Device and method for producing a cable, as well as a cable

Abstract

A device 100 is provided for producing an endless winding cable. Two thimble holders 116, 118 are provided at a distance from one another. A carriage is movable relative to an elongated guide 110 in a length direction thereof. A yarn feeder 114 is connected to the carriage, and comprises at least one spool holder for holding one or more spools 122, each holding one yarn. An output guide 124 guides the yarns from the yarn feeder 114 to the cable during winding. The output guide 124 and the thimble holders 116, 118 are movable relative to each other for guiding the yarns half a turn around the thimbles during winding. The output guide and the thimble holder are further movable relative to each other in a second direction perpendicular to the first direction and the length direction, for controlling at which position on the thimbles the yarns are wound.

Description

[0001] Title: Device and method for producing a cable, as well as a cable

[0002] The invention relates to a device for producing an endless winding cable according to the preamble of claim 1, as well as a method according to the preamble of claim 18 and a cable according to the preamble of claim 23.

[0003] A cable produced by a device or method of this type can be used in different types of industry, including but not limited to offshore, mining and heavy lifting and construction. In offshore, such a cable may be used as a mooring line for ships and structures like a floating oil exploration or production facility, or a floating wind turbine. In mining and heavy lifting such a cable may be used as a pendant for a crane. In construction these cables may be used as a tension member in a bridge or a roof.

[0004] The concept of endless winding cable, or rope, is explained on the page Rope of the English version of Wikipedia as follows. 'Endless winding rope is made by winding single strands of high- performance yarns around two end terminations until the desired break strength or stiffness has been reached. This type of rope (often specified as cable to make the difference between a braided or twined construction) has the advantage of having no construction stretch as is the case with above constructions. Endless winding is pioneered by SmartRigging and FibreMax.'

[0005] A device and method for producing an endless winding cable are known from WO 2017 / 099589 Al (WO '589). The device comprises a carriage that moves along an elongated guide. The carriage moves back and forth between two thimbles for winding yarns around the thimbles. A spool holder is connected to the carriage and feeds the yarns to an output guide that guides the yarns to the cable during winding.

[0006] The known devices and methods for producing an endless winding cable have as a disadvantage that the thimble size is limited by the maximum number of yarns that can be wound simultaneously. For example, when ten yarns are wound simultaneously, this results in yarn layers of ten times the yarn width each. If the winding surface of a thimble (i.e., the circumferential surface for bearing the yarns) has a width that is greater than the layer width (e.g., a layer width of ten times the yarn width), this thimble cannot be filled completely. An additional disadvantage of known devices and methods is that they require that both thimbles have the same size, as both thimbles need to hold the same number of simultaneously wound yarn (e.g., ten yarns). However, for some applications, it is desirable to provide cables with differently sized thimbles at each end.

[0007] The invention aims to solve this problem, or at least to provide an alternative. In particular, the invention aims to provide a device and a method which enable producing cables with thimbles of various sizes. The invention achieves the aim with a device according to claim 1, as well as with a method according to claim 18. The invention further relates to a cable as defined in claim 23. Preferred embodiments are defined in the dependent claims.

[0008] The device is designed for producing an endless winding cable by winding a plurality of yarns around two thimbles that are provided at opposite ends of the cable. The device comprises an elongated guide, a carriage, a yarn feeder, an output guide, a first thimble holder, and a second thimble holder. The first thimble holder and the second thimble holder are provided at a distance from one another. Each of the thimble holders is designed to hold one of the two thimbles. The elongated guide and the carriage are movably connected to one another for a movement of the carriage relative to the elongated guide in a length direction of the elongated guide. The yarn feeder is connected to the carriage. The yarn feeder comprises at least one spool holder for holding one or more spools. Each spool holds one of the plurality of yarns. The output guide is connected to the carriage. The output guide is configured for guiding the plurality of yarns from the yarn feeder to 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 at least a first direction perpendicular to the length direction of the elongated guide for guiding the plurality of yarns half a turn around respectively the first one of the two thimbles and the second one of the two thimbles 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 second direction perpendicular to the first direction and the length direction of the elongated guide, for controlling at which position on the thimbles the plurality of yarns are wound.

[0009] The length direction of the elongated guide may be referred to as the x-direction, the first direction may be referred to as the y-direction and the second direction may be referred to as the z- direction.

[0010] By moving the output guide relative to the thimble holders in the second direction (z- direction), the position of the yarns relative to the thimble holders can be adjusted. This enables adjusting at which position along the second direction (z-direction) the plurality of yarns is wound onto the thimbles. Therefore, the device of the present invention is capable of producing cables with a wide range of different thimble sizes. Particularly, the thimble size is not limited by the number of yarns that the device can simultaneously wind (e.g., the maximum number of yarns the yarn feeder can hold). For example, if the yarn feeder holds a maximum of N yarns, the device of the invention can also produce a cable with thimbles having a width for accommodating 2N yarns or 3N yarns (or even more). Particularly, the device is capable of laying multiple bundles of N yarns next to each other on the thimbles' winding surface. Thimbles with widths for fitting between / V and 2N yarns next to each other can be handled by loading less than N yarns onto the yarn feeder.

[0011] The movement of the output guide relative to the thimble holders can be achieved in various manners. In a first example, the output guide is connected to the yarn feeder, which is connected to the carriage via a shaft that is movable in the z-direction, e.g., by extending or retracting the shaft using a cylinder. In a further example, the shaft is configured for both rotation of the output guide and yarn feeder relative to the carriage (in the x-y plane), as well as a translational movement of the output guide and yarn feeder in the z-direction relative to the carriage. A drawback of this first example is that the shaft is subject to wear, especially when combining rotation and translation, due to the heavy weight carried by the shaft (particularly the yarn feeder) and the tension exerted by the yarns during winding. In a second example, the first and second thimble holders are arranged for movement in the z-direction relative to the carriage. A drawback of the second example is that the thimble holders are subject to high tensile loads during winding (as tension builds up during winding), such that the mechanism for moving the thimble holders wears easily (or even breaks).

[0012] In a preferred embodiment, the output guide is movable relative to the yarn feeder in the second direction. By moving the output guide relative to the yarn feeder, a construction is provided that is less susceptible to wear than the two examples described above. Preferably, the output guide is arranged to move in the second direction, while the yarn feeder is connected to the carriage in a manner that does not allow movement in the second direction relative to the carriage.

[0013] In a further embodiment, the output guide comprises a plurality of guide elements. Each guide element is configured to guide one of the plurality of yarns. The plurality of guide elements is movable relative to the yarn feeder in the second direction (z-direction). Preferably, the guide elements comprise rollers. By providing a separate guide element for each yarn, the yarns are kept separated during winding, avoid friction and wear between the yarns during winding.

[0014] In a further embodiment, the guide elements are movable relative to each other in the second direction (z-direction), for controlling at which mutual distance the plurality of yarns are wound. In other words, the distance between the yarn as they are wound around the thimbles is controllable by moving the guide elements relative to each other in the z-direction. A greater distance between the guide elements results in a greater distance between the yarns as they are wound around the thimbles, and likewise a smaller distance between the guide elements results in the yarns being laid onto the thimbles more closely together. By providing movable guide elements, it becomes possible to build a layer of yarn at the thimble by laying the yarns in the interspacing between the yarns of a previous winding round. An advantage of this manner of winding compared to winding the yarns as a closely packed bundle, is that each yarn crosses fewer other yarns. This improves the strength of the cable, as friction between yarn is reduced. Additionally, less yarn is needed to achieve the same cable length. Particularly, when laying multiple turns of yarns next to each other onto a thimble during multiple winding rounds, the yarns extend in the z-direction over a distance of ten yarn widths between turns in case of winding as a closely packed bundle, while the yarns extend over only one yarn width in case the yarns are laid with interspacing (of one yarn width). Although the difference in path length is relatively small when considering a single layer, this difference adds up, as a typical endless winding cable comprises 100-300 layers of yarn.

[0015] In a further embodiment, the plurality of guide elements is mounted to an elongated support that is movable relative to the yarn feeder for moving the guide elements in the second direction (z- direction). Preferably, the elongated support is tiltable for moving the guide elements relative to each other in the second direction (z-direction). By providing a movable support, the guide elements are movable by means of a single component, which is less complex than providing each guide element with a separate movement mechanism.

[0016] In a further embodiment, the guide elements are mounted in a row along the length direction of the support, wherein at least one end of the elongated support is movable in the second direction (z-direction) relative to the yarn feeder.

[0017] In a further embodiment, both ends of the elongated support are movable in the second direction (z-direction) relative to the yarn feeder. Thereby, all guide elements can be moved together in the z-direction, to change the position of all yarns relative to the thimbles. Preferably, both ends of the elongated support are movable independently of each other. This enables changing the relative distance (in the z-direction) between the guide elements.

[0018] Preferably, the output guide comprises at least one guide rod extending in the second direction (z-direction) and the at least one movable end of the elongated support is movably connected to the at least one guide rod for movement along the at least one guide rod. The guide rod provides constructional strength to the output guide to account for the forces in the x-direction exerted on the output guide during winding. Particularly, mechanisms for moving the ends of the elongated support, e.g., linear actuators, typically have limited constructional strength in the x-direction, which can be accounted for by providing the guide rod.

[0019] In an embodiment, the device further comprises at least one actuator configured to move the output guide.

[0020] In a further embodiment, the actuator is arranged to move the elongated support relative to the yarn feeder. Preferably, the actuator comprises a linear actuator arranged to move the at least one end of the elongated support along the guide rod, wherein the actuator preferably is a ball screw. A ball screw enables precise control of the movement of the output guide. In a further embodiment, the device further comprises a controller configured to control the actuator to move the output guide during winding, for adjusting at which position on the first and / or second thimble the plurality of yarns is wound. Preferably, the controller is configured to move the guide elements relative to each other during winding, for adjusting the distance between the plurality of yarns. In particular, the controller enables automatically adjusting the position of the plurality of yarns during the winding process, e.g., in accordance with a predetermined winding program.

[0021] In an embodiment, the output guide is rotatably connected to the carriage for rotation of the output guide around a rotation axis. The output guide comprises an a-centrical guide for guiding the plurality of yarns. The a-centrical guide is positioned at a position offset relative to the rotation axis. Preferably, the rotation axis extends in the second direction (z-direction).

[0022] Preferably, the output guide comprises both an a-centrical guide and a plurality of guide elements. The plurality of yarn is guided from the spool holder to the guide elements, from the guide elements to the a-centrical guide and from the a-centrical guide to the cable during winding.

[0023] A method for producing an endless winding cable according to the invention comprises the steps of: positioning a first thimble and a second thimble at a predetermined distance from one another along a length direction (x), which distance corresponds to a required cable length, providing a plurality of yarns, winding the plurality of yarns from the first thimble to the second thimble, a half turn around the second thimble, back to the first thimble, and a half turn around the first thimble, repeating the previous step until a predetermined number of layers of yarn turns is provided in both the first thimble and the second thimble, corresponding to a required cable thickness, and controlling at which position on the thimbles the plurality of yarns is wound by moving the plurality of yarns relative to the first and second thimbles, in a second direction (z) perpendicular to the length direction (x).

[0024] This solves the problem of the prior art in a similar manner as described above in relation to the device. Preferably, the method is performed using the device as described above.

[0025] The step of controlling at which position on the thimbles the plurality of yarns is wound can be performed prior to winding or during winding. Moreover, the controlling step can be performed manually or using an actuator.

[0026] Winding half a turn around the first thimble and winding half a turn around the second thimble is performed by moving the yarn in at least a first direction (y-direction) perpendicular to the length direction (x), e.g., by rotation of the output guide relative to the thimbles. In an embodiment, moving the plurality of yarns relative to the first and second thimbles comprises moving the plurality of yarns in the second direction (z-direction).

[0027] Preferably, the thimbles are not movable in the z-direction. Preferably, the yarns are moved using a plurality of guide elements, each configured to guide one of the plurality of yarns, as described above.

[0028] In an embodiment, the method comprises controlling at which mutual distance the plurality of yarns is wound onto the thimbles by moving the plurality of yarns relative to each other in the second direction (z). For example, by tilting the elongated support as described above with respect to the device according to the invention.

[0029] In an embodiment, the method comprises adjusting, during winding, at which position on the thimbles the plurality of yarns is wound by moving, during winding, the plurality of yarns relative to the first and second thimbles, in the second direction (z-direction).

[0030] For example, the method comprises providing at least one thimble with a winding surface that is wider than the number of yarns times the yarn width. By adjusting the position of the plurality of yarns during winding, the entire winding surface of such a thimble can be filled with yarn. In a first example, the method comprises providing two thimbles having the same width, both widths exceeding the yarn width times the number of yarns. In a second example, the method comprises providing two thimbles of different width, wherein at least one of two thimbles has a winding surface that is wider than the yarn width times the number of yarns.

[0031] In an embodiment, the method comprises adjusting, during winding, the mutual distance between the plurality of yarns by moving, during winding, the plurality of yarns relative to each other in the second direction (z-direction). In a further embodiment, the method comprises laying, in a first round, the plurality of yarns onto a thimble at a mutual distance of at least one yarn width, and laying, in a second round, the plurality of yarns onto the thimble in between the yarns that were laid during the previous round.

[0032] The invention further relates to a cable producible by the method described above. Such a cable comprises a first thimble and a second thimble and a plurality of N yarn wound around the first and second thimbles. The first thimble and a second thimble are provided at opposite ends of the cable. The plurality of N yarns extend from the first thimble to the second thimble, turns around the second thimble, extends from the second thimble to the first thimble, and turns around the first thimble, such that the plurality of N yarns form turns around the first and second thimbles, and each thimble holds a stack of a plurality of layers of turns of the plurality of N yarns.

[0033] This solves the problem of the prior art in a similar manner as described above in relation to the method and the device. In an embodiment, the plurality of yarn extends over a greater width at the first thimble than at the second thimble. For example, the first thimble has a larger winding surface than the second thimble. The larger winding surface of the first thimble can more yarns next to each other than the second thimble.

[0034] In an embodiment, each of the plurality of yarns crosses at most one other yarn for each turn around the first and second thimbles.

[0035] In an embodiment, the stack of yarn layers at the first and / or second thimble has a width that exceeds N times the width of the individual yarns.

[0036] In an embodiment, the cable comprises a third thimble provided at the same end of the cable as the first thimble, wherein the first thimble and third thimble are positioned at distance to each other for receiving a thimble of another cable, or other connecting element, between the first and third thimble. The first and third thimble may be referred to as a female connector. The end opposite to the female connector may comprise a single thimble (the second thimble), to form a male connector, or the cable may be formed with a female connector at each end.

[0037] The invention, its effects, and advantages will be explained in more detail on the basis of the schematic drawings, in which

[0038] Fig. 1 shows an end of a cable according to an embodiment the invention;

[0039] Fig. 2 shows section ll-ll from fig. 4;

[0040] Fig. 3 shows a detail from fig. 2;

[0041] Fig. 4 shows a top view of the cable of fig. 1;

[0042] Fig. 5 shows section V-V from fig. 4;

[0043] Fig. 6 shows a perspective view of a device according to the invention;

[0044] Fig. 7 shows a top view of the device of fig. 6;

[0045] Fig. 8 shows a side view of the device of fig. 6;

[0046] Fig. 9 shows a detail of the output guide of the device of fig. 6;

[0047] Fig. 10 shows the output guide of Fig 9 in a top view along line B-B;

[0048] Fig. 11 shows the device of fig. 6 in use;

[0049] Fig. 12 shows section XII-XII from fig. 11;

[0050] Fig. 13 shows details of the yarn wound around thimble 102 of Fig 11; and

[0051] Figs. 14 and 15 show opposite ends of a cable according to another embodiment of the invention.

[0052] The figures 1-5 show a cable according to the invention, which is denoted in its entirety by reference number 1. The cable 1 has a first thimble 2 and a second thimble 4, and a plurality of yarns 6. The first 2 and the second 4 thimble are made of stainless steel, and are provided at opposite ends of the cable 1. The plurality of yarns 6 are in this embodiment ten yarns 6 which all extend from the first to the second thimble, turn around the second thimble 4, extend from the second thimble 4 to the first thimble 2, and turn around the first thimble 2. In this manner each of the plurality of yarns 6 forms a semi-continuous loop around the first and second thimbles. This loop is repeated a plurality of times, in this embodiment 950 times. So, each of the yarns 6 makes 950 turns, resulting in a total of 9500 turns of yarns 6. This will be explained in more detail later when describing the device and method according to the invention. The yarns 6 consist of fibres, in this embodiment aramid fibres with a density of 3220 dTex that are provided with a marine coating. This coating makes the fibres smoother which results in less fibre-to-fibre wear. These yarns are sold under the name Twaron® D2204 by Teijin Aramid.

[0053] Figure 2 shows that the thimble 2 holds a stack 9 with a plurality of layers 10 of yarn turns 6. This is shown in more detail in figure 3. In the upper part of figure 2 the stack 9 is shown in an exploded view for clarity. In reality, the stack 9 is held in the first thimble 2 as shown in the lower part of figure 2. The second thimble 4 holds layers of the same yarn turns 6 in the same manner and is therefore not shown in detail.

[0054] An inside 12 of the stack 9 is defined as a side of a first layer 13 of yarn turns 6 being closest to a centre 14 of the thimble 2. An outside 16 of the stack 9 is defined as a side of a last layer 15 of yarn turns 6 being farthest away from the centre 14 of the thimble 2. A stack height h is defined as the distance from the inside of the stack 12 to the outside of the stack 16. A previous layer 18 of turns of the at least one yarn 6 and a subsequent layer 20 of turns of the at least one yarn 6 are defined with respect to the centre 14 of the first thimble 2, in that the subsequent layer 20 of turns of the at least one yarn 6 is further away from the centre 14 of the respective thimble 2, than the previous layer 18 of turns of the at least one yarn 6.

[0055] A cable cover 28 extends around the cable 1 from the first thimble 2 to the second thimble 4, and bundles all yarn turns 6 extending between the first and the second thimble 2, 4 in one compact bundle 30 in a middle section 32 of the cable 1. In this embodiment, the cable cover 28 also covers the yarn turns 6 at the thimbles 2, 4.

[0056] A device 100 according to the invention is shown in figures 6-12. The device 100 is designed to produce an endless winding cable 101 by winding a plurality of yarns 106, in this embodiment ten yarns 106, simultaneously around two thimbles 102, 104 that are provided at opposite ends of the cable 101. The device 100 comprises an elongated guide 110 that extends in the x-direction, a carriage 112, a yarn feeder 114, a first thimble holder 116, and a second thimble holder 118. In this embodiment the elongated guide 110 comprises two elongated l-prof iles 119. The elongated guide 110 is suspended from a ceiling of a production facility via supports (not shown) at an interval of approximately 2 meters.

[0057] The yarn feeder 114 comprises in this embodiment ten spool holders 120, each designed for holding a spool 122. Each of the ten spools 122 holds a yarn 106. The device further comprises an output guide 124 for guiding all ten yarns 106 to the cable 101 during winding (see fig. 11). In this embodiment, the output guide 124 is connected to the yarn feeder 114, and the yarn feeder 114 is connected to the carriage 112, for moving the output guide 124 and the yarn feeder 114 with the carriage along the length direction (x) of the elongated guide 110, back and forth between the thimble holders 116, 118.

[0058] Referring to figures 9 and 10, the output guide 124 of this embodiment comprises a plurality of guide elements in the form of rollers 126 for guiding the ten yarns 106. For clarity of illustration, only two of the yarns 106 are illustrated in Figure 9. The output guide 124 further comprises an a-centric guide 128, in this example in the form of a cylindrical rod. The rod 128 is in a fixed position relative to the yarn feeder 114. This fixed position is offset from a pivot 125 which in this embodiment is positioned at a middle of the yarn feeder 114. The yarns 106 are guided from the yarn feeder 114, via the rollers 126 to a further rod 129, and from the further rod 129 to the a- centric guide 128. From the a-centric guide 128, the yarns 106 are guided to the cable 101.

[0059] The yarn feeder 114 is connected to the carriage 112, in this embodiment via the pivot 125. This enables the yarn feeder 114 to rotate about a vertical axis (z) with respect to the carriage 112. This rotation results in the a-centric guide 128 moving along an arc, in this case a semi-circle, with respect to the elongated guide 110 and thus relative to the first thimble holder 116 and to the second thimble holder 118. This semi-circle includes a movement in a direction (y) perpendicular to the length direction (x) of the elongated guide 110, and enables the output guide 124 to guide the ten yarns 106 half a turn around respectively the first thimble 102 at the first thimble holder 116 and the second thimble 104 at the second thimble holder 118 during winding when the a-centric guide 128 is just beyond the respective one of the two thimbles 102, 104.

[0060] As illustrated in Figure 9, the output guide 124 comprises an elongated support 130 to which the rollers 126 are mounted. One end of the support 130 is movably connected to a first threaded shaft 132, while the other end of the support 130 is movably connected to a second threaded shaft 134. The threaded shafts 132, 134 are part of a ball screw for moving the respective end of the elongated support 130 in the z-direction along the shaft 132, 134. The ball screws are each driven by an actuator (not shown) that rotates the respective threaded shaft 132, 134. In the present example, the actuator comprises a servo motor with an encoder for precise control of the movement. The ends of the support 130 are independently movable along their respective shaft 132, 134 so that the support 130 is tiltable to adjust the position of the rollers 126 relative to each other. Specifically, the distance between the rollers 126 as measured in the z-direction is adjusted by tilting. Additionally, both ends of the support 130 can be moved together, to move the rollers 126 in the z- direction without adjusting their relative position. Optionally, each end of the support 130 may be movably connected to a rigid guide rod 133, 135 (see fig. 9, not shown in fig. 10) to provide additional strength to the output guide 124 (as compared to using only the threaded shafts 132, 134 of the ball screw).

[0061] 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 each designed to hold one of the two thimbles 102, 104 (Figure 11).

[0062] In the illustrated examples, a thimble has a circumferential surface for bearing the yarns, with the circumferential surface extending around an axis of the thimble. Figure 11 illustrates the thimble axis A of thimble 104. The thimbles 102, 104 of the illustrated examples have a substantially circular cross-section, with the axis A at the centre of the circular cross-section, and the thimble axis A is parallel to the z-direction, and perpendicular to the x-direction and y-direction.

[0063] In this embodiment, both the first thimble holder 116 and the second thimble holder 118 are each detachably connected to the elongated guide 110 via a fastener. This fastener comprises in this embodiment a pin and a hole. The elongated guide 110 comprises the respective holes 136. The holes 136 have a mutual distance of 15 cm. The pins (not shown in the figures) are movably held in the respective thimble holder 116, 118 for connecting the respective thimble holder 116, 118 to the elongated guide 110 at a plurality of different positions along the elongated guide 110, which positions are defined by the holes 136. By retracting the pin, the respective thimble holder 116, 118 is disconnected from the elongated guide 110 and can be moved along the elongated guide 110 for adjusting the distance between the two thimbles 102, 104. The pins are entered into one of the holes 136 when the respective thimble holder 116, 118 is at a required position. This enables producing cables 101 of different lengths with the same device.

[0064] The carriage 112 is connected with the elongated guide 110 for a movement of the carriage 112 along the elongated guide 110 in a length direction of the elongated guide 110. The movable connection comprises in this embodiment wheels 140 that run inside the two elongated l-prof iles 119 of the elongated guide 110 (Figure 12). The carriage 112 further comprises a carriage motor for moving the carriage along the elongated guide 110.

[0065] A method for producing an endless winding cable preferably uses a device, such as device 100 which has been described above. For the sake of clarity, the method will be described below in relation to this device. It should be noted however, that any other device or tools may be used within the scope of the invention, as longs as it operates according to a method within the scope of the attached method claims.

[0066] The method starts with positioning a first thimble 102 and a second thimble 104 at a predetermined distance from one another, which distance corresponds to a required cable length. Ten yarns 106 are provided on the spools 122, which are held on the spool holders 120 of the yarn feeder 114 as described above. The support 130 with the rollers 126 is moved to a desired starting position and tilt angle. The tilt angle of the support 130 determines the mutual distance between the yarns 106. The position of the support 130 in the z-direction determines the position of the bundle of yarns 106 on rod 129, and thus at which position the bundle of yarns 106 is laid onto the thimbles 102, 104. The desired position and tilt angle of the support 130 is set by controlling the servo motors that are coupled to the ball screws, to move the ends of the support 130 along the threaded shafts 132, 134.

[0067] The carriage 112 moves along the elongated guide 110. At the same time, the ten yarns 106 are wound off from the spools 122. The carriage 112 moves from the first thimble holder 116 to the second thimble holder 118, thus winding the ten yarns 106 from the first thimble 102 to the second thimble 104. When the carriage arrives at the second thimble holder 118, the pivot 125 is rotated by a motor (not shown) such that the spool holder 114 makes a half turn. This results in the output guide 124 making a half turn around the second thimble 104, such that the ten yarns 106 make a first half turn around the second thimble 104. Then the carriage 112 moves back to the first thimble holder 116 so that the ten yarns 106 run back to the first thimble 102, where the pivot 125 is again rotated such that the spool holder 114 and thus the output guide 124 make another half turn such, that the output guide 124 lets the ten yarns 106 make a second half turn around the first thimble 102.

[0068] In case that the first and second thimbles 102, 104 are so wide that a multitude of ten yarn turns are provided next to each other in one layer, the support 130 is moved during winding to adjust at which position on the thimbles the yarns are wound, and the movement of the carriage 112 and spool holder 114 is repeated.

[0069] In a first example, the support 130 has a relatively small tilt angle such that the ten yarns 106 are packed closely together. In this example, after the carriage has moved from the first thimble 102 to the second thimble 104, the support 130 is moved in the z-direction without changing the tilt angle. This is done by controlling the ball screws such that the ends of the support 130 move the same distance in the same direction (z-direction in figure 9). Particularly, the support 130 is moved over a distance corresponding to ten times the yarn width. The movement of the carriage 112 is then repeated using the new position of the support 130, to wind the ten yarns 109 as a bundle next to the previously wound yarn turns.

[0070] In a second example, the support 130 is set to a greater tilt angle such that the yarns 106 are wound around the thimbles with a distance of at least one yarn width between them. In this example, after the carriage has moved from the first thimble 102 to the second thimble 104, the support 130 is moved in the z-direction such that the carriage, in the next iteration of its movement, lays the yarns 106 in the interspacing of the previously wound yarns. This is illustrated in Figure 13. Figure 13 shows only a top portion of thimble 102. In a first round, ten yarns are wound around thimble 102, to form a first set 106a of ten yarns on the thimble (of which only two are shown). The yarns in set 106a have a mutual distance corresponding to one yarn width. In a second round (after winding the ten yarns around the second thimble 104), the ten yarns are again wound round thimble 102 to form a second set 106b of ten yarns on the thimble (of which also only two are shown). The second set 106b is offset with respect to the first set 106b by one thimble width, such that the yarns second set 106b are in the interspacing between the yarns of the first set 106a.

[0071] Winding the cable with yarns 106 at a mutual distance has as advantage that each of the yarns crosses at most one other yarn for each turn around the first and second thimbles. A cable produced in this manner is less susceptible to wear as compared to a cable produced by winding the yarns as a bundle of closely packed yarns, as in the first example (i.e., with no or almost no interspacing). In the latter case, the entire bundle crosses the previously wound yarns for each turn around the first and second thimble. A further advantage of winding the yarns 106 at a mutual distance as compared to winding as a closely packed bundle of yarn is that less yarn is required.

[0072] In case of thimbles 102, 104 of different sizes, the support 130 is moved during winding to account for the size difference. For example, the first thimble 102 has a width to accommodate twenty yarns next to each other, while the second thimble 104 is smaller and can accommodate ten yarns next to each other. In such a case, the position and / or tilt angle of the support 130 is controlled during winding to ensure both thimbles 102, 104 are filled with yarn over the entire width of the winding surface. In a first example, the ten yarns 106 are wound from the first thimble 102 to the second thimble 104, half a turn around the second thimble 104, and back to the first thimble 102. During the movement of the carriage 112 from the second thimble 104 back to the first thimble 102, the position of the support 130 relative to the thimble 102 is adjusted such that when the ten yarns 106 are moved half a turn around the first thimble 102, the yarns 106 are laid next to the previous set of ten yarns 106 on the first thimble 102. Then, while moving the carriage 112 again towards the second thimble 104, the original position of the support 130 is restored such that the yarns 106 are again aligned with the second thimble 104 and laid on top of the previous layer of ten yarns 106 as the yarns are wound half a turn around the second thimble 104. The carriage then moves back again to the first thimble 102, winds the yarns 106 half a turn around the first thimble 102, after which the previous steps can be repeated for further layers of yarn in both thimbles. In a second example, the ten yarns 106 are kept at a mutual distance by setting an appropriate tilt angle of the support 130, and the yarns are wound around the first thimble 102 and then the carriage 112 moves to the second thimble 104. The mutual distance is reduced by reducing the tilt angle of the support 130 such that the ten yarns 106 form a closely packed bundle that fits around the second thimble 104. The carriage 112 moves back to the first thimble 102, while the mutual distance of the yarns 106 is increased by tilting the support 130. Additionally, z-position of the support 130 is adjusted to align the ten yarns 106 with the interspacing between the previously wound yarn at the first thimble 102. The yarn 106 is wound half a turn around the first thimble 102, and the carriage 112 moves again to the second thimble 104, while reducing the tilt angle again to form a closely packed bundle of yarn, and a second layer of yarn is wound around the second thimble 102. The support 130 is then adjusted again to its starting orientation and position, and all steps are repeated to wind further layers around the thimbles.

[0073] In order to finish the cable 101, a cable cover is provided around the turns of the yarn 106, such as the cable cover 28 which is shown in figs. 2 and 5. Such a cable cover bundles the turns of the yarn 106 into one compact bundle. Preferably, the same or another cover also covers the yarns which loop around the thimbles 102, 104.

[0074] An example of a cable producible by the method of the invention is shown in Figures 14 and 15. A cable 201 is produced that has an end 204 comprising two thimbles 204, to form a female connector. Another cable 301 is shown that has an end with a single thimble 302. To connect cables 201 and 301, the thimble 302 of cable 301 is inserted in the space between the thimbles 204 of cable 201, and a bolt 205 is inserted through the through holes of the thimbles 204, 302 (Fig. 15). Variants of the shown embodiments of the device, method, and cable are well possible within the scope of the attached claims. It is possible to combine one or more features of one embodiment with one or more features of another embodiment. The features of the abovedescribed embodiments may be replaced by any other feature within the scope of the attached claims, such as the features described in the following paragraphs.

[0075] A cable according to the invention may be made of more or less than ten yarns, such as one yarn, two yarns, or at least five yarns. The total number of yarn turns, i.e., yarn turns per layer and number of layers, depends on the required strength of the cable, and the strength of one individual yarn, as well as the required safety margin. The number of yarn layers in the stack of layers is at least one, but is usually a plurality of layers. The number of layers depends on the required number of yarn turns. Different types of yarns may be used. Preferably the yarns comprise fibres, such as aramid fibres with a density of 1610 dTex, 6440 dTex, or 4830 dTex, with or without a coating. A first example of such fibres is aramid fibres, e.g., Twaron® D2204 by Teijin Aramid. A second example of such fibres is Ultra-High Molecular Weight Polyethylene (UHMwPE) fibres, also known as high- modulus polyethylene (HMPE) fibres, such as Dyneema® DM. A third example of such fibres is carbon fibres, such as Tenax® UTS50 F24 24K 1600tex D.

[0076] Instead of using aramid fibres, one could use other types of plastic fibres, in particular thermoplastic fibres, such as polyamide fibres, polyester fibres, polypropylene fibres, polyethylene fibres, HMPE fibres, LCAP fibres, or PBO fibres. The cable could even comprise other types of yarns, e.g., yarns made of carbon fibres, a metal, or a natural fibre, such as basalt fibres. Yarns of fibres may consist for 100% of the relevant fibre type, but could also comprise a small portion of an auxiliary material, e.g., a coating on the fibres to protect the fibres against wear and / or environmental influences. As such auxiliary material is only a small portion in weight, and does not contribute to the strength of the cable, the phrase 'yarn consisting of fibres' is considered to include embodiments with such auxiliary materials within the context of this document.

[0077] The winding surface of a thimble, i.e., the surface for bearing the yarn turns, may be substantially fully covered with yarn using the method and / or device according to the invention. Alternatively, a cable is provided wherein the yarns do not cover the entire width of at least one of the thimble's winding surface. For example, the cable has two identical thimbles, but one of the thimbles has a smaller portion of its winding surface covered than the other thimble.

[0078] The thimbles may be made of a plastic material instead of a metal, or of a different metal than stainless steel, including but not limited to different steel alloys, aluminium alloys, magnesium alloys, and titanium.

[0079] A device according to the invention has some of the components connected fixedly to each other, instead of connecting the different components of the device detachably and movably to each other as in the shown embodiment. By connecting fixedly one or both thimble holders to the elongated guide, a simpler construction is possible. If one thimble holder is connected fixedly, and the other detachably at different positions, it is still possible to produce cables of different lengths. If both thimble holders are connected fixedly, cables of one length can be produced, or - if such an embodiment has a thimble holder with a main frame and sub-frame - the cable length can still be varied insofar the movability of the sub-frame relative to the main frame allows. It is further possible to connect the components in an indirect manner to each other, e.g., via the ground or another construction such as a wall or ceiling of a building. As an example, the thimble holders may be connected directly to a ceiling of a building, instead of via the elongated guide. The elongated guide may be fixed to a floor or to wall, instead of to the ceiling.

Claims

CLAIMS1. Device (100) for producing an endless winding cable (101) by winding a plurality of yarns (106) around two thimbles (102, 104) that are provided at opposite ends of the cable, the device comprising an elongated guide (110), a carriage (112), a yarn feeder (114), an output guide, a first thimble holder (116), and a second thimble holder (118), wherein the first thimble holder (116) and the second thimble holder (118) are provided at a distance from one another, and are each designed to hold one of the two thimbles (102, 104), the elongated guide (110) and the carriage (112) are movably connected to one another for a movement of the carriage (112) relative to the elongated guide (110) in a length direction (x) of the elongated guide (110), the yarn feeder (114) is connected to the carriage (112), and comprises at least one spool holder (120) for holding one or more spools (122), each spool holding one of the plurality of yarns (106), the output guide (124) is configured for guiding the plurality of yarns (106) from the yarn feeder (114) to the cable during winding, and the output guide (124) and the first thimble holder (116), as well as the output guide (124) and the second thimble holder (118), are movable relative to each other in at least a first direction (y) perpendicular to the length direction (x) of the elongated guide (110) for guiding the plurality of yarns (106) half a turn around respectively the first one of the two thimbles (102) and the second one of the two thimbles (104) during winding, characterised in that, the output guide (124)and the first thimble holder (116), as well as the output guide (124) and the second thimble holder (118), are movable relative to each other in a second direction (z) perpendicular to the first direction (y) and the length direction (x) of the elongated guide (110), for controlling at which position on the thimbles (102, 104) the plurality of yarns (106) are wound.

2. Device (100) according to claim 1, wherein the output guide (124) is movable relative to the yarn feeder (114) in the second direction (z).

3. Device (100) according to claim 2, wherein the output guide (124) comprises a plurality of guide elements (126), each guide element (126) being configured to guide one of the plurality of yarns (106), wherein the plurality of guide elements (126) is movable relative to the yarn feeder (114) in the second direction (z).

4. Device (100) according to claim 3, wherein the guide elements (126) are movable relative to each other in the second direction (z), for controlling at which mutual distance the plurality of yarns (106) is wound.

5. Device (100) according to claim 3 or 4, wherein the plurality of guide elements (126) is mounted to an elongated support (130) that is movable relative to the yarn feeder (114) for moving the guide elements (126) in the second direction (z).

6. Device (100) according to the combination of claims 4 and 5, wherein the elongated support (130) is tiltable for moving the guide elements (126) relative to each other in the second direction (z).

7. Device (100) according to claim 5 or 6, wherein the guide elements (126) are mounted in a row along the length direction of the support (130), wherein at least one end of the elongated support (130) is movable in the second direction (z) relative to the yarn feeder (114).

8. Device (100) according to claim 7, wherein both ends of the elongated support (130) are movable in the second direction (z) relative to the yarn feeder (114).

9. Device (100) according to claim 8, wherein both ends of the elongated support (130) are movable independently of each other.

10. Device (100) according to claim 7, 8 or 9, wherein the output guide (124) comprises at least one guide rod (133, 135) extending in the second direction (z) and the at least one movable end of the elongated support (130) is movably connected to the at least one guide rod (133, 135) for movement along the at least one guide rod (133, 135).

11. Device (100) according to any one or more of the preceding claims, further comprising at least one actuator configured to move the output guide.

12. Device (100) according to claim 11, as far as dependent on claim 5, wherein the actuator is arranged to move the elongated support (130) relative to the yarn feeder (114).

13. Device (100) according to the combination of claims 11 and 12, wherein the actuator comprises a linear actuator (132) arranged to move the at least one end of the elongated support (130) in the second direction (z), wherein the actuator preferably is a ball screw.

14. Device (100) according to any one or more of claims 11-13, further comprising a controller configured to control the actuator to move the output guide (124) during winding, for adjusting at which position on the first (102) and / or second (104) thimble the plurality of yarns (106) is wound.

15. Device (100) according to claim 14, as far as dependent on claim 3, wherein the controller is configured to move the guide elements (126) relative to each other during winding, for adjusting the distance between the plurality of yarns (106).

16. Device (100) according to any one or more of the preceding claims, wherein the output guide (124) is rotatably connected to the carriage (112) for rotation of the output guide (124) around a rotation axis, and the output guide (124) comprises an a-centrical guide (128) for guiding the plurality of yarns (106), wherein the a-centrical guide (128) is positioned at a position offset relative to the rotation axis.

17. Device (100) according claim 16, as far as dependent on claim 3, wherein the a-centrical guide (128) and the plurality of guide elements (126) are arranged to guide the plurality of yarn (106) from the spool holder (120) to the guide elements (126), from the guide elements (126) to the a-centrical guide (128), and from the a-centrical guide (128) to the cable (101) during winding.

18. Method for producing an endless winding cable (1, 101), comprising the steps of: positioning a first thimble (2, 102) and a second thimble (4, 104) at a predetermined distance from one another along a length direction (x), which distance corresponds to a required cable length, providing a plurality of yarns (6, 106), winding the plurality of yarns from the first thimble to the second thimble, a half turn around the second thimble, back to the first thimble, and a half turn around the first thimble, repeating the previous step until a predetermined number of layers (10, 13, 18, 20) of yarn turns is provided in both the first thimble and the second thimble, corresponding to a required cable thickness, characterized by the step of:controlling at which position on the thimbles the plurality of yarns is wound by moving the plurality of yarns relative to the first and second thimbles, in a second direction (z) perpendicular to the length direction (x).

19. Method according to claim 18, wherein moving the plurality of yarns (106) relative to the first and second thimbles (2, 102, 4, 104) comprises moving the plurality of yarns (6, 106) in the second direction (z).

20. Method according to claim 18 or 19, comprising controlling at which mutual distance the plurality of yarns (6, 106) is wound onto the thimbles (2, 102, 4, 104) by moving the plurality of yarns (6, 106) relative to each other in the second direction (z).

21. Method according to any one or more of the claims 18-20, comprising adjusting, during winding, at which position on the thimbles (2, 102, 4, 104) the plurality of yarns are wound by moving, during winding, the plurality of yarns (6, 106) relative to the first and second thimbles (2, 102, 4, 104), in the second direction (z).

22. Method according to any one or more of the claims 18-21, comprising adjusting, during winding, the mutual distance between the plurality of yarns (6, 106) by moving, during winding, the plurality of yarns (6, 106) relative to each other in the second direction (z).

23. Cable (1, 101, 201) produced by the device of any one or more of claims 1-17 or the method of any one or more of claims 18-22, wherein a first thimble (2, 102) and a second thimble (4, 104) are provided at opposite ends of the cable (1, 101, 201), a plurality of N yarns (6, 106) extend from the first thimble (2, 102) to the second thimble (4), turns around the second thimble (4, 104), extends from the second thimble (4, 104) to the first thimble (2, 102), and turns around the first thimble (2, 102), such that the plurality of N yarns (6, 106) form turns around the first and second thimbles, and each thimble holds a stack (9) of a plurality of layers (10) of turns of the plurality of N yarns (6, 106).

24. Cable (1, 101, 201) according to claim 23, whereinthe plurality of yarn (6, 106) extends over a greater width at the first thimble than at the second thimble.

25. Cable (1, 101, 201) according to claim 23 or 24, wherein each of the plurality of yarns (6, 106) crosses at most one other yarn for each turn around the first and second thimbles.

26. Cable (1, 101, 201) according to any one or more of the claims 23-25, wherein the stack of yarn layers (6, 106) at the first and / or second thimble (2, 102, 4, 104) has a width that exceeds N times the width of the individual yarns (6, 106).

27. Cable (201) according to any one or more of the claims 23-26, comprising a third thimble provided at the same end (204) of the cable as the first thimble, wherein the first thimble and third thimble are positioned at distance to each other for receiving a thimble (302) of another cable, or other connecting element, between the first and third thimble.

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