Method for manufacturing a cable comprising two layers of wires in a single operation

Abstract

The invention relates to a method for manufacturing a cable comprising a core wire covered with an inner layer of a plurality of inner wires and an outer layer of a plurality of outer wires, the method comprising the steps of: - unwinding the core wire from a core wire reel and feeding it into an initial forming device, this initial forming device comprising a feed nacelle mounted between two rotating flywheels and a forming plate, the inner wire reels and the forming plate being carried by the feed nacelle; - joining the inner wires of the inner layer with the core wire using the initial forming device; - removing the semi-finished cable comprising the core wire joined with the inner wires from the initial forming device; - feeding the semi-finished cable into a final forming device, the final forming device comprising a fixed rack that supports the outer wire reels, a forming plate and a finished cable receiving device comprising a receiving nacelle mounted between two rotating flywheels and carrying a finished cable receiving reel; - joining the outer wires of the outer layer to the semi-finished cable using the forming plate of the final forming device; - winding the finished cable onto the receiving reel.

Description

METHOD FOR MANUFACTURING A CABLE COMPRISING TWO LAYERS OF WIRES IN ONE OPERATION

[0001] The present invention relates to the manufacture of a cable comprising a core wire covered with an inner layer of several wires and an outer layer of several wires.

[0002] According to a known method, to manufacture a cable comprising a core wire covered with an inner layer of several wires and an outer layer of several wires, a first cable comprising the core wire assembled with the wires of the inner layer is produced in a first step on a first machine, then this first cable is stored on a reel which is then used to supply a second machine in which, in a second step, the wires of the outer layer are assembled with the wires of the inner layer and with the core wire.

[0003] This known manufacturing method, in two operations and on two separate machines, is not optimal because the operator must manage several machines simultaneously and manage the transfer of coils from one machine to another. In addition, the installation corresponding to this manufacturing method requires two investments corresponding to the two machines, and at least three locations in a manufacturing workshop: two locations for the machines and one location for the storage area of ​​the coils to be transferred between the two machines.

[0004] Document CN109338771 describes a single-operation manufacturing method.

[0005] According to this document CN109338771, the manufacturing method consists of firstly producing, in a first rotating assembly device of a single manufacturing machine, a first assembly comprising the core wire assembled with the wires of the inner layer, then directly feeding this first assembly to a second assembly device of the manufacturing machine in which the wires of the outer layer are assembled with the wires of the inner layer and with the core wire.

[0006] This document CN109338771 provides that the core wire feed reel is installed with the internal wire reels in the first rotating assembly device. The presence of this core wire feed reel can limit the productivity of the first assembly device and therefore of the machine.

[0007] According to another drawback of the solution described in document CN109338771, the core wire and the wires of the inner layer undergo a twist at the outlet of the first assembly device which is not compensated before their assembly with the wires of the outer layer.

[0008] Also, in the solution described in document CN109338771, it is necessary to provide a straightener to eliminate residual twists and stabilize the assembly of the inner layer wires with the core wire before their assembly with the outer layer wires.

[0009] The present invention aims to overcome the drawbacks of the manufacturing methods of the prior art.

[0010] To this end, the invention relates to a method for manufacturing a cable comprising a core wire covered with an inner layer of several inner wires and an outer layer of several outer wires, the method comprising the steps of: - unwinding the core wire from a core wire reel and introducing it into an initial assembly device, this initial assembly device comprising a feeder nacelle mounted between two rotating flywheels and an assembly grain, the inner wire reels of the inner layer and the assembly grain being supported by the feeder nacelle, and the core wire reel being located outside the initial assembly device, - assembling the inner wires of the inner layer and the core wire with the initial assembly device, the inner wires of the inner layer being wound helically around the core wire using the assembly grain and the two rotating flywheels, - extracting from the initial assembly device the semi-finished cable comprising the core wire assembled with the internal wires of the internal layer, - introducing said semi-finished cable into a final assembly device, said final assembly device comprising a fixed rack supporting the external wire coils of the outer layer, an assembly grain and a device for receiving the finished cable, said receiving device comprising a receiving cradle mounted between two rotating flywheels, and the receiving cradle supporting a receiving coil of the finished cable, - assembling the external wires of the external layer to the semi-finished cable with the assembly grain of the final assembly device and under the effect of the rotation of the flywheels of the receiving device, the external wires of the external layer being wound in a helix around the semi-finished cable using the assembly grain and the two rotating flywheels of the final assembly device, - wind the finished cable onto the receiving reel.

[0011] Advantageously, the method according to the invention provides that the core wire coil is located outside the initial assembly device. Thus, the productivity of the initial assembly device and therefore of the machine can be increased.

[0012] The method according to the invention can also provide that: - a twist is applied to the core wire when it is introduced into the feed nacelle, - the semi-finished cable is twisted when it is extracted from the feeder nacelle and before it is introduced into the final assembly device, - the cable extracted from the final assembly device is twisted before being wound onto the receiving reel, - the unwinding of the core wire, the internal wires of the internal layer and the external wires of the external layer are passive and slowed down, - the unwinding of the core wire and the wires of the inner and outer layer are driven by the rotation of the receiving reel, assisted by a capstan, in its receiving nacelle, - the inner wires of the inner layer are preformed before being wound helically around the core wire in the feeder nacelle, - the core wire is assembled with an inner layer of six inner wires and with an outer layer of eleven outer wires.

[0013] Advantageously, the pre-formation, in particular plastic, of the internal wires of the internal layer makes it possible to avoid the presence of a straightener between the initial assembly device and the final assembly device.

[0014] Other characteristics and advantages of the invention will appear in the description which follows. This description, given by way of example and not as a limitation, refers to the attached drawings in which: - [Fig.l] schematically represents the section of a cable manufactured using the method according to the invention, - [Fig.2] schematically illustrates a front view of a manufacturing installation allowing the implementation of the method according to the invention, - [Fig.3] schematically represents a top view of a manufacturing installation allowing the implementation of the method according to the invention.

[0015] The invention relates to a method for manufacturing a cable 10 comprising a core wire 12 covered with an inner layer of several inner wires 14 and an outer layer of several outer wires 16. The core wire and the inner and outer wires have, for example, diameters of between 0.15 mm and 0.4 mm. Preferably, the inner and outer wires have diameters of between 0.18 mm and 0.35 mm. Preferably, the inner and outer wires have identical diameters, while the core wire has a diameter greater than the diameter of the inner and outer wires. Preferably, the core wire has a diameter of between 0.2 mm and 0.38 mm. Preferably, all the wires of the cable 10 are metallic.

[0016] As illustrated in Figure 1, the cable 10 manufactured with the method according to the invention is preferably of type 18.XX with a 1+6+11 architecture of unit wires. In other words, the cable 10 preferably comprises a single core wire 12 covered with an inner layer of 6 inner wires then an outer layer of 11 outer wires. Preferably, the cable 10 is an assembly of wires with staggered pitches: the winding pitch of the outer wires around the inner wires and the core wire being different from the winding pitch of the inner wires around the core wire. Preferably, the winding pitch of the outer wires is larger than that of the inner wires. The winding pitch of the inner wires of the inner layer is for example between 4 and 20 mm, and the winding pitch of the outer wires of the outer layer is for example between 7 and 30 mm.

[0017] The method according to the invention aims to make it possible to manufacture such a type of cable in a single operation, i.e. without an intermediate storage step of a semi-finished product.

[0018] To this end, the manufacturing method according to the invention comprises different successive steps.

[0019] In a first step, the manufacturing method provides for unwinding the core wire 12 from a core wire spool 20 and introducing it into an initial assembly device 22. This initial assembly device 22 comprises a feed nacelle 24 mounted between two rotating flywheels 26-1, 26-2 and an assembly grain 28. Preferably, the two rotating flywheels 26-1, 26-2 are integral in rotation and the feed nacelle 24 is suspended between the two rotating flywheels 26-1, 26-2 without being integral in rotation with these two flywheels.

[0020] According to the invention, the coils 30 of the internal wires 14 of the internal layer and the assembly grain 28 are supported by the feed pod 24, while the coil 20 of core wire is located outside the initial assembly device 22. Thus, the feed pod 24 is not overloaded with the coil 20 of core wire 12, which makes it possible to achieve higher productivity and therefore to increase the manufacturing rate of the machine.

[0021] In the manufacturing installation according to the invention, the coil 20 of core wire is positioned on an unwinder, preferably passive and braked, located upstream of the initial assembly device 22.

[0022] The spools 30 of internal wires 14 are mounted on unwinders supported by the feed nacelle 24. Preferably, these unwinders are passive and braked.

[0023] Advantageously, the method also provides that a first twist is applied to the core wire 12 when it is introduced into the feed pod 24. For this purpose, the core wire 12 first passes around and outside the feed pod 24 before being introduced inside the feed pod 24. More precisely, the core wire 12 undergoes a twist after passing around the feed pod 24 and before being introduced inside the feed pod 24. In more detail, the core wire 12 is guided around the feed pod 24 by two axes A1, A2 located on either side of the feed pod 24, as well as by the two rotating flywheels 26-1, 26-2, which include orifices for the passage of the core wire 12. The second axis A2 makes it possible to return the core wire 12 in the opposite direction towards the feed nacelle 24 and thus to apply this first twist to the core wire 12. Preferably, the two axes A1, A2 located on either side of the feed nacelle 24 are integral in rotation with the two rotating flywheels 26-1, 26-2.

[0024] In a second step, the manufacturing method provides for assembling the internal wires 14 of the inner layer and the core wire 12 with the initial assembly device 22, the internal wires 14 of the inner layer being wound helically around the core wire 12 using the assembly grain 28 and the two rotating flywheels. The assembly grain 28 is carried by the feed nacelle 24 and it takes for example the form of an eyelet made of a material that is very resistant to friction, such as carbide or ceramic for example. In more detail, the rotation of the rotating flywheels 26-1, 26-2 around the feed nacelle 24, combined with the pulling of the internal wires and the core wire, causes the internal wires to be wound around the core wire within the assembly grain 28.

[0025] In a third step, the manufacturing method provides for extracting from the initial assembly device 22 the semi-finished cable SF comprising the core wire 12 assembled with the internal wires 14 of the internal layer. And in a fourth step, the manufacturing method provides for introducing said semi-finished cable SF into a final assembly device 32.

[0026] In the manufacturing installation according to the invention, the final assembly device 32 is located downstream of the initial assembly device 22.

[0027] Advantageously, the manufacturing method also provides that the semi-finished cable SF undergoes a twist during its extraction from the feed pod 24 and before its introduction into the final assembly device 32. Consequently, the core wire 12 undergoes a second twist between its exit from the feed pod 24 and before its entry into the final assembly device 32. This second twist undergone by the core wire at the exit from the feed pod is the exact opposite of the twist it undergoes before its entry into the feed pod, and it can therefore be considered as an untwisting. The internal wires 14 undergo their first twist during their exit from the feed pod 24 and before their entry into the final assembly device 32.

[0028] The twisting of the semi-finished cable SF at the outlet of the feeder nacelle 24 is obtained by passing the semi-finished cable SF around and outside the feeder nacelle 24 before its introduction into the final assembly device 32. In more detail, the semi-finished cable SF is guided around the feeder nacelle 24 by two other axes A3, A4 located on either side of the feeder nacelle 24, as well as by the two rotating flywheels 26-1, 26-2, which comprise orifices for the passage of the semi-finished cable SF. The third axis A3 makes it possible to return the semi-finished cable SF in the opposite direction towards the feeder nacelle 24 and thus to apply said twist to the core wire 12, while the fourth axis A4 makes it possible to accompany the semi-finished cable SF towards the inlet of the final assembly device 32.Preferably, the third axis A3 and the fourth axis A4 located on either side of the feed nacelle 24 are integral in rotation with the two rotating flywheels 26-1, 26-2.

[0029] According to the invention, the final assembly device 32 comprises a fixed rack 34 supporting the coils 36 of external wires 16 of the external layer, a fixed assembly grain 38 and a device 40 for receiving the finished cable. This second assembly grain 38 takes for example the form of an eyelet made of a material that is very resistant to friction, such as carbide or ceramic for example.

[0030] Preferably, the reels 36 of external wires 16 are mounted on passive and braked unwinders supported by the fixed rack 34. Different axles, wheels or pulleys make it possible to lead the external wires 16 from their respective reel to the assembly grain 38 of this final assembly device.

[0031] The receiving device 40 comprises a receiving cradle 42 mounted between two rotating flywheels 44-1, 44-2, and the receiving cradle 42 supports a receiving reel 46 of the finished cable 10 and a capstan 50 for multiplying the tensile force provided by the receiving reel. This receiving device 40 is located downstream of the final assembly device 32. Preferably, the two rotating flywheels 44-1, 44-2 are rotationally integral and the receiving cradle 42 is suspended between the two rotating flywheels 44-1, 44-2 without being rotationally integral with these two flywheels.

[0032] In a fifth step, the manufacturing method provides for assembling the external wires 16 of the external layer to the semi-finished cable SF with the assembly grain 38 of the final assembly device 32 and under the effect of the rotation of the flywheels 44-1, 44-2 of the receiving device 40. During this fifth step, the external wires 16 of the external layer are wound in a helix around the semi-finished cable SF using the assembly grain 38 and the two rotating flywheels of the final assembly device. The rotation of the flywheels 44-1, 44-2 of the receiving device 40 causes the external wires to be wound around the semi-finished cable SF. During this second assembly, the flywheels give twists to the wires of the internal layer and to the wires of the external layer making it possible to obtain a finished cable with the desired winding pitches for the internal wires of the internal layer and for the external wires of the external layer.

[0033] In a sixth step, the manufacturing method provides for winding the finished cable 10 onto the receiving reel 46 by driving the receiving reel 46, assisted by the capstan 50, in rotation around its central axis. The rotation of this receiving reel 46 around its central axis pulls all the wires constituting the cable and allows them to be assembled through the assembly grains of the two assembly devices.

[0034] Advantageously, the manufacturing method also provides that the cable 10 extracted from the final assembly device 32 undergoes a twist before being wound onto the receiving reel 46. For this purpose, the cable 10 first passes around and outside the receiving nacelle 42 before being introduced inside the receiving nacelle 42. More precisely, the cable 10 undergoes a twist after passing around the receiving nacelle 42 and before being introduced inside the receiving nacelle 42. In more detail, the cable 10 is guided around the receiving nacelle 42 by two axes A5, A6 located on either side of the receiving nacelle 42, as well as by the two rotating flywheels 44-1, 44-2 which include orifices for the passage of the semi-finished cable SF. The second axis A6 makes it possible to return the cable 10 in the opposite direction towards the receiving nacelle 42 and thus to apply this last twist to the wires of the cable 10.Preferably, the fifth axis A5 and the sixth axis A6 located on either side of the receiving nacelle 42 are integral in rotation with the two rotating flywheels 44-1, 44-2.

[0035] As indicated above, the method according to the invention provides that the unwinding of the core wire, the internal wires of the internal layer and the external wires of the external layer are passive and braked. These unwindings of the core wire and the wires of the internal and external layers are driven by the rotation of the receiving reel, assisted by the capstan 50, in its receiving cradle.

[0036] Advantageously, the manufacturing method according to the invention provides that the internal wires 14 of the internal layer are preformed, preferably plastically, before being helically wound around the core wire 12 in the feed pod 24. In more detail, the internal wires 14 of the inner layer are preformed to promote their helical winding around the core wire 12 in the feed pod 24. For this purpose, preformers 48 are provided on the path of the internal wires 14 between their respective coil and the assembly grain of the initial assembly device. The preforming also makes it possible to give a slight excess length to the internal wires of the inner layer before their assembly with the core wire and it makes it possible to prevent the core wire from coming out of the inner layer once it has been assembled with the internal wires of this inner layer by guaranteeing sufficient space for the core wire inside the internal wires of the inner layer.

[0037] The preformers 48 take the form of axles or pulleys with a diameter of between 5 and 10 millimeters. Return axles or pulleys 52 may also be provided between the coils of the internal wires and the preformers 48, these axles or return pulleys having a larger diameter than that of the preformers 48.

[0038] Preferably, the initial assembly device 22 and its feed pod 24, the final assembly device 32 and its assembly grain 38 and the receiving device 40 are aligned along the same direction.

Claims

Claims 1. A method of manufacturing a cable comprising a core wire covered with an inner layer of several inner wires and an outer layer of several outer wires, the method comprising the steps of: - unwinding the core wire from a core wire spool and introducing it into an initial assembly device, this initial assembly device comprising a feed cradle mounted between two rotating flywheels and an assembly grain, the inner wire spools of the inner layer and the assembly grain being supported by the feed cradle, and the core wire spool being located outside the initial assembly device, - assembling the inner wires of the inner layer and the core wire with the initial assembly device, the inner wires of the inner layer being wound helically around the core wire using the assembly grain and the two rotating flywheels, - extracting from the initial assembly device the semi-finished cable comprising the core wire assembled with the internal wires of the internal layer, - introducing said semi-finished cable into a final assembly device, said final assembly device comprising a fixed rack supporting the external wire coils of the outer layer, an assembly grain and a device for receiving the finished cable, said receiving device comprising a receiving cradle mounted between two rotating flywheels, and the receiving cradle supporting a receiving coil of the finished cable, - assembling the external wires of the external layer to the semi-finished cable with the assembly grain of the final assembly device and under the effect of the rotation of the flywheels of the receiving device, the external wires of the external layer being wound in a helix around the semi-finished cable using the assembly grain and the two rotating flywheels of the final assembly device, - wind the finished cable onto the receiving reel.

2. A method of manufacturing a cable according to claim 1, wherein a twist is applied to the core wire when it is introduced into the feed nacelle.

3. Method of manufacturing a cable according to claim 2, in which the semi-finished cable undergoes twisting during its extraction from the supply nacelle and before its introduction into the final assembly device.

4. Method of manufacturing a cable according to one of the preceding claims, in which the cable extracted from the final assembly device undergoes twisting before being wound onto the receiving reel.

5. Method of manufacturing a cable according to one of the preceding claims, in which the unwinding of the core wire, the internal wires of the internal layer and the external wires of the external layer are passive and braked.

6. Method of manufacturing a cable according to claim 5, in which the unwinding of the core wire and the wires of the inner and outer layer are driven by the rotation of the receiving reel, assisted by a capstan, in its receiving nacelle.

7. A method of manufacturing a cable according to one of the preceding claims, wherein the internal wires of the inner layer are preformed before being wound helically around the core wire in the feeder nacelle.

8. A method of manufacturing a cable according to one of the preceding claims, wherein the core wire is assembled with an inner layer of six inner wires and with an outer layer of eleven outer wires.

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