Apparatus and method for manufacturing endless wound cables

Abstract

The apparatus 100 manufactures an endless winding cable by winding yarn around two thimbles 2, 4. The apparatus comprises a guide 110, a carriage 112, a yarn feeder 114, and two thimble holders. The thimble holders are connected to each other at a distance. The carriage moves longitudinally relative to the guide. The yarn feeder is connected to the carriage and comprises a spool holder that holds a spool containing yarn, and an output guide that guides the yarn onto the cable during winding. The apparatus includes an elastic assembly 129 that provides a restoring force when deformed by an external force resulting from the tensile force caused by the winding of the yarn. The elastic assembly is configured to allow the first thimble holder to move toward the second thimble holder against the restoring force so that the distance between the thimble holders decreases during winding.

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing endless wound cables according to the preamble of claim 1, and a method according to the preamble of claim 14.

[0002] Cables manufactured by this type of apparatus or method can be used in various types of industries including, but not limited to, offshore, mining, heavy load lifting and construction. In offshore applications, such cables can be used as mooring lines for floating oil exploration or production facilities, or ships and structures such as floating wind turbines. In mining and heavy load lifting, such cables may be used as crane pendants. At construction sites, these cables may be used as tension members for bridges or roofs.

Background Art

[0003] Cables manufactured by this type of apparatus are known from Patent Document 1. This document discloses manufacturing a cable by arranging two shimbles at a predetermined distance from each other and winding at least one thread around the shimbles until a predetermined number of layers of yarn turns are provided on both shimbles. In particular, this document discloses adjusting at least one thread tension or length during winding. This adjustment of tension during winding is achieved by controlling the thread brake of the thread feeder. Alternatively, an actuator approaches the shimbles towards each other during winding. As a result, a cable is obtained in which each layer of the thread has a predetermined amount of tension and the thread tension of the later layer is higher than that of the previous layer. By this pre-tensioning of the yarn turns, the breaking load of the resulting cable is increased.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

[0005] However, when relatively large pre-tension is applied to the thread, the thread brake and / or thread feeder cannot withstand such a large force. Furthermore, precise control of the thread tension is required, which can complicate manufacturing. For example, the sensors that measure the thread tension need to be calibrated regularly, which can delay production.

[0006] The present invention aims to solve at least one of these problems, or to provide at least an alternative. In particular, the present invention aims to provide an improved or at least an alternative method for manufacturing an endless winding cable in which the thread tension increases from the innermost to the outermost layer of the thread. [Means for solving the problem]

[0007] This objective is achieved by the apparatus described in claim 1.

[0008] This apparatus is designed to manufacture an endless winding cable by winding at least one thread onto two thimbles provided at both ends of the cable. The apparatus comprises a long guide, a carriage, a thread feeder, a first thimble holder, and a second thimble holder. The first and second thimble holders are connected to the long guide at a distance from each other and are designed to hold one of two thimbles each. The long guide and the carriage are connected to each other so as to allow the carriage to move relative to the long guide in the longitudinal direction of the long guide. The thread feeder is connected to the carriage. The thread feeder comprises at least one spool holder for holding a spool with at least one thread. The thread feeder further comprises an output guide for guiding at least one thread onto the cable during winding. The output guide and the first thimble holder, as well as the output guide and the second thimble holder, are movable relative to each other in a direction at least perpendicular to the longitudinal direction of the long guide, and during winding, guide at least one thread to make a half turn around each of the first thimble of the two thimbles and the second thimble of the two thimbles. The device includes an elastic assembly that provides a restoring force when deformed by the application of an external force, which results from the tensile force brought about by the winding of at least one thread wound around the first and second thimbles during winding. The elastic assembly is configured to allow the first thimble holder to move toward the second thimble holder against the restoring force, thereby decreasing the distance between the first and second thimble holders during winding as more windings are made.

[0009] In other words, as more turns of at least one thread are wound around the thimble, the total tensile force they exert on the thimble increases. The total tensile force is the sum of the tensions of all the turns of thread already wound around the thimble at any given point in the winding process. This tension is initially equal to the pre-tension applied to the thread during winding. This pre-tension decreases with each turn of thread as the distance between the thimbles decreases, but remains at a minimum due to the weight of the thread itself. The final effect is that the total tension increases as the number of turns of thread increases. This increase in tension results in an increase in the external force acting on the elastic assembly. Thus, the external force applied to the elastic assembly increases as more turns of thread are formed, deforming the elastic assembly and bringing the thimbles closer together. By decreasing the distance between thimbles as more threads are wound, the thread tension of the next layer of at least one thread will be higher than the thread tension of the previous layer of at least one thread. For example, the decrease in distance between thimbles per layer of thread ranges from 0.1 to 1 mm.

[0010] An elastic assembly deforms elastically when subjected to an external force, for example, by elastically compressing or stretching, and exerts a restoring force against the external force. By using an elastic assembly, the distance between two thimbles is automatically reduced by mechanical means as more layers of yarn are wound around the thimbles. Since the distance is adjusted via mechanical means, an electronic actuator for moving the thimbles is no longer required, nor is a corresponding electronic controller. This simplifies the apparatus or at least provides an alternative to controlling the distance between thimbles by an electronic actuator. Furthermore, a sensor is not required to measure the yarn tension and feed it back to the controller. Thus, the sensor calibration procedure is avoided, thus preventing apparatus downtime and thus improving production. In addition, the yarn brake and / or yarn feeder do not need to adjust the yarn tension; rather, the tension can be kept constant while winding new layers of yarn, avoiding the application of excessive force to the yarn feeder and / or yarn brake.

[0011] Preferred embodiments are defined in the dependent claims and the following paragraphs.

[0012] In one embodiment, the elastic assembly includes a spring or elastic material. In a particular embodiment, the elastic assembly includes a compression spring. The advantage of using a compression spring rather than a tension spring is that compression springs are less likely to break. Tension coil springs have hooks or grommets at the ends, which are typical points of failure. Also, tension coil springs are more prone to deformation beyond their elastic limit and more prone to plastic deformation than compression coil springs.

[0013] In one embodiment, the spring or elastic material is preferably detachably provided to adjust the restoring force of the elastic assembly. In other words, the spring or elastic material can be replaced with a spring or elastic material having different properties, such as different spring constants or force-displacement curves.

[0014] In another embodiment, the elastic assembly includes an adjustable spring for adjusting the restoring force of the elastic assembly. This eliminates the need to completely replace the spring or elastic material and makes it easier to adjust the properties of the elastic assembly, such as the spring constant or force-displacement curve. For example, the elastic assembly is equipped with an adjustable gas spring.

[0015] The advantage of the two embodiments described above is that the properties of the elastic assembly can be selected based on the desired length and thickness of the cable to be manufactured, the elastic modulus of the yarn used, and the desired yarn tension gradient. Based on these variables, the required reduction in distance per yarn layer can be calculated. This can be converted into a desired force-displacement curve for the elastic assembly. The elastic assembly is then selected or adjusted to match the desired force-displacement curve as closely as possible. In general, longer cables require a greater reduction in distance per yarn layer. The stiffer the cable, the smaller the reduction in distance per layer required.

[0016] In one embodiment, the first thimble holder is provided on the frame, and the frame is movably connected to the elongated guide via an elastic assembly for the movement of the first thimble holder relative to the elongated guide.

[0017] In a further embodiment, the elastic assembly includes at least one spring oriented in the longitudinal direction of the elongated guide. Thus, the restoring force provided by the at least one spring is aligned with the direction of the tensile force provided by the wound thread. In an alternative embodiment, the at least one spring is oriented at a predetermined angle with respect to the direction of the elongated guide. In such an embodiment, the component of the tensile force is still aligned with the restoring force.

[0018] In further embodiments, the elastic assembly further includes at least one wheel for moving the frame relative to the elongated guide, or at least one joint for rotating the frame relative to the elongated guide. For example, a first portion of the frame is connected to the elongated guide via a spring assembly, and a second portion of the frame is connected to the elongated guide via a wheel or joint.

[0019] In one embodiment, the frame is rigidly connected to the elongated guide, and the first thimble holder is movably connected to the frame via an elastic assembly for the movement of the first thimble holder relative to the elongated guide.

[0020] In one embodiment, the frame is detachably connected to a length guide and can be connected to the length guide at multiple different positions along the length guide to set the distance between two thimbles. This allows cables of different lengths to be manufactured using the same apparatus.

[0021] In one embodiment, the thread feeder includes tension-applying means for maintaining a constant thread tension in at least one portion of the thread guided onto the cable during winding.

[0022] Furthermore, the present invention relates to a method for manufacturing an endless winding cable according to claim 14. Such a method brings about the same technical effects as those described above with respect to the device of the present invention. Furthermore, the preferred and / or optional features defined above for the device are the preferred and / or optional features for the method.

[0023] This method includes the step of positioning a first single holder and a second single holder at a predetermined distance from each other. This distance corresponds to the required cable length. A first single is provided on the first single holder, and a second single is provided on the second single holder. At least one thread is provided. This method further includes the steps of winding at least one thread from the first single to the second single, winding a half turn around the second single, returning to the first single, and winding a half turn around the first single. The winding steps are repeated until a predetermined number of thread winding layers corresponding to the required cable thickness are provided on both the first single and the second single. An elastic assembly is provided, and this elastic assembly exhibits a restoring force when deformed by an external force. During the winding steps, the first single holder is able to move towards the second single holder against the restoring force of the elastic assembly by applying an external force generated from the tensile force caused by the winding of at least one thread wound around the first and second singles.

[0024] This method results in an endless winding cable having the same or similar technical effects as described above.

[0025] In one embodiment, this method includes the step of adjusting the restoring force of the elastic assembly. In a further embodiment, the step of adjusting the restoring force of the elastic assembly includes the step of adjusting the spring force of an adjustable spring of the elastic assembly.

[0026] The present invention, its effects and advantages will be explained in more detail based on schematic diagrams.

Brief Description of the Drawings

[0027] [Figure 1] This figure shows a cable end that can be manufactured by the apparatus and method of the present invention. [Figure 2] This is a diagram showing the II-II section of Figure 4. [Figure 3] This is a detailed view of Figure 2. [Figure 4] Figure 1 is a top view of the cable. [Figure 5] Figure 4 shows the VV cross-section. [Figure 6] This is a perspective view of a device according to the first embodiment of the present invention. [Figure 7] Figure 6 is a top view of the apparatus. [Figure 8] This is a side view of the apparatus shown in Figure 6, without thimbles 2 and 4. [Figure 9] This is an end view of the apparatus in Figure 6, without thimbles 2 and 4. [Figure 10] This is an end view of the device in Figure 6, seen from the opposite end to Figure 9. [Figure 11] This figure shows the device in use as shown in Figure 6. [Figure 12] This is a perspective view of a device according to a second embodiment of the present invention. [Figure 13] This is a perspective view of a device according to a third embodiment of the present invention. [Figure 14] This figure shows a top view of the apparatus shown in Figure 13. [Modes for carrying out the invention]

[0028] Figures 1 to 5 show a cable that can be manufactured by the apparatus and method according to the present invention, the whole of which is referenced to reference number 1. The cable 1 has a first thimble 2 and a second thimble 4 and a plurality of threads 6. The first thimble 2 and the second thimble 4 are made of stainless steel and are provided at both ends of the cable 1. In this embodiment, the plurality of threads 6 are 10 threads 6 that extend from the first thimble to the second thimble, wrap around the second thimble 4, extend from the second thimble 4 to the first thimble 2, and wrap around the first thimble 2. In this way, each of the plurality of threads 6 forms a semi-continuous loop around the first and second thimbles. This loop is repeated multiple times, 950 times in this embodiment. Therefore, each thread 6 is wound 950 times, resulting in a total of 9500 windings of thread 6. This will be explained in more detail later when describing the apparatus and method according to the present invention. In this embodiment, yarn 6 consists of aramid fibers with a density of 3220 dtex that are treated with a marine coating. This coating makes the fibers smoother and reduces friction between them. These yarns are sold by Teijin Aramid under the name Twaron® D2204.

[0029] Figure 2 shows that thimble 2 holds a stack 9 having multiple layers 10 of spools 6. This is explained in detail in Figure 3. At the top of Figure 2, the stack 9 is shown in an exploded view for clarity. In reality, the stack 9 is held within the first thimble 2, as shown at the bottom of Figure 2. The second thimble 4 is not shown in detail as it holds the same layers of spools 6 in the same manner.

[0030] The inside 12 of stack 9 is defined as the side of the first layer 13 of the spool 6 closest to the center 14 of the thimble 2. The outside 16 of stack 9 is defined as the side of the last layer 15 of the spool 6 furthest from the center 14 of the thimble 2. The stack height h is defined as the distance from the inside 12 to the outside 16 of stack 9. The layers 18 before at least one winding of yarn 6 and the layers 20 after at least one winding of yarn 6 are defined with respect to the center 14 of the first thimble 2, with the layers 20 after at least one winding of yarn 6 being further from the center 14 of each thimble 2 than the layers 18 before at least one winding of yarn 6.

[0031] The cable cover 28 extends around the cable 1 from the first thimble 2 to the second thimble 4, and bundles all the spools 6 extending between the first thimble 2 and the second thimble 4 into a single compact bundle 30 at the middle portion 32 of the cable 1. In this embodiment, the cable cover 28 also covers the spools 6 at the thimbles 2 and 4.

[0032] The winding of thread 6 has a specific predetermined tension, which will be described in more detail in the following embodiments.

[0033] Figures 6 to 11 show an apparatus 100 according to a first embodiment of the present invention. The apparatus 100 is designed to manufacture an endless wound cable 1 by simultaneously winding at least one thread 6, in this embodiment 10 threads 6, around two thimbles 2, 4 provided at both ends of a cable 1. The apparatus 100 comprises a long guide 110, a carriage 112, a thread feeder 114, a first thimble holder 116 (Figures 8 to 10), and a second thimble holder 118 (Figures 8 to 10). In this embodiment, the long guide 110 includes two elongated I-shaped sections 119. The long guide 110 is suspended from the ceiling of the production equipment via supports (not shown) at intervals of approximately 2 meters.

[0034] In this embodiment, the thread feeder 114 comprises ten spool holders 120, each designed to hold a spool 122. Each of the ten spools 122 holds a thread. The thread feeder 114 further comprises an output guide 124 for guiding all ten threads onto the cable 1 during winding (see Figure 11). In this embodiment, the output guide 124 comprises rollers for guiding the ten threads and is fixed relative to the thread feeder 114. This fixed position is offset from the center of the thread feeder 114.

[0035] In this embodiment, the thread feeder 114 is connected to the carriage 112 via a pivot 125 located in the center of the thread feeder 114. This allows the thread feeder 114 to rotate about an axis perpendicular to the carriage 112. As a result of this rotation, the output guide 124 moves along an arc, in this case a semicircle, relative to the length guide 110 and therefore to the first thimble holder 116 and the second thimble holder 118. This semicircle includes movement in a direction perpendicular to the length direction of the length guide 110, and when the output guide 124 is just past one of each of the two thimbles 2, 4, during winding, the output guide 124 allows the output guide 124 to guide the 10 threads 6 around the first thimble 2 of the first thimble holder 116 and the second thimble 4 of the second thimble holder 118, respectively, by a half turn.

[0036] The thread feeder 114 further comprises 10 thread brakes 126, each corresponding to one of the spools 122, to maintain a constant thread tension on each thread 6 during winding. In this embodiment, the thread brakes 126 are electromechanical brakes.

[0037] The first thimble holder 116 and the second thimble holder 118 are connected to the elongated guide 110 at a distance from each other and are designed to hold one of two thimbles 2, 4, respectively. Figures 6 and 7 show the thimbles 2, 4 arranged in the thimble holders 116, 118, and Figures 8 to 10 show the thimble holders 116, 118 without a thimble. In the embodiments of Figures 6 to 11, the first thimble holder 116 is provided on a first frame 128 connected to the elongated guide 110 via an elastic assembly 129. In this embodiment, the elastic assembly 129 includes a compression spring, specifically a coil spring 130. One end of the spring 130 is connected to the first frame 128, and the other end is provided with a coupling portion 131 for connection to the elongated guide 110. The first frame 128 further includes a wheel 133 for moving along the elongated guide 110. The elastic assembly 129 and wheel 133 are provided at both ends of the first frame 128. The second thimble holder 118 is provided on the second frame 132, which is connected to the elongated guide 110. In this embodiment, the second frame 132 is securely connected to the elongated guide 110, i.e., without the elastic assembly or wheel.

[0038] In this embodiment, both the first frame 128 and the second frame 132 are detachably connected to the elongated guide 110 via fasteners. In this embodiment, the fasteners include pins and holes. The elongated guide 110 is provided with holes 136, which are 15 cm apart. Pins (not shown) are movably held by each frame 128, 132, and connect each frame 128, 132 to the elongated guide 110 at several different positions along the elongated guide 110, the positions of which are defined by the holes 136. By retracting the pins, each frame 128, 132 can be detached from the elongated guide 110 and moved along the elongated guide 110 to adjust the distance between the two thimbles 2, 4. The first frame 128 is provided with a movable pin at the connecting portion 131 of the elastic assembly 129. The pins are inserted into one of the holes 136 when the respective frames 128 and 132 are in the required positions. This allows the same apparatus to manufacture cables 1 of different lengths.

[0039] The carriage 112 is connected to the elongated guide 110 and is configured to move along the elongated guide 110 in the longitudinal direction of the elongated guide 110. In this embodiment, the movable connection includes wheels 140 that run inside the two elongated I-shaped sections 119 of the elongated guide 110. The carriage 112 further comprises a carriage motor for moving the carriage along the elongated guide 110.

[0040] A method for manufacturing an endless winding cable preferably uses an apparatus according to the present invention, such as apparatus 100 described above. For clarity, this method will be described below in relation to this apparatus. However, it should be noted that any other apparatus or tool may be used within the scope of the invention, as long as it operates according to a method within the scope of the appended method claims.

[0041] This method begins by positioning the first thimble 2 and the second thimble 4 at a predetermined distance from each other, the distance corresponding to the required cable length. Ten threads 6 are placed on a spool 122 held in the spool holder 120 of the thread feeder 114. The carriage 112 moves along the long guide 110. Simultaneously, the ten threads 6 are wound from the spool 122 with constant tension using the thread brake 126. The carriage 112 moves from the first thimble holder 116 to the second thimble holder 118, winding the ten threads 6 from the first thimble 2 to the second thimble 4. When the carriage reaches the second thimble holder 118, the spool holder 114 rotates half a turn around the pivot 125. As a result, the spool guide 124 makes a half turn around the second thimble 4, and the 10 threads 6 make a first half turn around the second thimble 4. Next, the carriage 112 moves back to the first thimble holder 116 so that the 10 threads 6 return to the first thimble 2. Here, the spool holder 114 and spool guide 124 make another half turn around the pivot 125 so that the 10 threads 6 make a second half turn around the first thimble 2 by the spool guide 124. These movements of the carriage 112 and spool holder 114 are repeated when the first and second thimbles 2, 4 are very wide and a large number of 10-turns of thread are provided adjacent to each other in one layer. If only 10 threads are provided adjacently in one layer, the device immediately proceeds to create the next layer.

[0042] Once the first layer of thread winding is provided on both the first thimble and the second thimbles 2 and 4, the movement of the carriage 112 and the spool holder 114 is repeated until the next layer of thread winding is provided on both the first and second thimbles 2 and 4. These steps are repeated until a predetermined number of thread winding layers are provided on both the first thimble 2 and the second thimble 4. This predetermined number of thread winding layers corresponds to the required cable thickness.

[0043] During winding, the already wound thread 6 exerts a tensile force on the thimbles 2 and 4. This tensile force acts along the length of the cable 1, parallel to the length of the long guide 110. The tensile force of the wound thread 6 compresses the spring 130 of the elastic assembly 129, thereby reducing the distance between the thimbles 2 and 4. For example, the distance between the thimbles 2 and 4 decreases by 0.1 mm with each layer. Due to the reduced distance, the tension of the wound thread 6 decreases, and the next winding of thread 6 will have a higher tension than the previous winding. As more windings of thread are wound, the total tensile force increases, and therefore the spring 130 of the elastic assembly 129 is compressed more with each winding of thread. This results in a cable 1 in which the outer layers of thread have a higher tension than the inner layers of thread.

[0044] To finish cable 1, a cable cover, such as the cable cover 28 shown in Figures 2 and 5, is provided around the windings of yarn 6. Such a cable cover bundles the windings of yarn 6 into a single compact bundle. Preferably, the yarn that forms loops around thimbles 2 and 4 is also covered with the same or a different cover.

[0045] If necessary, adhesive is applied to the thimble to connect at least two layers of thread to each other. The adhesive is applied only to the thimble; that is, not to the thread between the thimbles along the entire length of the cable. Preferably, the adhesive is a resin such as epoxy resin.

[0046] Figure 12 shows apparatus 200 according to a different embodiment of the present invention. Apparatus 200 has many features in common with apparatus 100 in Figures 6 to 11, and corresponding features are given the same reference numbers, with 100 added. In particular, the long guide 210, carriage 212, thread feeder 214, and the I-shaped cross section 219 of apparatus 200 are the same as those of apparatus 100 in Figures 6 to 11. Features that are not given reference numbers in Figure 12 are also the same as those in Figures 6 to 11.

[0047] The difference between device 200 and device 100 is that the elastic assembly 229 is positioned at an angle to the longitudinal direction of the long guide 210. The elastic assembly 229 includes a compression spring integrated with the first frame 228. Furthermore, device 200 includes a joint 233 for rotating the first frame 228 when the elastic assembly 229 is compressed by the tensile force applied to it during winding, instead of a wheel. This rotation moves the thimble holder of the first frame 228 closer to the thimble holder of the second frame 232, thus reducing the distance between the thimbles as more windings of thread are wound around the thimbles.

[0048] Further alternative devices 300 are shown in Figures 13 and 14. Features common to devices 300 and 100, 200 are not described in detail, and the above description applies to such common features. Corresponding features are given with the same reference numbers as in Figures 6 to 11, plus 200.

[0049] In apparatus 300, the first frame 328 is rigidly connected to the elongated guide 310. As described above with respect to apparatus 100, the first frame 328 is removably connected to the elongated guide 310 to position the thimble holders at a desired distance from each other at the start of the winding process. However, once attached to the elongated guide 310, the first frame 328 does not move relative to the elongated guide 310. The first frame 328 includes an elastic assembly 329 that allows the first thimble holder 316 to move relative to the first frame 328. As shown in Figure 14, the first thimble holder 316 extends from a slot 334 in the frame 328. The first thimble holder 316 is configured to move within the slot 334 in the longitudinal direction of the elongated guide 310. In particular, the first thimble holder 316 is configured to move toward the second thimble holder to reduce the distance between the thimbles during winding. The elastic assembly 329 includes a rod 336 connected to the first thimble holder 316 and extending from the rear of the first frame 328 (the side of the first frame away from the second thimble holder). The elastic assembly 329 also includes a plate 338 connected to the rod 336, the plate 338 being movably connected to the first frame 328 via two compression springs 330. Thus, the first thimble holder 316, the rod 336 and the plate 338 are configured to move together relative to the first frame 328, and their movement toward the second thimble holder is opposed to the spring force of the compression springs 330. During winding, as more thread is wound, the tensile force exerted on the thimble by the wound thread increases, which compresses the springs 330 and moves the first thimble holder 316 closer to the second thimble holder. As a result, the subsequent layer of yarn has higher tension than the preceding layer of yarn.

[0050] The first embodiment is a cable made of aramid fiber yarn with a density of 3220 dtex and a marine coating. These yarns are sold by Teijin Aramid under the name Twaron® D2204. The cable is 25 meters long. The cable consists of 9500 turns, with 10 yarns wound at a time. There are 317 layers, with 30 turns per layer.

[0051] The second embodiment is a cable similarly made from Twaron® D2204 yarn. The cable is 29 meters long. The cable is made by winding 10 strands of yarn at a time. There are 10 windings per layer, for a total of 350 layers.

[0052] The third embodiment is a cable similarly made from Twaron® D2204 yarn. The cable is 45 meters long. The cable consists of 8800 turns, with 10 threads wound at a time. There are 30 turns per layer, for a total of 293 layers.

[0053] The fourth embodiment is a cable made from 1760 dtex Dyneema® DM20 yarn. Dyneema® is a trademark of DSM GmbH of the Netherlands. Dyneema® fibers are made from ultra-high molecular weight polyethylene (UHMwPE), also known as high modulus polyethylene (HPPE). The cable is 29 meters long. The cable consists of 47,870 turns, with 10 threads wound at a time. There are 479 layers, with 100 turns per layer.

[0054] The fifth example is a cable manufactured by Toho Tenax Europe, made from carbon fiber threads called filaments. The product name is Tenax® UTS50 F24 24K 1600tex D. This thread has 24,000 filaments and a nominal linear density of 1600tex. Tenax® is a trademark of Toho Tenax Co., Ltd. The cable is 12.5 meters long. The cable consists of 470 turns in total, with 10 threads wound at a time. There are 12 layers, with 40 turns per layer.

[0055] Modifications of the described embodiments of the apparatus and method are readily possible within the scope of the appended claims. One or more features of one embodiment can be combined with one or more features of another embodiment. Features of the embodiments described above can be replaced by any other features within the scope of the appended claims (e.g., features described in the following paragraphs).

[0056] The cable according to the present invention may be made from more or fewer than 10 threads, such as one thread, two threads, or at least five threads. The total number of spools, i.e., the number of spools per layer and the number of layers, depends on the required strength of the cable, the strength of the individual threads, and the required safety factor. The number of thread layers in a stack of layers is at least one, but is usually multiple. The number of layers depends on the required number of spools and the available width in the thimble that maximizes the number of spools in the width direction.

[0057] Different types of yarns can be used, such as aramid yarns sold under the names Twaron (a registered trademark of Teijin Aramid Co., Ltd.) and Kevlar (a registered trademark of DuPont de Nemours), having densities of 1610 dtex, 4830 dtex, 6440 dtex, 16100 dtex, or 17000 dtex, as well as higher densities, lower densities, and intermediate densities, with or without coatings. Instead of using aramid fibers, other types of plastic fibers can be used, such as para-copolyamide yarn sold under the name Technora (a registered trademark of Teijin Aramid Co., Ltd.), and yarns made from fibers with similar properties. Furthermore, thermoplastic fibers such as polyamide fibers, polyester fibers, polypropylene fibers, polyethylene fibers, HPPE fibers, LCAP fibers, or PBO fibers (poly-paraphenylenebenzoxazole: sold under the name Zylon® by Toyobo Co., Ltd.), polyarylate fibers (sold under the name Vectran® by Kuraray Co., Ltd.) can be used. The cable may even contain threads made of other types of fibers, such as carbon fiber, metal, or natural fibers like basalt fiber. The fiber threads may consist of 100% of the relevant fiber type, but may also contain small amounts of auxiliary materials, such as coatings on the fibers to protect them from abrasion and / or environmental influences. Since such auxiliary materials constitute only a small portion of the weight and do not contribute to the strength of the cable, the phrase “fiber threads” is considered to include embodiments having such auxiliary materials within the context of this specification.

[0058] The thimble may be made of a plastic material instead of metal, or of a metal other than stainless steel, including but not limited to different alloy steels, aluminum alloys, magnesium alloys, and titanium.

[0059] The apparatus according to the present invention, as shown in the illustrated embodiment, does not connect different components of the apparatus to each other in a detachable and movable manner, but rather connects some of the components to each other permanently. A simpler structure is possible by permanently connecting one or both frames equipped with thimble holders to a long guide. Even when one frame is fixed and the other is detachably connected at a different position, cables of different lengths can be manufactured. When both frames are permanently connected, a cable of one length can be created. Furthermore, it is also possible to connect components to each other indirectly, for example, via another structure such as the ground or the walls or ceilings of a building. As an example, the thimble holders and / or their frames may be connected directly to the ceiling of a building instead of via a long guide.

[0060] In an alternative embodiment, the carriage and thread feeder are connected to a fixed structure, while the long guide and thimble holder and / or their frames are connected to each other and are movable together with respect to the carriage and therefore to the thread feeder.

[0061] In a simple embodiment, the spool holder and the output guide may be integrated. The movement of the output guide relative to the first and second thimble holders can be carried out in an alternative manner. Instead of moving the entire thread feeder relative to the carriage, the output guide can be moved relative to the thread feeder, particularly along a line at least partially perpendicular to the longitudinal direction of the long guide. In a further alternative embodiment, the first and second thimble holders are movable relative to the long guide, and therefore the output guide, perpendicular to the longitudinal direction of the long guide.

[0062] In one embodiment, the elongated guide includes one or more members. In an alternative embodiment, the elongated guide comprises a T-shaped member. In one embodiment, the elongated guide includes a rack that cooperates with a pinion for driving the carriage. In one embodiment, the movable connection between the carriage and the elongated guide includes a linear slide.

[0063] An optional thread brake may engage with the spool or directly with the thread. In one embodiment, the thread brake is integrated with the output guide. In one embodiment, the thread brake is a hydraulically controlled brake.

[0064] An elastic assembly provides a restoring force that may be linearly or nonlinearly related to the amount of deformation due to compression or extension, for example. Alternatively, the elastic assembly may be linear over a first deformation range and nonlinear over a second deformation range.

[0065] The embodiment shown in the figure illustrates a coil spring. Alternatively or additionally, different types of springs, such as leaf springs, spiral springs, or gas springs, can be used.

[0066] Examples of elastic materials can include natural or synthetic rubbers such as polybutadiene, or elastic polymers such as elastomers.

[0067] In one embodiment, the elongated guide includes an elastic assembly configured to be elastically compressible. In the first embodiment, the elongated guide includes a telescopic structure for adjusting the length of the elongated guide, and the elastic assembly is positioned to resist the reduction in length. For example, the telescopic structure includes a hollow beam and a second beam extending within the hollow beam, the second beam being movable relative to the hollow beam. In this embodiment, a thimble holder can be firmly attached to the elongated guide. During winding, the tensile force provided by the wound thread acts against the restoring force of the elastic assembly to contract the telescopic structure, thereby reducing the distance between the two thimble holders. In the second embodiment, the elongated guide includes a material or shape that is elastically compressible by applying an external force in the longitudinal direction of the elongated guide.

[0068] As described above, the first thimble holder is configured to move toward the second thimble holder. In other words, at least one of the thimble holders is configured to move toward the other thimble holder. In one embodiment, both thimble holders are configured to move toward each other thimble holder.

[0069] Optionally, a sensor is provided to measure the tension of the thread guided by the cable during winding. Optionally, a sensor is provided to measure the distance between thimble holders.

[0070] In each embodiment of the drawings, the elastic assembly includes two springs. Alternatively, a different number of springs may be provided, for example, one, four, or six springs. For example, the device 100 may include two or more springs 130 instead of the wheel 133.

[0071] Preferably, the cable is manufactured by winding multiple threads at once, with each winding forming a layer of thread windings. For example, 40 threads may be wound at once, with each layer containing 40 threads. Alternatively, one layer may contain multiple thread windings. In such cases, in addition to the thread tension gradient from the innermost layer to the outermost layer, there may also be a thread tension gradient within the layers of thread windings. This is acceptable. As long as the outermost layer has a higher thread tension than the innermost layer, the breaking load of the resulting cable will be increased compared to a cable manufactured with constant thread tension.

[0072] Please note that in the above specification, British spelling is applied to terms such as "fiber" and "center." These terms may be replaced with their corresponding American spellings, "fiber" and "center," without changing the content of this specification.

Claims

1. An apparatus (100, 200, 300) for manufacturing an endless winding cable (1) by winding at least one thread (6) around two thimbles (2, 4) provided at both ends of a cable (1), comprising: a long guide (110, 210, 310); a carriage (112, 212, 312); a thread feeder (114, 214, 314); a first thimble holder (116, 316); and a second thimble holder (118). The first thimble holder (116, 316) and the second thimble holder (118) are connected to the long guide (110, 210, 310) at a distance from each other and are designed to hold one of two thimbles (2, 4), The elongated guides (110, 210, 310) and the carriages (112, 212, 312) are movably connected to each other for the movement of the carriages (112, 212, 312) relative to the elongated guides (110, 210, 310) in the longitudinal direction of the elongated guides (110, 210, 310). The thread feeder (114, 214, 314) is connected to the carriage (112, 212, 312) and comprises at least one spool holder (120) for holding the spool (122) with the at least one thread (6), and an output guide (124) for guiding the at least one thread (6) onto the cable during winding. The output guide (124) and the first thimble holder (116, 316), and the output guide (124) and the second thimble holder (118) are movable relative to each other in a direction perpendicular to the length direction of the long guide (110, 210, 310), and during winding, they guide the at least one thread (6) to rotate half a turn around the first thimble (2) of the two thimbles (2, 4) and the second thimble (4) of the two thimbles (2, 4), The apparatus includes an elastic assembly (129, 229, 329) that provides a restoring force when deformed by an external force resulting from the tensile force caused by the winding of the at least one thread (6) wound around the first thimble (2) and the second thimble (4) during winding, wherein the elastic assembly (129, 229, 329) is configured to allow the first thimble holder (116, 316) to move toward the second thimble holder (118) against the restoring force, thereby configuring the distance between the first thimble holder (116, 316) and the second thimble holder (118) to decrease as more windings are wound during winding.

2. The apparatus (100, 200, 300) according to claim 1, wherein the elastic assembly (129, 229, 329) comprises a spring (130, 330) or an elastic material.

3. The apparatus (100, 200, 300) according to claim 2, wherein the elastic assemblies (129, 229, 329) are equipped with compression springs (130, 330).

4. The apparatus (100, 200, 300) according to claim 2 or 3, wherein the spring (130, 330) or the elastic material is detachably provided to adjust the restoring force of the elastic assembly (129, 229, 329).

5. The apparatus (100, 200, 300) according to claim 2 or 3, wherein the elastic assembly (129, 229, 329) comprises an adjustable spring for adjusting the restoring force of the elastic assembly.

6. The apparatus (100, 200) according to claim 1, wherein the first thimble holders (116, 316) are provided on a frame (128, 228, 328), and the frame (128, 228, 328) is movably connected to the elongated guides (110, 210, 310) via the elastic assembly (129, 229, 329) for the movement of the first thimble holders (116, 316) relative to the elongated guides (110, 210, 310).

7. The apparatus (100) according to claim 6, wherein the elastic assembly (129) comprises at least one spring (130) oriented in the longitudinal direction of the elongated guide (110).

8. The apparatus (200) according to claim 6, wherein the elastic assembly (229) comprises at least one spring oriented at a predetermined angle with respect to the direction of the elongated guide (220).

9. The apparatus (100, 200) according to claim 7 or 8, wherein the elastic assembly (129, 229) further comprises at least one wheel (133) for moving the frame relative to the elongated guides (110, 210).

10. The apparatus (200) according to claim 8, wherein the elastic assembly (229) further comprises at least one joint (233) for rotating the frame (228) relative to the elongated guide (210).

11. The apparatus (300) according to claim 1, wherein a frame (328) is firmly connected to the elongated guide (310), and the first thimble holder (316) is movably connected to the frame (328) via the elastic assembly (329) for movement of the first thimble holder (316) relative to the elongated guide (310).

12. The apparatus (100, 200, 300) according to claim 6, wherein the frames (128, 228, 328) are detachably connected to the elongated guides (110, 210, 310) and can be connected to the elongated guides (110, 210, 310) at a plurality of different positions along the elongated guides (110, 210, 310) to set the distance between the two thimbles (2, 4).

13. The apparatus (100, 200, 300) according to claim 1, wherein the thread feeders (112, 212, 312) are equipped with tension-applying means (126) for maintaining a constant thread tension in a portion of the at least one thread (6) that is guided onto the cable (1) during winding.

14. A method for manufacturing an endless winding cable (1), The steps include: separating the first thimble holder (116, 316) and the second thimble holder (118) by a predetermined distance corresponding to the required cable length; The steps include providing a first thimble (2) to the first thimble holder (116, 316) and providing a second thimble (4) to the second thimble holder (118), The steps include providing at least one thread (6), The steps include winding the at least one thread (6) from the first thimble (2) to the second thimble (4), winding it half a turn around the second thimble (4), returning it to the first thimble (2), and winding it half a turn around the first thimble (2), The winding step is repeated until both the first thimble (2) and the second thimble (4) have a predetermined number of winding layers corresponding to the required cable thickness, Includes, The steps include providing an elastic assembly (129, 229, 329) that provides a restoring force when deformed by an external force, During the winding step, the first thimble holder (116, 316) is moved toward the second thimble holder (118) against the restoring force of the elastic assembly (129, 229, 329) by applying an external force resulting from the tensile force produced by the winding of the at least one thread (6) wound around the first thimble (2) and the second thimble (4), A method characterized by further comprising the following.

15. The method according to claim 14, further comprising the step of adjusting the restoring force of the elastic assembly (129, 229, 329).

16. The method of claim 15, wherein the step of adjusting the restoring force of the elastic assembly (129, 229, 329) includes the step of adjusting the spring force of the adjustable spring of the elastic assembly.

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