Method and apparatus for manufacturing trolley wires
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- PROTERIAL LTD
- Filing Date
- 2022-03-18
- Publication Date
- 2026-06-30
Smart Images
Figure 0007881944000001 
Figure 0007881944000002 
Figure 0007881944000003
Abstract
Description
Technical Field
[0002]
[0001] The present invention relates to a method and an apparatus for manufacturing trolley wires.
Background Art
[0002] Conventionally, in the overhead trolley wire system, which is one of the current collection methods for railway vehicles, the pantograph of a railway vehicle contacts the trolley wire strung along the track. As shown in, for example, Patent Document 1, the trolley wire has a pair of grooves called ear grooves to which suspension fittings are locked. Further, as shown in, for example, Patent Document 2, the trolley wire is wound around a take-up drum provided with disk-shaped flange plates at both ends of a cylindrical body portion, shipped, pulled out from the take-up drum, and strung on an overhead electric wire line.
[0003] As an example of a method for manufacturing a trolley wire, there is one described in Patent Document 3. This manufacturing method is characterized by continuously performing a wire drawing process of subjecting a rough wire to wire drawing to produce a drawn wire, a grooving process of forming grooves in the drawn wire to produce a grooved trolley wire, and a winding process of winding the grooved trolley wire around a take-up drum. In the wire drawing process and the grooving process, the rough wire fed out from the supply device passes through a wire drawing die, a wire stripping device, and a grooving device to produce a grooved trolley wire.
Prior Art Documents
Patent Documents
[0004]
Patent Document 1
Patent Document 2
Patent Document 3
Summary of the Invention
Problems to be Solved by the Invention
[0005] As described in Patent Document 3, in a manufacturing method in which the production and winding of the trolley wire are performed in a continuous manner, the alignment of the trolley wire when wound on the winding drum may not always be sufficient. Furthermore, even if cosmetic damage or dirt is found on the trolley wire during the winding of the produced trolley wire onto the winding drum, it was not possible to confirm in detail whether or not the damage or dirt would affect the quality of the trolley wire.
[0006] This invention was conceived in view of these circumstances, and its purpose is to provide a method and apparatus for manufacturing trolley wire that can improve the alignment and quality of the trolley wire when it is wound on a winding drum. [Means for solving the problem]
[0007] The present invention aims to solve the above problems and provides a method for manufacturing a trolley wire, comprising: a process of stretching a rough-drawn wire to produce a trolley wire; a winding step of continuously winding the trolley wire from the starting end to the ending end onto a wire storage machine; and a drum winding step of unwinding the trolley wire from the wire storage machine and winding it onto a winding drum after the completion of the winding step.
[0008] Furthermore, the present invention aims to solve the above problems by providing a trolley wire manufacturing apparatus comprising: a wire drawing machine for producing a trolley wire by drawing a rough-drawn wire; a wire storage machine for winding the trolley wire from the starting end to the ending end; and a drum winding machine for winding the trolley wire unwound from the wire storage machine onto a winding drum. [Effects of the Invention]
[0009] According to the trolley wire manufacturing method and apparatus of the present invention, it is possible to improve the alignment and quality of the trolley wire when it is wound on a winding drum. [Brief explanation of the drawing]
[0010] [Figure 1] This is a schematic diagram showing a trolley wire manufacturing apparatus according to an embodiment of the present invention. [Figure 2] (a) is an external view showing a portion of the trolley wire. (b) is a cross-sectional view of (a) along line AA. [Figure 3] This is an explanatory diagram showing a manufacturing machine performing the wire winding process, viewed from above. [Figure 4] This is an explanatory diagram showing the manufacturing equipment used in the process of removing imperfections, viewed from above. [Figure 5] This is an explanatory diagram showing a manufacturing machine performing the drum winding process, viewed from above. [Modes for carrying out the invention]
[0011] [Embodiment] Figure 1 is a schematic diagram showing an example of the configuration of a trolley wire manufacturing apparatus according to an embodiment of the present invention. This manufacturing apparatus 1 is for manufacturing trolley wire 11 from rough-drawn wire 10 and winding it onto a winding drum 12 for shipment, and comprises a rough-drawn wire feeder 2 for feeding out the coiled rough-drawn wire 10, first to fifth wire drawing machines 31 to 35, a wire storage machine 5 for storing the trolley wire 11 produced by the first to fifth wire drawing machines 31 to 35, and a drum winding machine 6 for winding the trolley wire 11 fed out from the wire storage machine 5 onto the winding drum 12.
[0012] The rough-drawn wire feeder 2 feeds the rough-drawn wire 10, which is made by casting and hot-rolling molten pure copper or copper alloy, from the coil 21 at a constant speed. The first to fifth wire drawing machines 31 to 35 each have dies 311, 321, 331, 341, 351 and capstans 41, 42, 43, 44, 45, respectively, with the inner diameter of the dies 311, 321, 331, 341, 351 gradually decreasing towards the downstream side. The rough-drawn wire 10 is drawn by sequentially passing through the dies 311, 321, 331, 341, 351 of the first to fifth wire drawing machines 31 to 35, gradually drawing the wire and reducing its outer diameter, while the wire speed transferred by the capstans 41 to 45 increases.
[0013] The wire storage machine 5 has a cylindrical winding body 51 and winds the trolley wire 11 produced by the first to fifth wire drawing machines 31 to 35 onto the winding body 51 continuously from the starting end to the ending end (i.e., without stopping the unwinding of the rough-drawn wire 10 and the rotation of the capstans 41 to 45). The drum winding machine 6 does not operate until the wire storage machine 5 has wound up the end of the trolley wire 11, and after the wire storage machine 5 has wound up the end of the trolley wire 11, it winds the trolley wire 11 unwinding from the wire storage machine 5 onto the winding drum 12. In other words, the method for manufacturing a trolley wire 11 using the manufacturing apparatus 1 according to this embodiment includes a winding step in which a rough-drawn wire 10 is stretched to produce a trolley wire 11, and the trolley wire 11 is wound continuously from the starting end to the ending end onto a winding machine 5, and a drum winding step in which, after the winding step is completed, the trolley wire 11 is unwound from the winding machine 5 and wound onto a winding drum 12.
[0014] Figure 2(a) is an external view showing a part of the trolley wire 11. Figure 2(b) is a cross-sectional view taken along line AA in Figure 2(a). The trolley wire 11 that has passed through the first to fifth wire drawing machines 31 to 35 has a setup section 11a, a speed-increasing section 11b, and a constant speed section 11c. The setup section 11a is a portion in which the end of the rough-drawn wire 10 has been rolled into an elongated shape in advance, and includes the starting end 111 of the trolley wire 11. The outer diameter of the setup section 11a is smaller than the inner diameter of the die 351 of the fifth wire drawing machine 35, which is the last stage among the first to fifth wire drawing machines 31 to 35.
[0015] At the start of the wire winding process, the setup section 11a of the trolley wire 11 is inserted through the dies 311, 321, 331, 341, and 351 of the first to fifth wire drawing machines 31 to 35, and the starting end 111 is fixed to the winding body 51 of the wire storage machine 5. Subsequently, the trolley wire 11 is continuously drawn as the capstans 41 to 45 and the winding body 51 rotate. The speed-increasing section 11b is the part where the rough-drawn wire 10 has passed through the dies 311, 321, 331, 341, and 351 of the first to fifth wire drawing machines 31 to 35 during the process in which the rotational speed of the capstans 41 to 45 and the winding body 51 gradually increases. The constant speed section 11c is the portion where the rough-drawn wire 10 has passed through the dies 311, 321, 331, 341, and 351 of the first to fifth wire drawing machines 31 to 35 while the rotational speeds of the capstans 41 to 45 and the winding body 51 are constant.
[0016] Figure 2(b) shows a cross-section of the trolley wire 11 in the constant-speed section 11c. The trolley wire 11 has a roughly circular cross-sectional shape, and ear grooves 110 are formed at two locations on the outer surface of the trolley wire 11 for securing the trolley wire 11 with suspension fittings. The two ear grooves 110 are formed during the process in which the rough wire 10 fed from the rough wire feeder 2 passes through the dies 331, 341, and 351 of the first to fifth wire drawing machines 31 to 35. The trolley wire 11 is suspended from a suspension wire arranged along the railway track via a hanger and a pair of ear fittings. The ear fittings secure the pair of ear grooves 110 of the trolley wire 11. The pantograph of the railway vehicle comes into contact with the large arc surface 11f of the trolley wire 11.
[0017] The trolley wire 11 has a longitudinally partial section including a starting end portion 111 that is an irregular portion 11d. This irregular portion 11d is a portion not formed in the regular shape of the trolley wire 11 shown in Fig. 2(b), and includes the entire setting-up portion 11a and at least a part of the speed-up portion 11b. The irregular portion 11d is an unnecessary portion not strung on the overhead power line, and is a portion removed by an operator after the entire trolley wire 11 is stored in the wire storage machine 5. That is, the manufacturing method of the trolley wire 11 according to the present embodiment has an irregular portion removing step of removing the irregular portion 11d of the trolley wire 11 including the starting end portion 111 after the completion of the wire storage winding step and before performing the drum winding step. In the drum winding step, the main body portion 11e of the trolley wire 11 from which the irregular portion 11d has been removed is wound around the winding drum 12.
[0018] Fig. 3 is an explanatory view of the manufacturing apparatus 1 during the execution of the wire storage winding step as seen from above. Fig. 4 is an explanatory view of the manufacturing apparatus 1 when performing the irregular portion removing step as seen from above. Fig. 5 is an explanatory view of the manufacturing apparatus 1 during the execution of the drum winding step as seen from above.
[0019] The wire storage machine 5 includes a winding body 51, a rotation drive mechanism 52 for rotating the winding body 51, and a movement mechanism 53 for moving the winding body 51 in the rotational axis direction. The winding body 51 rotates about a rotation axis O1 perpendicular to the arrangement direction of the first to fifth wire drawing machines 31 to 35 and winds the trolley wire. The rotation drive mechanism 52 has a support portion 521 that rotatably supports the winding body 51 and a rotation drive portion 522 that rotates the winding body 51. The rotation drive portion 522 is configured to include, for example, a servo motor and a speed reducer capable of speed control and position control. In Figs. 3 to 5, the winding body 51 is shown in a cross section along the rotation axis O1.
[0020] The moving mechanism 53 includes a slide table 531, a pair of guide rails 532 that guide the slide table 531 parallel to the rotation axis O1, and a moving drive unit 533 that moves the slide table 531 forward and backward. The support portion 521 and the rotation drive portion 522 of the rotation drive mechanism 52 are mounted on the slide table 531, and the winding body 51 rotates above the slide table 531. As an example, the moving drive unit 533 rotates a ball screw 533a by a servo motor to move the slide table 531 forward and backward. However, the configuration of the moving drive unit 533 is not limited to this. For example, the slide table 531 may be moved forward and backward by rotating a pinion gear meshed with a rack rail laid parallel to the guide rail 532.
[0021] In the wire storage winding process, the winding body 51 is rotated by the rotation drive mechanism 52 while being moved in the rotational axis direction along the rotation axis O1 by the moving mechanism 53, and the trolley wire 11 is wound around the outer periphery of the winding body 51 in a single layer so that the trolley wire 11 does not overlap in the radial direction of the winding body 51. More specifically, while the rotation drive mechanism 52 rotates the winding body 51 once, the slide table 531 is moved by the moving mechanism 53 by a moving distance greater than the diameter of the trolley wire 11, and the trolley wire 11 is wound around the winding body 51 in a spiral shape.
[0022] As shown in FIG. 4, when the trolley wire 11 is wound around the winding body 51 up to the end portion 112 and the wire storage winding process is completed, an operator performs an irregular portion removing process on the trolley wire 11. Specifically, the operator pulls out a part of the trolley wire 11 including the irregular portion 11d from the winding body 51, and cuts and removes the irregular portion 11d with a cutting tool 7. The main body portion 11e of the trolley wire 11 excluding the removed irregular portion 11d has its tip fixed to the winding drum 12.
[0023] The winding drum 12 has a cylindrical body 121 for winding the main body portion 11e of the trolley wire 11, and disc-shaped first and second flange plates 122 and 123 that protrude radially outward from both ends of the body 121. Figures 3 to 5 show the winding drum 12 in cross-section along the axis of rotation O2. The axis of rotation O2 of the winding drum 12 is parallel to the axis of rotation O1 of the winding body 51. The outer diameter of the winding body 51 is, for example, 3 m or more, and is larger than the outer diameter of the body 121 of the winding drum 12. In this embodiment, the outer diameter of the winding body 51 is three times or more the outer diameter of the body 121.
[0024] The drum winding machine 6 has a support section 61 that rotatably supports the winding drum 12 and a rotary drive section 62 that rotates the winding drum 12. The rotary drive section 62 is configured, for example, with a servo motor and a reduction gear capable of speed control and position control. In the drum winding process, the rotary drive section 62 rotates the winding drum 12 around the rotation axis O2, thereby winding the trolley wire 11 wound around the winding body 51 of the wire storage machine 5 onto the winding drum 12. After the drum winding process is completed, the winding drum 12 is removed from the drum winding machine 6 and shipped together with the trolley wire 11. The shipped trolley wire 11 is pulled out from the winding drum 12 and installed on the overhead power line.
[0025] In the drum winding process, the trolley wire 11 is wound in multiple layers onto the winding drum 12 so that the trolley wire 11 overlaps radially with the body portion 121. Figure 5 shows the state in which the ninth layer of trolley wire 11 is wound around the outer circumference of the body portion 121. The first layer of trolley wire 11 is wound horizontally in a spiral from the first flange plate 122 side toward the second flange plate 123 side so as to be in contact with the outer surface 121a of the body portion 121. The second layer of trolley wire 11 is wound horizontally in a spiral from the second flange plate 123 side toward the first flange plate 122 side around the outer circumference of the first layer of trolley wire 11. The third layer of trolley wire 11 is wound horizontally in a spiral from the first flange plate 122 side toward the second flange plate 123 side around the outer circumference of the second layer of trolley wire 11. In this way, when the Nth layer (where N is a natural number) of the trolley wire 11 reaches the end on the first flange plate 122 side or the second flange plate 123 side, the (N+1)th layer of trolley wire 11 rides over the outer circumference of the Nth layer of trolley wire 11 and folds back, thus continuing the winding of the trolley wire 11.
[0026] In the drum winding process, the winding body 51 is moved in the rotational direction along the rotational axis O1 by the moving mechanism 53, while the winding body 51 is rotated by the rotational drive unit 522 and the winding drum 12 is rotated by the rotational drive unit 62 of the drum winding machine 6. The position of the winding body 51 in the rotational direction is adjusted so that the trolley wire 11 between the winding body 51 and the winding drum 12 is perpendicular to the rotational axis O1 and the rotational axis O2. This allows each layer of the multi-layered trolley wire 11 to be wound horizontally in a spiral shape at a constant angle with virtually no gaps, thereby improving the alignment of the trolley wire 11 on the winding drum 12.
[0027] Furthermore, during the drum winding process, when the trolley wire 11 reaches the end on the first flange plate 122 side or the second flange plate 123 side and folds back, the rotational speed of the winding body 51 and the winding drum 12 is reduced. At this time, the operator may perform assistive work such as pushing the trolley wire 11 from the side toward the first flange plate 122 side or the second flange plate 123 side. By reducing the rotational speed of the winding body 51 and the winding drum 12 in the time period before and after the folding of the trolley wire 11, it is possible to suppress the disorder of alignment, especially at the folding section where the alignment of the trolley wire 11 is prone to disorder.
[0028] Furthermore, during the drum winding process, the trolley wire 11 is transferred from the winding body 51 to the winding drum 12, and the trolley wire 11 is inspected for any external abnormalities such as scratches or dirt. This external inspection may be performed, for example, by a flaw detector or by visual inspection by an operator. If an external abnormality is found, the rotation of the winding body 51 and the winding drum 12 is stopped, and the external abnormality is thoroughly examined to determine whether it affects the quality of the trolley wire. If there is no problem, the drum winding process is continued. If the external abnormality is a repairable scratch, the scratch is removed by processing, and if the external abnormality is dirt that can be removed, the dirt is removed. This makes it possible to improve the quality of the trolley wire 11.
[0029] On the other hand, if any external abnormalities are found that would affect the strength or durability of the trolley wire 11, the drum winding process is stopped. The trolley wire 11 from which the drum winding process has been stopped is, for example, melted down and used to create the rough-drawn wire 10.
[0030] As described above, this embodiment makes it possible to improve the alignment and quality of the trolley wire 11 when it is wound on the winding drum 12. In Figure 5, the case in which the trolley wire 11 is wound vertically so that the large arc surface 11f (see Figure 1) of the trolley wire 11 is in contact with the outer peripheral surface 121a of the body 121 of the winding drum 12 is shown, but the trolley wire 11 may be wound horizontally so that the large arc surface 11f faces the first flange plate 122 or the second flange plate 123.
[0031] (Summary of the embodiments) Next, the technical concept understood from the embodiments described above will be described using the reference numerals and other symbols from the embodiments. However, the reference numerals in the following description are not limited to the components in the claims that are specifically shown in the embodiments.
[0032] [1] A method for manufacturing a trolley wire, comprising: a winding step of stretching a rough-drawn wire (10) to produce a trolley wire (11), winding the trolley wire (11) continuously from a starting end (111) to a terminal end (112) onto a wire storage machine (5); and a drum winding step of, after the completion of the winding step, unwinding the trolley wire (11) from the wire storage machine (5) and winding it onto a winding drum (12).
[0033] [2] The method for manufacturing a trolley wire according to [1], wherein, after the completion of the storage wire winding step and before the drum winding step, there is an irregular portion removal step in which the irregular portion (11d) of the trolley wire (11), including the starting end (111), is removed, and in the drum winding step, the trolley wire (11) from which the irregular portion (11d) has been removed is wound onto the winding drum (12).
[0034] [3] The method for manufacturing a trolley wire according to [1] or [2] above, wherein the wire storage machine (5) comprises a winding body (51) for winding the trolley wire (11) and a rotational drive mechanism (52) for rotating the winding body (51), and the winding drum (12) has a cylindrical body (121) for winding the trolley wire (11) and first and second flange plates (122, 123) extending radially outward from both ends of the body (121), and the outer diameter of the winding body (51) is larger than the outer diameter of the body (121).
[0035] [4] The method for manufacturing a trolley wire according to [3] above, wherein in the storage wire winding step, the trolley wire (11) is wound in a single layer on the winding body (51) so as not to overlap in the radial direction of the winding body (51), and in the drum winding step, the trolley wire (11) is wound in multiple layers on the winding drum (12) so as to overlap in the radial direction of the body portion (121).
[0036] [5] The method for manufacturing a trolley wire according to [4], wherein the wire storage machine (5) further comprises a moving mechanism (53) for moving the winding body (51) in the rotational axis direction, and in the wire storage winding step, the winding body (51) is moved in the rotational axis direction by the moving mechanism (53) while being rotated by the rotational drive mechanism (52).
[0037] [6] A trolley wire manufacturing apparatus (1) comprising: a wire drawing machine (31-35) for drawing a rough wire (10) to produce a trolley wire (11); a wire storage machine (5) for winding the trolley wire (11) from a starting end (111) to a terminal end (112); and a drum winding machine (6) for winding the trolley wire (11) unwound from the wire storage machine (5) onto a winding drum (12).
[0038] Although embodiments of the present invention have been described above, the embodiments described above do not limit the invention as defined in the claims. Furthermore, it should be noted that not all combinations of features described in the embodiments are necessarily essential for solving the problem of the invention. [Explanation of Symbols]
[0039] 1...Trolley wire manufacturing equipment 10...Roughly drawn wire 11...Trolley wire 111...Starting point 112...Terminal part 11d...Irregular part 12...Rewinding drum 121...Body 122...First guard plate 123...Second guard plate 2... Rough wire feeding machine 31-35... First to fifth wire drawing machines 5... Wire storage machine 51... Winding body 52...Rotating drive mechanism 53...Moving mechanism 6…Drum winding machine
Claims
1. A winding process involves stretching a rough-drawn wire to produce a trolley wire, and continuously winding the trolley wire from the starting end to the ending end into a wire storage machine. After the completion of the wire storage winding process, a drum winding process is performed in which the trolley wire is unwound from the wire storage machine and wound onto a winding drum. In a method for manufacturing a trolley wire having, The wire storage machine comprises a winding body for winding the trolley wire and a rotational drive mechanism for rotating the winding body. The winding drum has a cylindrical body for winding the trolley wire, and first and second flange plates that extend radially outward from both ends of the body. The outer diameter of the winding body is larger than the outer diameter of the body. In the aforementioned wire winding process, the trolley wire is wound in a single layer around the winding body so that it does not overlap in the radial direction of the winding body. In the drum winding process, the trolley wire is wound in multiple layers around the winding drum so that they overlap in the radial direction of the body. A method for manufacturing trolley wires.
2. After the completion of the storage wire winding process and before the drum winding process, there is an irregular portion removal process in which the irregular portion of the trolley wire, including the starting end, is removed. In the drum winding step, the trolley wire from which the irregular portion has been removed is wound onto the winding drum. A method for manufacturing a trolley wire according to claim 1.
3. The cable storage machine further comprises a moving mechanism for moving the winding body in the rotational axis direction, In the wire winding process, the winding body is moved in the rotational axis direction by the moving mechanism while being rotated by the rotational drive mechanism. A method for manufacturing a trolley wire according to claim 1.
4. A wire drawing machine that stretches rough-drawn wire to produce trolley wire, A wire storage machine that winds the trolley wire from the starting end to the ending end, A drum winding machine that winds the trolley wire unwound from the wire storage machine onto a winding drum, In a trolley wire manufacturing apparatus having, The wire storage machine comprises a winding body for winding the trolley wire and a rotational drive mechanism for rotating the winding body. The winding drum has a cylindrical body for winding the trolley wire, and first and second flange plates that extend radially outward from both ends of the body. The outer diameter of the winding body is larger than the outer diameter of the body. The wire storage machine includes a mechanism for winding the trolley wire in a single layer around the winding body so that the wires do not overlap in the radial direction of the winding body. Through the operation of the drum winding machine and the wire storage machine, the trolley wire is wound in multiple layers on the winding drum so that it overlaps in the radial direction of the body. A manufacturing device for trolley wires.