Special-shaped Cable Core Forming Mechanism for Multi-layer Stranding
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Solution Overview
Problem
Conventional cable core forming devices can only strand a single layer of wires at a time, leading to inefficiencies and insufficient tightness in multi-layer structures, particularly for special-shaped cable cores.
Innovation Solution
A special-shaped cable core forming mechanism featuring a guide assembly, pre-stranding assemblies, and a main stranding mold, which allows for simultaneous stranding of multiple layers by guiding wires through tapered supports and rotating connectors, ensuring tightness and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single-layer stranding is used, then the device complexity is low, but the productivity is reduced due to multiple stranding steps required for multi-layer structures
Solution Approach 1:
The patent combines multiple stranding functions into a single integrated device. The stranding device includes multiple wire drawing molds arranged in a circular array, allowing simultaneous stranding of multiple layers in one operation. The rotating connector and synchronized rotation mechanism enable multiple wires to be stranded together, merging what would traditionally require separate stranding steps into a single productive operation.
Solution Approach 2:
The patent transitions from linear sequential stranding to radial parallel stranding by arranging wire drawing molds in a circular array around a central rotating connector. This dimensional reorganization allows multiple layers to be stranded simultaneously in different radial directions, converting a time-sequential process into a spatially-parallel process that dramatically improves productivity.
2Manufacturing precision
If conventional stranding method is used for multi-layer structures, then the processing time increases due to multiple stranding steps, but the manufacturing precision is maintained
Solution Approach 1:
The patent achieves continuous stranding action by having all wire drawing molds rotate synchronously around the central axis. The rotating connector ensures continuous feed and stranding of multiple wires simultaneously without interruption. This continuous action allows multi-layer cable cores to be formed in a single uninterrupted operation, eliminating the time loss associated with multiple discrete stranding steps while maintaining precision through consistent rotational motion.
Solution Approach 2:
The wire drawing molds perform preliminary shaping and positioning of individual wires before they are combined in the final stranding operation. The tapered supports and guide structures pre-align the wires in the correct configuration, ensuring that when they are stranded together, the cable core achieves the desired tightness and geometric precision without requiring subsequent adjustment steps.
3Shape
If special-shaped wires are guided through conventional mechanisms, then the cross section may deform, but the device complexity remains low
Solution Approach 1:
The patent applies specialized guide structures with locally optimized geometries matched to the specific cross-sectional shape of the wires being guided. The guide rollers and tapered supports have surface contours and dimensions specifically designed for particular wire shapes (e.g., fan-shaped, Z-shaped), providing localized support that prevents deformation at critical contact points while allowing the overall device to remain relatively simple.
Data Source
AI summary
A layer of wires is preliminarily stranded by a layer of strand-through holes, and a first strand cylinder is used for the second pressing and stranding. The next layer of special-shaped single wires is stranded through a second pre-stranding assembly, and then the last layer of wires is stranded through a main stranding mold, thus stranding a plurality of layers at the same time with a compact structure. The outer circumference of the guide roller matches that of the special-shaped single wire, avoiding the reduced quality of stranded cable core. The first rotating connector is bowl-shaped and is provided with a layer of strand-through holes together with a structure in which a first pull rod is in fit with the rotating connector and a structure in which a second pull rod is in fit with the rotating connector.