METHOD FOR MANUFACTURED 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 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 feeding pod mounted between two rotating flywheels and an assembly bead, the inner wire reels and the assembly bead being supported by the feeding pod, - assembling the inner wires of the inner layer and the core wire with the initial assembly device, - extracting from the initial assembly device the semi-finished cable comprising the core wire assembled with the inner wires, - introducing said semi-finished cable into a final assembly device, said final assembly device comprising a fixed rack supporting the outer wire reels.An assembly unit and a finished cable receiving device comprising a receiving pod mounted between two rotating flywheels and supporting a finished cable receiving reel; assembling the outer wires of the outer layer to the semi-finished cable with the assembly unit of the final assembly device; winding the finished cable onto the receiving reel. Figure in the abstract: none.

Description

Title of the invention: METHOD FOR MANUFACTURED A CABLE COMPRISING TWO LAYERS OF WIRES IN A SINGLE 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 firstly on a first machine, then this first cable is stored on a reel which is then used to feed 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 the core wire.

[0003] This known manufacturing method, involving two operations on two separate machines, is not optimal because the operator must manage several machines simultaneously and handle the transfer of reels from one machine to the other. Furthermore, the installation corresponding to this manufacturing method requires two investments for the two machines and at least three locations in a manufacturing workshop: two locations for the machines and one location for storing the reels to be transferred between the two machines.

[0004] Document CN109338771 describes a one-step manufacturing method.

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

[0006] This document CN109338771 specifies that the core wire feed spool is installed with the internal wire spools in the first rotating assembly device. The presence of this core wire feed spool may 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 inner layer wires undergo a twisting motion at the exit 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 prior art manufacturing processes.

[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 yarn from a core yarn reel and introducing it into an initial assembly device, this initial assembly device comprising a feed pod mounted between two rotating flywheels and an assembly grain, the inner yarn reels of the inner layer and the assembly grain being supported by the feed pod, and the core yarn reel being located outside the initial assembly device, - assemble the inner layer yarns and the core yarn with the initial assembly device, the inner layer yarns being wound helically around the core yarn using the assembly grain and the two rotating flywheels, - extract from the initial assembly device the semi-finished cable comprising the core wire assembled with the internal wires of the inner layer, - to introduce said semi-finished cable into a final assembly device, said final assembly device comprising a fixed rack supporting the external wire reels of the outer layer, an assembly bead and a finished cable receiving device, said receiving device comprising a receiving pod mounted between two rotating flywheels, and the receiving pod supporting a finished cable receiving reel, - to assemble the outer wires of the outer 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 outer wires of the outer layer being wound helically 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 spool 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 may also provide that: - a twist is applied to the core wire when it is inserted into the gondola food, - the semi-finished cable undergoes twisting during its extraction from the feed pod and before its introduction into the final assembly device, - The cable extracted from the final assembly device undergoes a twist before being wound onto the receiving reel, - The unwinding of the core yarn, the inner yarns of the inner layer, and the outer yarns of the outer layer are passive and controlled. - The unwinding of the core wire and the inner and outer layer wires is driven by the rotation of the receiving reel, assisted by a capstan, in its receiving pod, - the internal yarns of the inner layer are pre-formed before being wound helically around the core yarn in the feed 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 preforming, in particular plastic, of the internal threads of the inner layer makes it possible to do without the presence of a straightener between the initial assembly device and the final assembly device.

[0014] Other features and advantages of the invention will become apparent in the following description. This description, given by way of example and not limitation, refers to the accompanying drawings in which: - [Fig. 1] schematically represents the cross-section of a cable manufactured using the process according to the invention, - [Fig.2] schematically illustrates a front view of a manufacturing installation enabling the implementation of the process according to the invention, - [Fig.3] schematically represents a top view of a manufacturing installation enabling the implementation of the process 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 may, for example, have diameters between 0.15 mm and 0.4 mm. Preferably, the inner and outer wires have diameters 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 between 0.2 mm and 0.38 mm. Preferably, all the wires of the cable 10 are metallic.

[0016] As illustrated in [Fig. 1], the cable 10 manufactured using the method according to the invention is preferably of type 18.XX with a 1+6+11 architecture of individual wires. In other words, the cable 10 preferably comprises a single core wire 12 covered with a layer The cable consists of an inner layer of 6 internal wires followed by an outer layer of 11 external wires. Preferably, the cable is an assembly of wires with staggered pitches: the winding pitch of the outer wires around the internal wires and the core wire is 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. For example, the winding pitch of the inner wires in the inner layer is between 4 and 20 mm, and the winding pitch of the outer wires in the outer layer is between 7 and 30 mm.

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

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

[0019] In a first step, the manufacturing process involves 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 pod 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 rotationally fixed and the feed pod 24 is suspended between the two rotating flywheels 26-1, 26-2 without being rotationally fixed to these two flywheels.

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

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

[0022] The internal wire spools 30 are mounted on unwinders supported by the feed pod 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 nacelle 24. To this end, the core wire 12 first passes around and outside the feed nacelle 24 before being introduced inside the feed nacelle 24. More precisely, the core wire 12 undergoes a twist after passing around the feed nacelle 24 and before being introduced inside the feed nacelle 24. In more detail, the core wire 12 is guided around the feed nacelle 24 by two axes A1, A2 located on either side of the feed nacelle 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 allows the core wire 12 to be returned 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 Al, A2 located on either side of the feed nacelle 24 are rotationally fixed to the two rotating flywheels 26-1,26-2.

[0024] In a second step, the manufacturing process involves assembling the inner wires 14 of the inner layer and the core wire 12 with the initial assembly device 22. The inner wires 14 of the inner layer are wound helically around the core wire 12 using the assembly grain 28 and two rotating flywheels. The assembly grain 28 is carried by the feed nacelle 24 and, for example, takes the form of an eyelet made of a material highly resistant to friction, such as carbide or ceramic. More specifically, the rotation of the rotating flywheels 26-1, 26-2 around the feed nacelle 24, combined with the pulling of the inner wires and the core wire, causes the inner wires to wind around the core wire within the assembly grain 28.

[0025] In a third step, the manufacturing process provides for extracting the semi-finished SF cable, comprising the core wire 12 assembled with the inner wires 14 of the inner layer, from the initial assembly device 22. And in a fourth step, the manufacturing process provides for introducing said semi-finished SF cable 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 process also provides that the semi-finished cable SF undergoes a twist during its extraction from the feed nacelle 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 nacelle 24 and before its entry into the final assembly device 32. This second twist undergone by the core wire upon exiting the feed nacelle is the exact opposite of the twist it undergoes before entering the feed nacelle, and it can therefore be considered a detwist. The inner wires 14 undergo their first twist upon exiting the feed nacelle 24 and before their entry into the final assembly device 32.

[0028] The twisting of the semi-finished cable SF at the exit of the feed nacelle 24 is achieved by passing the semi-finished cable SF around and outside the feed nacelle 24 before its introduction into the final assembly device 32. More specifically, the semi-finished cable SF is guided around the feed nacelle 24 by two other axes A3, A4 located on either side of the feed nacelle 24, thus that by the two rotating flywheels 26-1,26-2, which include openings for the passage of the semi-finished cable SF. The third axis A3 allows the semi-finished cable SF to be returned in the opposite direction towards the feed nacelle 24 and thus to apply said torsion to the core wire 12, while the fourth axis A4 allows the semi-finished cable SF to be guided towards the entrance 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 rotationally fixed to 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 outer wire spools 36 of the outer layer, a fixed assembly bead 38, and a receiving device 40 for the finished cable. This second assembly bead 38 takes, for example, the form of an eyelet made of a material highly resistant to friction, such as carbide or ceramic.

[0030] Preferably, the spools 36 of external wires 16 are mounted on passive and braked unwinders supported by the fixed rack 34. Different shafts, wheels or pulleys allow the external wires 16 to be driven from their respective spool to the assembly grain 38 of this final assembly device.

[0031] The receiving device 40 comprises a receiving platform 42 mounted between two rotating wheels 44-1, 44-2, and the receiving platform 42 supports a receiving reel 46 for 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 wheels 44-1, 44-2 are rotationally fixed, and the receiving platform 42 is suspended between the two rotating wheels 44-1, 44-2 without being rotationally fixed to them.

[0032] In a fifth step, the manufacturing process involves assembling the outer wires 16 of the outer layer to the semi-finished SF cable using the assembly grain 38 of the final assembly device 32 and by rotating the flywheels 44-1, 44-2 of the receiving device 40. During this fifth step, the outer wires 16 of the outer layer are wound helically around the semi-finished SF cable 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 outer wires to wind around the semi-finished SF cable. During this second assembly, the flywheels impart twists to the wires of the inner layer and the wires of the outer layer, resulting in a finished cable with the desired winding pitch for the inner wires of the inner layer and for the outer wires of the outer layer.

[0033] In a sixth step, the manufacturing process involves winding the finished cable 10 onto the receiving reel 46 by rotating the receiving reel 46, assisted by the capstan 50, around its central axis. Rotating this receiving reel 46 around its central axis pulls all the strands constituting the cable and allows their assembly through the assembly grains of the two assembly devices.

[0034] Advantageously, the manufacturing process 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 openings for the passage of the semi-finished cable SF.The second axis A6 allows the cable 10 to be redirected 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 rotationally fixed to the two rotating flywheels 44-1,44-2.

[0035] As previously stated, the method according to the invention provides that the unwinding of the core wire, the inner wires of the inner layer, and the outer wires of the outer layer are passive and braked. This unwinding of the core wire and the inner and outer layer wires is driven by rotating the receiving reel, aided by the capstan 50, in its receiving cradle.

[0036] Advantageously, the manufacturing process according to the invention provides that the inner yarns 14 of the inner layer are preformed, preferably plastically, before being wound helically around the core yarn 12 in the feed nacelle 24. More specifically, the inner yarns 14 of the inner layer are preformed to facilitate their helical winding around the core yarn 12 in the feed nacelle 24. To this end, preformers 48 are provided in the path of the inner yarns 14 between their respective spools and the assembly grain of the initial assembly device. The preforming also provides a slight extra length to the inner yarns of the inner layer before their assembly with the core yarn and prevents the core yarn from protruding from the inner layer once it has been assembled with the inner yarns of this inner layer by ensuring sufficient space for the core yarn inside the inner yarns of the inner layer.

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

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

Claims

Demands

1. 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 feed pod 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 feed pod, 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,- extract from the initial assembly device the semi-finished cable comprising the core wire assembled with the inner wires of the inner layer, - introduce said semi-finished cable into a final assembly device, said final assembly device comprising a fixed rack supporting the outer wire reels of the outer layer, an assembly bead and a finished cable receiving device, said receiving device comprising a receiving pod mounted between two rotating flywheels, and the receiving pod supporting a finished cable receiving reel, - assemble the outer wires of the outer layer to the semi-finished cable with the assembly bead of the final assembly device and under the effect of the rotation of the flywheels of the receiving device, the outer wires of the outer layer being wound helically around the semi-finished cable with the help of the assembly bead 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 pod.

3. A method for manufacturing a cable according to claim 2, wherein the semi-finished cable undergoes a twist during its extraction from the nacelle power supply and before its introduction into the final assembly device.

4. A method of manufacturing a cable according to any one of the preceding claims, wherein the cable extracted from the final assembly device undergoes a twist before being wound onto the receiving reel.

5. A method of manufacturing a cable according to any one of the preceding claims, wherein the unwinding of the core wire, the inner wires of the inner layer and the outer wires of the outer layer are passive and braked.

6. A method of manufacturing a cable according to claim 5, wherein 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 any one of the preceding claims, wherein the inner wires of the inner layer are preformed before being wound helically around the core wire in the feed nacelle.

8. A method of manufacturing a cable according to any 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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