the present disclosure.

[0047] Figure 5B This is a schematic diagram of a cross-section of the main body component of the torsion arm, perpendicular to the axis of the main body component.

[0048] Figure 6 This is a schematic side view of a cord manufacturing machine according to an embodiment of the present disclosure.

[0049] Figure 7 This is a schematic diagram of the cord.

[0050] In different figures, the same reference numerals denote the same or similar elements. Detailed Implementation

[0051] This disclosure will be described with reference to specific embodiments and certain accompanying drawings, but is not limited thereto, only by the claims. The drawings are illustrative only and not restrictive. In the drawings, for illustrative purposes, the dimensions of some elements may be exaggerated and not drawn to scale. Dimensions and relative dimensions do not correspond to an actual scale-down of embodiments of this disclosure.

[0052] Furthermore, the terms "first," "second," "third," etc., used in the specification and claims are used to distinguish similar elements and are not necessarily used to describe a temporal, spatial, or any other order. It should be understood that the terms used are interchangeable where appropriate, and the embodiments of this disclosure described herein can operate in orders other than those stated or shown herein.

[0053] Furthermore, the terms "top," "bottom," "above," "below," etc., used in the specification and claims are for descriptive purposes and not necessarily for describing relative positions. It should be understood that the terms used are interchangeable where appropriate, and the embodiments of this disclosure described herein can operate in orientations other than those described or shown herein.

[0054] It should be noted that the term "comprising" as used in the claims and specification should not be construed as limited to the means listed thereafter; it does not exclude other elements or steps. Therefore, it should be interpreted as specifying the presence of the stated feature, integer, step, or component, but not excluding the presence or addition of one or more other features, integers, steps, or components, or groups thereof. Thus, the term "comprising" covers both the presence of only the stated feature and the presence of these features plus one or more other features. Therefore, according to this disclosure, the word "comprising" also includes embodiments where no other components are present. Therefore, the scope of the statement "the device comprises means A and B" should not be construed as limited to a device consisting only of components A and B. This means that, for the purposes of this disclosure, the only relevant components of the device are A and B.

[0055] Similarly, it should be noted that the term "connection" as used in the claims and specification should not be construed as limited to direct connection. The terms "connection" and "linkage" and their derivatives may be used. It should be understood that these terms are not intended to be synonyms with each other. Therefore, the scope of the statement "device A is connected to device B" should not be limited to devices or systems in which the output of device A is directly connected to the input of device B. This means that there is a path between the output of A and the input of B, which may include other devices or apparatuses. "Connection" can mean two or more elements in direct physical or electrical contact, or two or more elements that are not in direct contact with each other but still cooperate or interact with each other.

[0056] Throughout this specification, references to "an embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of this disclosure. Therefore, the phrases "in one embodiment" or "in an embodiment" appearing throughout this specification do not necessarily refer to the same embodiment, but may refer to the same embodiment. Furthermore, specific features, structures, or characteristics may be combined in one or more embodiments in any suitable manner that is obvious to those skilled in the art from the contents of this disclosure.

[0057] Similarly, it should be understood that in the description of exemplary embodiments of this disclosure, various features of this disclosure are sometimes combined in a single embodiment, figure, or description thereof in order to simplify the content of this disclosure and aid in understanding one or more of the various inventive aspects. However, this approach to disclosure should not be construed as reflecting that the claimed disclosure requires more features than expressly listed in each claim. Rather, as reflected in the following claims, the inventive aspect lies in fewer than all the features of a single embodiment of the foregoing disclosure. Therefore, the claims following the detailed description are hereby expressly incorporated into this detailed description, and each claim is itself a separate embodiment of this disclosure.

[0058] Furthermore, while some embodiments described herein include features included in other embodiments but not others, combinations of features from different embodiments should be within the scope of this disclosure and form different embodiments, as understood by those skilled in the art. For example, any claimed embodiment may be used in any combination in the following claims.

[0059] Numerous specific details are set forth in the description provided herein. However, it should be understood that embodiments of this disclosure can be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0060] The cord manufacturing machine according to embodiments of this disclosure allows for the formation of any type of cord. Examples of cords known in the prior art, which can be formed using the cord manufacturing machine according to embodiments of this disclosure, are now briefly described below. However, these examples should be understood as non-limiting, and different cords may also be formed.

[0061] refer to Figure 7 , Figure 7 This is a schematic diagram of cord 33.

[0062] A thread is a long, thin material element whose length is much greater than its width and height, which are dimensions orthogonal to its length. A thread can be a filament, strand, bundle, or cord. A filament is a thread element that cannot be further subdivided into finer components. Fibers (such as steel wire) are used as individual elements within strands or cords. Standard filament diameters can be, for example, 0.15 mm, 0.175 mm, 0.20 mm, 0.22 mm, 0.25 mm, 0.27 mm, 0.28 mm, 0.35 mm, and 0.38 mm.

[0063] The strand 32 is a group of filaments 31 joined together. Here, the strand comprises multiple filaments, each individually untwisted about its own axis (i.e., about the center of the strand). The strand can be in a bundle or in a cable. In a cabled strand, each filament is not twisted about its own axis. The filament bends around the center of the strand but does not acquire torque or twist. Conversely, in a bundled strand, each filament is twisted in the same way as the strand. The filament bends and is subjected to torque. Therefore, each filament acquires torque about its axis at the same speed as the strand.

[0064] The cord 33 is a shaped structure consisting of two or more filaments 31 (e.g., 2+2 or 1+6), or it may be a combination of strands 32 (e.g., 7x4) or a combination of filaments 31 and strands 32 (e.g., 1+5x7). (See the naming conventions used in parentheses below). The cord 33 may also include an outer winding 34, which is a thread spirally wound around the other threads 31 of the cord 33.

[0065] In this art, cord 33 is generally used to refer to the final product, but structurally it may not be different from strand 32. Therefore, throughout the specification, unless otherwise stated, cord 33 can be understood to refer to any two or more filaments 31 joined together. Filaments 31, strands 32, and cord 33 are all in the form of lines.

[0066] The construction of steel cord is typically defined by its structure, lay length, and lay direction. This structure is usually described by the following formula:

[0067] (N x F)x D+(N x F)x D+F x D

[0068] in:

[0069] N = the number of strands (or cables or bundles of wires).

[0070] F = the number of lines, and

[0071] D = Nominal diameter of the wire, in mm.

[0072] When N or F equals 1, they are usually not mentioned. Similarly, D (i.e., nominal diameter) is not always mentioned; for example, when the diameter is ignored, a 2x0.175+2x0.175 cord can be described as a 2+2 cord, thus only describing the arrangement of the wires in the cord.

[0073] This description of the steel cord construction follows the manufacturing sequence of the cord, that is, starting from the innermost strand or thread and moving radially outward.

[0074] For example, the following formula can describe the cord:

[0075] (1x4)x0.175+(6x4)x0.175+1x0.15,

[0076] Alternatively, it can be simplified to: 4x0.175+6x4(x0.175)+0.15.

[0077] In this text, 4x0.175 indicates that the core strand of the cord contains 4 filaments, each with a diameter of 0.175 mm. 6x(4x0.175) describes the first layer around the core strand as 6 strands, each containing 4 filaments with a diameter of 0.175 mm. Finally, an outer winding with a diameter of 0.15 mm is spirally wound as the second layer.

[0078] The following types of steel cords are particularly suitable for manufacture using this disclosure:

[0079] Nx1 type steel cord consists of N fine filaments twisted together, with a twist direction and a twist pitch. The twist direction is the direction in which the filaments twist together, usually represented by the letters S (or N) and Z, where the central part of the letter indicates the orientation of the filaments within the cord, which can be visually observed when viewing the cord. The twist pitch is the length along the axis of the cord, along which the filaments rotate once, twist once, and add twist once. A common example is 2x0.30: that is, two filaments with a diameter of 0.30 mm twisted together.

[0080] A specific type of Nx1 cord is an open cord, abbreviated as OC, in which the threads are loosely linked and can move relative to each other to allow rubber to permeate the cord. This loose linking can be achieved by plastically bending the threads while they are twisted together. Examples of open cords include:

[0081] 3x0.30OC,

[0082] 4x0.25OC, and

[0083] 5x0.22OC.

[0084] Another typical and widely used example of steel cord construction that does not fall into one of the above categories is the U+T type, where "U" indicates "untwisted" and "T" indicates "twisted". This type of steel cord consists of two intertwined strands. Both strands are spirally shaped. The filaments of the "U"-shaped strand have a very large twist pitch, while the filaments of the "T"-shaped strand are intertwined with a twist pitch that is essentially the same as that of the intertwined strands.

[0085] (2) + 1x0.25,

[0086] (2) + 2 × 0.30,

[0087] (3x0.28)+2x0.28.

[0088] The strands in parentheses are untwisted strands.

[0089] This disclosure will now be described in detail through several embodiments thereof. It will be apparent that other embodiments of this disclosure may be configured based on the knowledge of those skilled in the art without departing from the technical teachings of this disclosure, which is limited only by the terminology of the appended claims.

[0090] In a first aspect, this disclosure relates to a torsion arm assembly for a cord manufacturing machine for merging multiple cords. The torsion arm assembly includes at least one torsion arm (which may also be referred to as a cord guide arm) for rotatably guiding at least one of multiple cords about the main axis of the cord manufacturing machine. The torsion arm includes a groove embedded in the torsion arm adapted to receive the at least one cord for the guidance.

[0091] refer to Figure 2A and Figure 2B These are schematic diagrams of two different perspective views of an example of a torsion arm assembly 100 for merging multiple cords in a cord manufacturing machine according to embodiments of the present disclosure. The torsion arm assembly 100 includes a single torsion arm for rotatably guiding at least one of multiple cords about the main axis of the cord manufacturing machine. The torsion arm includes a body component 102 and a wear component (…). Figure 2A and Figure 2B (Not shown in the image). The torsion arm assembly 100 also includes means for coupling the main body 102 to a bearing of the cord manufacturing machine. In the example shown, the coupling means includes an aperture 108 for receiving the bearing, for example, for receiving a protruding portion or shaft of the bearing. The torsion arm assembly 100 also includes holes 110, 110', 110”, 110”’ for receiving fasteners (e.g., bolts) to secure the torsion arm assembly 100 to the bearing.

[0092] In the example shown, the rotation axis 101 of the torsion arm assembly 100 passes through the center of the orifice 108. When the torsion arm assembly 100 is coupled to the bearing of the cord manufacturing machine, the rotation axis 101 coincides with the main axis of the cord manufacturing machine. Therefore, when the bearing coupled to the torsion arm is induced to rotate, the main body component 102 is subsequently induced to rotate about the rotation axis 101.

[0093] In the example shown, the torsion arm assembly 100 comprises only a single torsion arm. The torsion arm assembly 100 also includes counterweights 106, 106', located on the diametrically opposite side of the torsion arm body 102 relative to the axis of rotation 101, to counteract centrifugal forces acting on the torsion arm (e.g., on the body 102 and wear parts) during rotation about the axis of rotation 101. In the example shown, counterweights 106, 106' include a first counterweight element 106 and a second counterweight element 106', each received in a separate recess in the torsion arm assembly 100. This facilitates precise installation of the counterweight elements 106 and 106', which is particularly important because the high rotational speeds that the torsion arm assembly 100 may reach generate significant centrifugal forces.

[0094] In the illustrated example, the body component 102 includes a first portion 112 of a groove that is recessed into the body component 102 through a surface 113 opposite to the axis of rotation 101, for receiving at least one wire. In the illustrated example, the body component 102 includes a cavity 104 located at a distal end for receiving a wear component. The distal end is remote from the central portion (which includes means for coupling the torsion arm assembly 100 to a bearing), i.e., remote from the axis of rotation 101. Furthermore, the body component 102 includes a slit 114 extending from the first portion 112 of the groove for exposing a second portion of the groove embedded in the wear component when the wear component is inserted into the cavity 104. The slit 114 is located between two retaining ridges 122, 122' for holding the wear component 115 in place when it is received in the cavity 104.

[0095] The purpose of the grooves is to reduce the air resistance acting on the cord as it moves along the torsion arm assembly. In fact, because the cord is not freely exposed, but rather covered in the grooves at least in those sections of the torsion arm assembly that experience high speeds, the reduction in drag is significant compared to existing technologies.

[0096] Also refer to Figure 3A , it is Figure 2A An enlarged view of a portion of the main component of the torsion arm within the dashed rectangle, and refer to... Figure 3B This is a schematic perspective view of an example of a wear member 115 according to an embodiment of the present disclosure. The cavity 104 includes an opening through a surface 120 at the distal end of the torsion arm body member 102, through which the wear member can be introduced into the cavity 104. A second portion 116 of the groove can be observed embedded in the wear member 115. The circular shape of the wear member 115 allows for easy introduction into the cavity 104.

[0097] By using, for example Figure 3CThe plate shown covers the opening to prevent the wear component 115 from moving through the opening of the cavity 104 in the surface 120 at the distal end of the main body component 102. Figure 3C A front view of this plate 119 is schematically shown. Plate 119 includes two openings 123, 123' for receiving fastening devices, such as (but not limited to) screws or bolts, and the surface 120 at the distal end of the torsion arm body component 102 includes two holes, such as threaded holes 118, 118', in which the fastening devices (such as screws or bolts) can be fastened, thereby securing plate 119 to the surface 120 at the distal end of the body component 102. Plate 119 includes another opening 121, which aligns with (e.g., as an extension of) the second portion 116 of the groove when the wear component 115 is received in the cavity 104, for receiving at least one thread at the end of the second portion 116 of the groove. The other opening 121 can hold at least one wire in place in the groove 116 because the top wall 117 of the other opening 121 can prevent at least one wire from leaving the groove 116 due to the large centrifugal force acting on at least one wire during the rotation of the body component 102.

[0098] The shape of the wear component 115 is substantially complementary to the shape of the cavity 104, allowing the wear component 115 to be properly received within the cavity 104. For example... Figure 3A and Figure 3B As can be observed, both the cavity 104 and the wear component 115 are circularly curved. Most of the wear, caused by at least one line sliding along the surface of the torsion arm, likely occurs at the bend of the torsion arm, where at least one line is guided along the bend by grooves 112, 116. Therefore, it is preferable that the wear component 115 includes a groove portion 116 that guides at least one line along the bend.

[0099] Embedded wear parts also help reduce air resistance by eliminating additional wear parts, such as small wheels or pulleys, or those that catch the wind when rotating.

[0100] Now for reference Figure 4A This is a front view of a portion of the distal end of the main body component 202 of a torsion arm according to an embodiment of the present disclosure. The cavity 204 includes retaining ridges 222, 222' at its top, the retaining ridges being separated from each other by a slit 214 in the main body component 202. Dashed lines indicate the obscured portion of the curved cavity 204. The cavity 204 can be formed in the main body component 202 using a conical cutter. Using a conical cutter allows for precise shaping of the cavity 204 (including the slit 214) and allows for the formation of a curved cavity 204, which would be more difficult or even impossible to achieve by other means.

[0101] A conical cutter can begin cutting a cavity 204 in the body component 202 by making an opening in the surface 220 at the distal end of the body component 202. The conical cutter can continue cutting deeper into the body component 202 of the torsion arm, thus forming the cavity 204 along its circular trajectory. Subsequently, the conical cutter can be removed from the now-formed cavity 204 by returning along its trajectory from one end of the cavity 204 to the opening in the surface 220 at the distal end of the body component 202. However, this requires precise movement of the conical cutter back through the cavity 204, which can be time-consuming.

[0102] At the same time, return to reference Figure 2B A hole 124 can be provided at the end of the cavity in the main body component 102 of the torsion arm, through which the conical cutter can be removed from the end of the cavity 204. The hole 124 can be formed by the conical cutter itself after the conical cutter forms the cavity 204, that is, the hole 124 is formed from the beginning of the cavity 204 completion, or the hole 124 can be formed before the conical cutter cuts out of the cavity 204. Removing the conical cutter through the hole 124 is a simpler and faster method of removing the conical cutter from the cavity 204 than returning through the cavity 204 along its trajectory, and limits the risk of damaging the cavity 204.

[0103] like Figure 4A As can be observed, a stop element 224, indicated by a dashed line, can be provided at the end of the cavity 204 to block wear components located within the cavity 204. (Reference) Figure 4B It is with Figure 4A In the same front view, the wear member 215 has been introduced into the cavity 204 through an opening in the surface 220 at the distal end of the body member 202. The obscured portion of the wear member 215 is indicated by dashed lines. Herein, a stop element 224 (e.g., a post or bolt) prevents the wear member 215 from moving too deep into the cavity 204. Therefore, the stop element 224 provides a means for facilitating the placement of the wear member 215 into the cavity 204.

[0104] from Figure 4BIt is particularly clear that the retaining ridges 222 and 222' prevent the wear member 215 from moving laterally in the upward direction outside the cavity 204. This lateral movement may occur due to the centrifugal force acting on the wear member 215 when the cord manufacturing machine, including the torsion arm assembly, is operated. In the example shown, since the height of the wear member 215 is substantially equal to the height of the cavity 204, the wear member 215 can be fixed between the retaining ridges 222 and 222' and the bottom of the cavity 204, thereby preventing vertical movement of the wear member 215 within the cavity 204. Furthermore, the width of the wear member 215 can be substantially equal to the width of the cavity 204, thereby preventing lateral movement of the wear member 215 within the cavity 204.

[0105] Preferably, when the wear member 215 is positioned in the cavity 204 and blocked at the end of the cavity 204 by the stop element 224, the surface of the wear member 215 located in the opening through the surface 220 at the distal end of the main body component 202 of the torsion arm is flush with said surface 220 of the main body component 202. In this case, the opening of the cavity 204 in the surface 220 at the distal end of the main body component 202 can be closed by a plate (see...). Figure 3C This prevents movement along the central axis of the cavity 204.

[0106] from Figure 4B As can be observed, slit 214 is configured to extend from cavity 204 through surface 213 of body component 202 away from the axis of rotation of torsion arm assembly, and expose a second portion 216 of a groove located in wear component 215. Herein, the width of slit 214 is at least as large as the width of the second portion 216 of the groove, preferably, the width of slit 214 is larger than the width of the second portion 216 of the groove, such that a line can be guided through the second portion 216 of the groove without contacting the body component 202 of the torsion arm, thereby preventing wear on the body component 202 of the torsion arm, for example, without contacting the retaining ridges 222, 222'.

[0107] refer to Figure 5A This is a side view of a torsion arm assembly 100, vertically bisected, including a main body 302 and a wear member 314 received in a cavity at the distal end of the main body 302. A first segment 312 of the groove is embedded in the main body 302, is substantially straight, and extends along the main body 302, extending beyond half the length of the groove. A second portion of the groove is located in the wear member 314, including a bend in the groove.

[0108] In the example shown, the first segment 312 of the groove is straight, and the pressure or friction exerted on the body component 302 by the line guided through the first portion 312 of the groove is expected to be small. Therefore, limited wear on the body component 302 due to the line can be expected. Alternatively, the first portion 312 of the groove can be deep enough that the line guided through the first portion 312 of the groove may not make significant contact with the bottom of the first portion 312 of the groove. Since limited wear on the body component 302 can be expected, the body component can be made of a lightweight material that is more easily worn.

[0109] Conversely, the second segment of the groove embedded in the wear member 314 causes the line to bend from the diagonal direction in the first segment 312 of the groove along the curved second segment of the groove to a more horizontal direction, resulting in the line exerting greater pressure and friction on the wear member 314. To limit wear, the wear member 314 may be made of a wear-resistant material, such as cermet (e.g., tungsten carbide) or ceramic.

[0110] The angle α between the rotation axis 301 and the straight section or first section 312 of the groove in the main body component 302 can be from 40° to 70°. Most preferably, in the example shown, the angle is 52.3°. This angle provides an optimal value for the volume limited and contained by the rotating cord. For a given linear stress, a smaller angle will allow for higher speeds but results in a smaller volume for mounting the reel. A larger angle will produce a larger volume, but the tension in the cord limits the maximum rotational speed. For example, for a freely rotating cord, the maximum volume limited by the rotating cord is reached at an angle of 71° at the turning point.

[0111] In addition, such as Figure 5A As can be observed, the width of the main body component 302 perpendicular to its axis, or the corresponding cross-sectional area of ​​the main body component 302, decreases from the central portion of the torsion arm assembly 300 toward the end of the main body component 302 away from the central portion.

[0112] like Figure 5A As can be observed, the aforementioned first counterweight element 306 and second counterweight element 306' are respectively received in separate recesses, such that the first counterweight element 306 and the second counterweight element 306' are spaced apart from each other by wall 326. This configuration facilitates the fastening of the counterweights 306, 306' to the torsion arm assembly 300, for example, by fasteners (e.g., bolts or screws) passing through the first counterweight element 306, wall 326, and second counterweight element 306'. However, this method of fastening the counterweights 306, 306' is not a limitation of this disclosure, and other methods of fastening the counterweights 306, 306' in the recesses can be used.

[0113] refer to Figure 5BThis is a cross-section of the main body component of the torsion arm perpendicular to its axis. It can be seen that the main body component includes, at least a portion thereof: a first convex surface 324 having a first radius of curvature, which faces away from the main axis when the torsion arm is connected to the bearing of the cord manufacturing machine; and a second convex surface 325 having a second radius of curvature, which faces the main axis when the torsion arm is connected to the bearing, wherein the second radius of curvature is greater than the first radius of curvature. During rotation, the main body component moves along a curved dotted line. When the first and second radii of curvature are the same, the main body component acts as a propeller or wing, and due to the curvature of the path taken by the main body component, it generates lift in the radial direction toward the main axis. However, since the second radius of curvature is greater than the first radius of curvature, this lift can be reduced.

[0114] In a second aspect, this disclosure relates to a cord manufacturing machine for merging multiple cords. The cord manufacturing machine includes: at least a first bearing coaxial with the main axis of the cord manufacturing machine; a first torsion arm assembly according to an embodiment of the first aspect of this disclosure, the first torsion arm assembly being connected to the first bearing; and a drive device for driving the first torsion arm assembly.

[0115] In the following example, an embodiment of the present disclosure describes a cord manufacturing machine configured to combine wires, particularly bundles, to form (2)+2 cords. While this particular example describes the formation of (2)+2 cords, more generally, the cord manufacturing machine can be used to manufacture any type of U+T cord, where “U” and “T” are integers that may be the same or different. The nomenclature for different types of cords comprising multiple wires is described in the preceding sections of the specification. As those skilled in the art will understand, any type of cord can be formed using the cord manufacturing machine of the embodiments of the present disclosure.

[0116] refer to Figure 6 This refers to a cord manufacturing machine 16 used for manufacturing cords according to embodiments of the present disclosure. The cord manufacturing machine 16 may also be referred to as a double-twisting device or a "cord-tying machine". In this example, the cord manufacturing machine 16 includes four torsion arm assemblies 100, 100'.

[0117] In the example shown, the first strand of wire 11 is pulled out from the spool 21 and passes through the hole 231 of the guide plate 23. The wires 11 converge at the first guide pulley 24 of the cord manufacturing machine 16, where they are temporarily twisted together. These wires are further passed through a pair of torsion arms in a pair of torsion arm assemblies 100, 100' as described in an embodiment of the first aspect of this disclosure. The effect is that the two wires 11 are twisted together to form the first strand.

[0118] The first strand thus formed then passes through the reverse pulley 26. Two additional spools 27 are fixedly mounted inside the rotor of the cord manufacturing machine 16, for example, within the volume defined by the rotating torsion arms of the torsion arm assemblies 100, 100', 100"'. Thread 12 of the second strand is pulled from these spools 27, passes through the holes 281 of the guide plate 28, and merges with the temporarily twisted thread 11 of the first strand at the cabling die 29. Threads 11 and 12 pass through the reverse pulley 210, the additional rotating torsion arms of the torsion arm assemblies 100"', 100"', and the guide pulley 212 to the winding unit 223 to wind the merged threads 11 and 12 together into a cord 15. Between the cabling die 29 and the guide pulley 212, thread 11 is untwisted to form a first strand consisting of substantially parallel threads 11, while thread 12 is twisted with the same pitch and direction as the two strands.

[0119] Because the torsion arm of this disclosure is lightweight and has reduced air resistance, power consumption can be significantly reduced compared to torsion arms or discs using existing technology. In particular, energy consumption is reduced by at least 1% to 3% compared to discs using existing technology, resulting in a gain. Lower energy consumption leads to less power consumption, thereby reducing greenhouse gas emissions.

[0120] It should be understood that although preferred embodiments, specific constructions and configurations, and materials of the apparatus according to this disclosure have been discussed herein, various changes or modifications in form and detail may be made without departing from the scope of this disclosure. Steps may be added to or removed from the methods described within the scope of this disclosure.

Claims

1. A torsion arm assembly (100) for a cord manufacturing machine (16) for merging multiple cords (11, 12), the torsion arm assembly (100) comprising: At least one torsion arm is provided for rotatably guiding at least one of the plurality of wires (11, 12) about the main axis (101) of the cord manufacturing machine (16). The feature is that the torsion arm includes a groove (112, 116) embedded therein, the groove being adapted to receive the at least one wire (11, 12) for the guidance.

2. The torsion arm assembly (100) according to claim 1, wherein, The groove is embedded in the side of the torsion arm opposite to the main axis.

3. The torsion arm assembly (100) according to claim 1 or 2, wherein, The torsion arm includes: a main body component (102) including a first section (112) of the groove; and a wear component (115) capable of being attached to or attached to the main body component, the wear component including a second section (116) of the groove.

4. The torsion arm assembly (100) according to claim 3, wherein, The wear component (115) includes, for example, tungsten carbide cermet or ceramic.

5. The torsion arm assembly (100) according to claim 3, wherein, The material of the main component (102) is selected from the group consisting of aluminum, aluminum alloys, titanium, titanium alloys, carbon-reinforced composites, glass fiber-reinforced composites, laminated wood, ferroalloys or steel, or combinations thereof.

6. The torsion arm assembly (100) according to claim 3, wherein, The main body component (102) includes a cavity (104) for receiving the wear component (115).

7. The torsion arm assembly (100) according to claim 6, wherein, The main body component (102) and the wear component (115) are configured such that the wear component (115) can be inserted into the distal end of the main body component (102) away from the center of the torsion arm assembly (100), thereby inserting the wear component (115) into the cavity (104), and The main body component (102) includes a slit (114) for exposing a second portion (116) of the groove of the wear component (115) when the wear component (115) is inserted into the cavity (104).

8. The torsion arm assembly (100) according to claim 6, wherein, The main body component (102) includes at least one retaining ridge (122) for holding the wear component (115) in place within the cavity (104).

9. The torsion arm assembly (100) according to claim 1 or 2, further comprising means for connecting the torsion arm to a bearing of the cord manufacturing machine (16).

10. The torsion arm assembly (100) according to claim 1 or 2, wherein, The area of ​​the cross section of the torsion arm perpendicular to the axis of the torsion arm decreases from the central portion of the torsion arm assembly toward the end of the torsion arm away from the central portion.

11. The torsion arm assembly (100) according to claim 1 or 2, wherein, The groove has a straight section along at least half of its length, wherein the angle between the straight section and the main axis (101) is 40° to 70°.

12. The torsion arm assembly (100) according to claim 11, wherein, The angle between the straight section and the main axis (101) is 50° to 60°.

13. The torsion arm assembly (100) according to claim 1 or 2, wherein the torsion arm comprises, at least a portion thereof: A first convex surface having a first radius of curvature, wherein when the torsion arm is connected to the bearing of the cord manufacturing machine, the first convex surface is away from the main axis (101); And a second convex surface having a second radius of curvature, wherein when the torsion arm is connected to the bearing, the second convex surface faces the main axis (101), wherein the second radius of curvature is greater than the first radius of curvature.

14. The torsion arm assembly (100) according to claim 1 or 2, wherein, The torsion arm assembly (100) includes two torsion arms, or wherein, The torsion arm assembly (100) includes a torsion arm and one or more counterweights (106).

15. The torsion arm assembly (100) according to claim 14, wherein, The torsion arm assembly (100) includes two torsion arms arranged opposite each other such that when installed in a cord manufacturing machine, the two torsion arms are located on opposite sides of the diameter of the main axis of the cord manufacturing machine.

16. A cord manufacturing machine (16) for merging multiple cords (11, 12), comprising: At least the first bearing is coaxial with the main axis (101) of the cord manufacturing machine (16). Characterized by, the first torsion arm assembly (100) according to any one of claims 1 to 15, being coupled to the first bearing, and A drive device for driving the first torsion arm assembly.

17. The cord manufacturing machine (16) according to claim 16, comprising: The second bearing is coaxial with the main axis (101) of the cord manufacturing machine (16). ； The second torsion arm assembly (100) according to any one of claims 1 to 15 is coupled to the second bearing; and a drive device for driving the second torsion arm assembly (100).

18. The cord manufacturing machine (16) according to claim 17, wherein, The second torsion arm assembly is offset from the plane formed by the first torsion arm assembly and the main axis by an angle greater than zero and less than twenty degrees.

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