CA2627840A1 - Multilayer unilay cable, manufacturing apparatus and process - Google Patents
Multilayer unilay cable, manufacturing apparatus and process Download PDFInfo
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- CA2627840A1 CA2627840A1 CA 2627840 CA2627840A CA2627840A1 CA 2627840 A1 CA2627840 A1 CA 2627840A1 CA 2627840 CA2627840 CA 2627840 CA 2627840 A CA2627840 A CA 2627840A CA 2627840 A1 CA2627840 A1 CA 2627840A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/02—Stranding-up
- H01B13/0271—Alternate stranding processes
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Abstract
A four layer multi-strand unilay cable of nominally 61 strands is formed without the aid of roll forming drives but rather by reliance on the tension in the strands provided by a pair of drive capstans carried in a single twist cage. The area reduction of the cable in the various roll forming stages is less than about 15 or 16 %, and may be in the range of about 12 - 14 %. The area reduction is greater than 10 %. The process is fed by stationary reels, and the feedstock may be replenished by splicing subsequent stock into the tail end of the stock of the preceding reel without having to cease production. The output reel may be greater than 76 inches in diameter, and may be 84 or 96 inches in some cases.
The line does not employ the large number of roll forming drives and drive metering devices that would be used if all stations were actively driven. The cables so produced are twisted together under tension, and the elements of those cables may tend to bind against each other when formed and twisted. The copper or aluminum cables so formed may then be coated in a plastic dielectric coating.
The line does not employ the large number of roll forming drives and drive metering devices that would be used if all stations were actively driven. The cables so produced are twisted together under tension, and the elements of those cables may tend to bind against each other when formed and twisted. The copper or aluminum cables so formed may then be coated in a plastic dielectric coating.
Description
MULTILAYER UNILAY CABLE. MANUFACTURING APPARATUS
AND PROCESS
Field of the Invention This invention relates to the field of multi-strand cables, machinery for manufacturing those cables, and processes by which to manufacture those cables.
Baclcground A number of industries employ multi-strand cables. One example is the electrical power distribution industry. High capacity cables may include many individual strands twisted together to form the larger whole.
The formation of a twisted strand is distinct from merely bunching cable elements together. First, the cable may be formed in distinct layers. There may be a core, which may typically have the form of a single conductor. Less commonly, the core may also be formed of more than one element. Subsequent layers may be closed around the core.
Most classically, the first layer outside the core has six conductors elements, the next layer has 12, the next 18, the next 24, and so on, such that the resultant multi-strand conductors may be referred to as 1, 7, 19, 37 or 61 strand conductors.
The elements, or strands of the cable may be of different diameters, or may be of a single diameter. A cable made of strands that have a single diameter permits the manufacturer to stock only that diameter rather than a range of diameters, and facilitates both supply and replacement of bobbins of input stock. However, the use of a single input wire diameter may pose a challenge with respect to manufacturing final products of varying diameters.
Although the most traditional cable constructions have a number of strands N
according to the formula N = 3n 2 + 3n + 1 where N is the number of strands, and n is the number of layers, a 37 strand (nominal) conductor does not necessarily have 37 strands, but may have some other number depending on the eventual properties desired. For example, the nominal 6 wire layer may have 5 or 7, or 8 wires. The nominal 12 wire layer may have 11, 13, 14 wires, the 18 wire layer may have 16 to 22 or 23 wires. The use of non-standard (i.e., not divisible by 6) numbers of strands may tend to occur where a single input wire diameter is to be used to produce a variety of final products of different diameters.
The stability of a cable may rely upon the helical twist imparted in manufacture. The twist of a cable is often called the "lay" of the cable, namely that the linear advance of the cable is so many inches per full revolution of twist. The lay may be either right handed or left handed A cable may be a unilay cable, in which all layers have a twist of the same hand and same length, or it may have an alternating lay in which layers of one hand alternate with layers of the other hand. Reverse lay cables (i.e., in which each successive layer is of opposite hand) have been favoured in the past, there having been an assumption, perhaps not necessarily justified, that multi-layer unilay cables had inferior qualities.
It is often desirable for the resultant product stranded cable to have a high effective density, and so the cable may be both compacted and compressed to minimize the interstitial gaps between the strand elements. To that end, the individual strands may be passed through roll forming dies prior to being brought together in a closing die to form the overall section of the resultant cable. Typically, this may involve forming the round wire into a generally trapezoidal or triangular element shape. When an input wire is formed in this way, it may also undergo a reduction in cross-sectional area as it is drawn through the die. The reduction of area may tend to be modest, and, in systems employing strand drives may be up to about 18 or 19 %. After the elements have been brought together in the closing die, the entire cable may be passed through a final die that compresses the cable as a whole, often with the tendency flatten the outside face of the last layer to a shape conforming to the final outside circumference of the diameter of conductor to be produced. The modification of shape and the reduction in area may also permit a larger range of output cables to be produced from a single input wire, particularly where a non-standard number of strands is employed in one or more of the various layers.
The machines that twist these elements together have typically fallen into two types, namely those with stationary paying out reels, and those with feedstock reels that are carried in a rotating cage. In a double twist machine, the feedstock reels may be carried within a rapidly revolving bow. Alternatively, the input reels may be stationary, while the output reel rotates inside a cage.
There are a number of practical difficulties to be addressed. In either process the assembled cable of multiple filaments is drawn through the forming, closing and twisting heads by a pulling device. In some instances this pulling device may be a capstan head, or multiple capstan head about which the cable winds. The outfeed of the capstan head is wound onto a receiving reel.
When a reverse lay strand is made, the cable passes first through one twisting stage, picked up on an output reel, and then fed back into a subsequent winding stage in which one or more additional layers are wound onto the cable. With each pass through a twisting operation the cable increases in size, until the final product size is reached. Clearly, the repeated intermediate steps of reeling and unreeling impose an inherent inefficiency on such a process, whether in terms of the process itself, or in terms of moving and storing of the intermediate partially finished product, or in terms of the time and space required.
When the feedstock reels are mounted in a rotating cage, whether in a single twist or a double twist apparatus, the duration of the operational run is limited by the quantity of input feedstock that can be carried on the reel, and the reel size is effectively limited by the size and weight of the objects to be rotated. In such a system, when one of the reels runs out, the entire machine must be stopped, and all of the reels replaced. This may tend to be a time consuming process, such that, with one interruption or delay and another, the machines may only be in operation a third or two fifths of the time. Inasmuch as capital equipment pays for itself by being busy rather than idle, a reduction in downtime may generally be desirable.
When a multi-layer unilay cable is made, where both the hand and the length of the lay are common to the layers, the rate at which the feedstock is paid out varies between the layers, since the helical arc length of each successive layer increases, and the area reduction in the various layers achieved by roll forming prior to compaction may not be equal.
Consequently, the speed of the feed of the layers may be metered by providing individual feedstock drives for each of thee layers. In one system, the speed of the central single core wire may be used as a reference, or datum, which is determined by the rate at which the capstan draws the core wire forward. The capstan speed, and the rate of rotation of the cage are matched to yield a fixed ratio of turns per lineal unit of advance of the core wire. The drive of each successive layer will operate to advance the feed of that layer at an appropriate rate to feed the corresponding helical arc length of that layer when referenced to the datum.
The capstan pull maintains the strands of all of the layers in tension in this process. These metered drives are relatively expensive, and the complexity of the co-ordination of the drives may tend to increase as the number of layers increases.
AND PROCESS
Field of the Invention This invention relates to the field of multi-strand cables, machinery for manufacturing those cables, and processes by which to manufacture those cables.
Baclcground A number of industries employ multi-strand cables. One example is the electrical power distribution industry. High capacity cables may include many individual strands twisted together to form the larger whole.
The formation of a twisted strand is distinct from merely bunching cable elements together. First, the cable may be formed in distinct layers. There may be a core, which may typically have the form of a single conductor. Less commonly, the core may also be formed of more than one element. Subsequent layers may be closed around the core.
Most classically, the first layer outside the core has six conductors elements, the next layer has 12, the next 18, the next 24, and so on, such that the resultant multi-strand conductors may be referred to as 1, 7, 19, 37 or 61 strand conductors.
The elements, or strands of the cable may be of different diameters, or may be of a single diameter. A cable made of strands that have a single diameter permits the manufacturer to stock only that diameter rather than a range of diameters, and facilitates both supply and replacement of bobbins of input stock. However, the use of a single input wire diameter may pose a challenge with respect to manufacturing final products of varying diameters.
Although the most traditional cable constructions have a number of strands N
according to the formula N = 3n 2 + 3n + 1 where N is the number of strands, and n is the number of layers, a 37 strand (nominal) conductor does not necessarily have 37 strands, but may have some other number depending on the eventual properties desired. For example, the nominal 6 wire layer may have 5 or 7, or 8 wires. The nominal 12 wire layer may have 11, 13, 14 wires, the 18 wire layer may have 16 to 22 or 23 wires. The use of non-standard (i.e., not divisible by 6) numbers of strands may tend to occur where a single input wire diameter is to be used to produce a variety of final products of different diameters.
The stability of a cable may rely upon the helical twist imparted in manufacture. The twist of a cable is often called the "lay" of the cable, namely that the linear advance of the cable is so many inches per full revolution of twist. The lay may be either right handed or left handed A cable may be a unilay cable, in which all layers have a twist of the same hand and same length, or it may have an alternating lay in which layers of one hand alternate with layers of the other hand. Reverse lay cables (i.e., in which each successive layer is of opposite hand) have been favoured in the past, there having been an assumption, perhaps not necessarily justified, that multi-layer unilay cables had inferior qualities.
It is often desirable for the resultant product stranded cable to have a high effective density, and so the cable may be both compacted and compressed to minimize the interstitial gaps between the strand elements. To that end, the individual strands may be passed through roll forming dies prior to being brought together in a closing die to form the overall section of the resultant cable. Typically, this may involve forming the round wire into a generally trapezoidal or triangular element shape. When an input wire is formed in this way, it may also undergo a reduction in cross-sectional area as it is drawn through the die. The reduction of area may tend to be modest, and, in systems employing strand drives may be up to about 18 or 19 %. After the elements have been brought together in the closing die, the entire cable may be passed through a final die that compresses the cable as a whole, often with the tendency flatten the outside face of the last layer to a shape conforming to the final outside circumference of the diameter of conductor to be produced. The modification of shape and the reduction in area may also permit a larger range of output cables to be produced from a single input wire, particularly where a non-standard number of strands is employed in one or more of the various layers.
The machines that twist these elements together have typically fallen into two types, namely those with stationary paying out reels, and those with feedstock reels that are carried in a rotating cage. In a double twist machine, the feedstock reels may be carried within a rapidly revolving bow. Alternatively, the input reels may be stationary, while the output reel rotates inside a cage.
There are a number of practical difficulties to be addressed. In either process the assembled cable of multiple filaments is drawn through the forming, closing and twisting heads by a pulling device. In some instances this pulling device may be a capstan head, or multiple capstan head about which the cable winds. The outfeed of the capstan head is wound onto a receiving reel.
When a reverse lay strand is made, the cable passes first through one twisting stage, picked up on an output reel, and then fed back into a subsequent winding stage in which one or more additional layers are wound onto the cable. With each pass through a twisting operation the cable increases in size, until the final product size is reached. Clearly, the repeated intermediate steps of reeling and unreeling impose an inherent inefficiency on such a process, whether in terms of the process itself, or in terms of moving and storing of the intermediate partially finished product, or in terms of the time and space required.
When the feedstock reels are mounted in a rotating cage, whether in a single twist or a double twist apparatus, the duration of the operational run is limited by the quantity of input feedstock that can be carried on the reel, and the reel size is effectively limited by the size and weight of the objects to be rotated. In such a system, when one of the reels runs out, the entire machine must be stopped, and all of the reels replaced. This may tend to be a time consuming process, such that, with one interruption or delay and another, the machines may only be in operation a third or two fifths of the time. Inasmuch as capital equipment pays for itself by being busy rather than idle, a reduction in downtime may generally be desirable.
When a multi-layer unilay cable is made, where both the hand and the length of the lay are common to the layers, the rate at which the feedstock is paid out varies between the layers, since the helical arc length of each successive layer increases, and the area reduction in the various layers achieved by roll forming prior to compaction may not be equal.
Consequently, the speed of the feed of the layers may be metered by providing individual feedstock drives for each of thee layers. In one system, the speed of the central single core wire may be used as a reference, or datum, which is determined by the rate at which the capstan draws the core wire forward. The capstan speed, and the rate of rotation of the cage are matched to yield a fixed ratio of turns per lineal unit of advance of the core wire. The drive of each successive layer will operate to advance the feed of that layer at an appropriate rate to feed the corresponding helical arc length of that layer when referenced to the datum.
The capstan pull maintains the strands of all of the layers in tension in this process. These metered drives are relatively expensive, and the complexity of the co-ordination of the drives may tend to increase as the number of layers increases.
Summary of the Invention In an aspect of the invention, there is a process for making a four layer twisted multistrand conductor employing a single input wire diameter, the conductor having unilay construction.
In another aspect of the invention, there is a four layer twisted multi-strand conductor that has a single input wire diameter, the conductor having unilay construction. In a feature of that aspect of the invention, the cable is encased in an external dielectric coating or layer.
In another aspect of the invention, the cable has an overall area reduction of between about 10 and 15 %. The apparatus described herein can be used to make a single input wire, four layer multi-strand unilay conductor in a single twist rigid strander. The conductor may have a dielectric coating. The conductor may have roll formed strands having a reduction in area in roll forming of between 10 % and 15 %. Alternatively, it may have strands that have a reduction in area of between 12 and 14 %. Alternatively still, it may be between 10 % and 13 %. The conductor may be made of (a) copper; (b) a copper alloy; (c) aluminum; and (d) an aluminum alloy. The conductor has an outer layer of electrically conductive strands, said outer layer of conductive strands includes strands formed in a keystone shape, and the outer layer has a residual elastic stress therein tending to bind said strands together.
In another aspect of the invention, there is an apparatus for making the cable. The apparatus itself may include a feedstock section, a forming section, and a winding section.
The feedstock section includes accommodations for an array of conductor strand reels, and paying off sheaves mounted to carry the feedstock strands from the feedstock section to said forming section. The forming section includes a core wire feed apparatus, a first layer feed apparatus, a second layer feed apparatus, a third layer feed apparatus, and a fourth layer feed apparatus. The first, second third and fourth feed layer apparatus are positioned, or aligned, in series. At least one of the feed layer apparatus includes roll forming dies through which feedstock strands are drawn. All of the feed layers include a respective lay plate for positioning the strands of its respective layer about the core wire and any preceding layers.
The winding, or reeling, or take-up section includes a rotating cage. The rotating cage having a capstan apparatus mounted therewithin. The capstan apparatus is mounted to draw the core wire and the respective layers of strands through the layer feed apparatus. The winding section includes an output cable accumulation reel mounted carried by the frame member of the rotating cage. The taken up output cable drawn through the capstan apparatus is accumulated on the output reel. All of the lay plates and rolling dies are sized to handle a single input wire diameter. At least most of the roll forming dies are passive roll forming dies. The apparatus may include a coating station for applying a dielectric coating to the output cable. In a feature of that aspect of the invention, all of the roll forming dies are passive roll forming dies. In one embodiment each of the first, second, third and fourth feed layer apparatus includes roll forming dies.
In further features of that aspect of the invention, the first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire. The second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including accommodations for between 9 and 14 strands. The third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands. The fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands.
In a further feature, the first, second, third and fourth lay plates have accommodations for 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. In the apparatus, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 15 %. In another feature, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 12 and 14 %. In still another feature, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 13 %. In a further feature, the output cable accumulation reel is greater than 72" in diameter. The apparatus is free of rate metering equipment at the first, second, third and fourth layer feed apparatus. Only the capstan has a rate metering control.
In another aspect of the invention there is a method or process of using the apparatus.
The method includes supplying feedstock from an array of reels equal to the number of strands in the conductor, one of the strands being a core wire, all of the strands being of the same diameter; conveying feedstock strands to each of a serially positioned set of first layer feed apparatus, a second feed layer apparatus, a third feed layer apparatus and a fourth feed layer apparatus; passively roll forming a plurality of the strands in at least a majority of the first, second, third, and fourth layer feed apparatus; orienting the strands for closure about the core wire and any previous layers of strands; closing the roll formed strands about the core wire and about any preceding layer of strands closed about the core wire;
pulling the closed strands and core wire through the first, second, third and fourth layer feed apparatus with a capstan apparatus to form the twisted cable; and accumulating the twisted cable on a take-up reel mounted in a rotating cage.
In further features of that aspect of the invention, the method may also include the subsequent step of encasing the twisted cable in a dielectric coating.
Further, it may include replacing or replenishing an empty reel of the array of feedstock reels with a full reel of feedstock while the capstan apparatus is in operation. The method may include feeding strands to the various lay plates in appropriate numbers. The first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire and the method includes feeding a number of strands equal to the number of accommodations to the first layer lay plate; the second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including accommodations for between 9 and 14 strands, and the method includes feeding a number of strands equal to the number of accommodations to the second layer lay plate; the third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands and the method includes feeding a number of strands equal to the number of accommodations to the third layer lay plate; and the fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands and the method includes feeding a number of strands equal to the number of accommodations to the fourth layer lay plate. In one embodiment, the first, second, third and fourth lay plates receive 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. The method includes providing all roll forming power through the tension applied by the capstan apparatus. It also includes monitoring at least one of (a) displacement and (b) velocity, of the workpiece in the method other than at the first, second, third and fourth later feed apparatus, namely monitoring at least one of (a) displacement, and (b) velocity, of the workpiece only at the capstan apparatus.
In another aspect of the invention, there is a four layer twisted multi-strand conductor that has a single input wire diameter, the conductor having unilay construction. In a feature of that aspect of the invention, the cable is encased in an external dielectric coating or layer.
In another aspect of the invention, the cable has an overall area reduction of between about 10 and 15 %. The apparatus described herein can be used to make a single input wire, four layer multi-strand unilay conductor in a single twist rigid strander. The conductor may have a dielectric coating. The conductor may have roll formed strands having a reduction in area in roll forming of between 10 % and 15 %. Alternatively, it may have strands that have a reduction in area of between 12 and 14 %. Alternatively still, it may be between 10 % and 13 %. The conductor may be made of (a) copper; (b) a copper alloy; (c) aluminum; and (d) an aluminum alloy. The conductor has an outer layer of electrically conductive strands, said outer layer of conductive strands includes strands formed in a keystone shape, and the outer layer has a residual elastic stress therein tending to bind said strands together.
In another aspect of the invention, there is an apparatus for making the cable. The apparatus itself may include a feedstock section, a forming section, and a winding section.
The feedstock section includes accommodations for an array of conductor strand reels, and paying off sheaves mounted to carry the feedstock strands from the feedstock section to said forming section. The forming section includes a core wire feed apparatus, a first layer feed apparatus, a second layer feed apparatus, a third layer feed apparatus, and a fourth layer feed apparatus. The first, second third and fourth feed layer apparatus are positioned, or aligned, in series. At least one of the feed layer apparatus includes roll forming dies through which feedstock strands are drawn. All of the feed layers include a respective lay plate for positioning the strands of its respective layer about the core wire and any preceding layers.
The winding, or reeling, or take-up section includes a rotating cage. The rotating cage having a capstan apparatus mounted therewithin. The capstan apparatus is mounted to draw the core wire and the respective layers of strands through the layer feed apparatus. The winding section includes an output cable accumulation reel mounted carried by the frame member of the rotating cage. The taken up output cable drawn through the capstan apparatus is accumulated on the output reel. All of the lay plates and rolling dies are sized to handle a single input wire diameter. At least most of the roll forming dies are passive roll forming dies. The apparatus may include a coating station for applying a dielectric coating to the output cable. In a feature of that aspect of the invention, all of the roll forming dies are passive roll forming dies. In one embodiment each of the first, second, third and fourth feed layer apparatus includes roll forming dies.
In further features of that aspect of the invention, the first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire. The second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including accommodations for between 9 and 14 strands. The third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands. The fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands.
In a further feature, the first, second, third and fourth lay plates have accommodations for 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. In the apparatus, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 15 %. In another feature, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 12 and 14 %. In still another feature, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 13 %. In a further feature, the output cable accumulation reel is greater than 72" in diameter. The apparatus is free of rate metering equipment at the first, second, third and fourth layer feed apparatus. Only the capstan has a rate metering control.
In another aspect of the invention there is a method or process of using the apparatus.
The method includes supplying feedstock from an array of reels equal to the number of strands in the conductor, one of the strands being a core wire, all of the strands being of the same diameter; conveying feedstock strands to each of a serially positioned set of first layer feed apparatus, a second feed layer apparatus, a third feed layer apparatus and a fourth feed layer apparatus; passively roll forming a plurality of the strands in at least a majority of the first, second, third, and fourth layer feed apparatus; orienting the strands for closure about the core wire and any previous layers of strands; closing the roll formed strands about the core wire and about any preceding layer of strands closed about the core wire;
pulling the closed strands and core wire through the first, second, third and fourth layer feed apparatus with a capstan apparatus to form the twisted cable; and accumulating the twisted cable on a take-up reel mounted in a rotating cage.
In further features of that aspect of the invention, the method may also include the subsequent step of encasing the twisted cable in a dielectric coating.
Further, it may include replacing or replenishing an empty reel of the array of feedstock reels with a full reel of feedstock while the capstan apparatus is in operation. The method may include feeding strands to the various lay plates in appropriate numbers. The first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire and the method includes feeding a number of strands equal to the number of accommodations to the first layer lay plate; the second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including accommodations for between 9 and 14 strands, and the method includes feeding a number of strands equal to the number of accommodations to the second layer lay plate; the third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands and the method includes feeding a number of strands equal to the number of accommodations to the third layer lay plate; and the fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands and the method includes feeding a number of strands equal to the number of accommodations to the fourth layer lay plate. In one embodiment, the first, second, third and fourth lay plates receive 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. The method includes providing all roll forming power through the tension applied by the capstan apparatus. It also includes monitoring at least one of (a) displacement and (b) velocity, of the workpiece in the method other than at the first, second, third and fourth later feed apparatus, namely monitoring at least one of (a) displacement, and (b) velocity, of the workpiece only at the capstan apparatus.
These and other aspects and features of the invention may be understood with reference to the description which follows, and with the aid of the illustrations of a number of examples.
Brief Description of the Fiiaures The description is accompanied by a set of illustrative Figures in which:
Figure 1 a is a general arrangement, side view of the layout of a manufacturing line for producing multi-strand cables;
Figure lb is a top view of the manufacturing line of Figure la; and Figure 2 is an enlarged view of a portion of the manufacturing line of Figure la.
Detailed Description The description that follows, and the embodiments described therein, are provided by way of illustration of an example, or examples, of particular embodiments of the principles, aspects or features of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention.
In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are generally to scale unless noted otherwise. The terminology used in this specification is thought to be consistent with the customary and ordinary meanings of those terms as they would be understood by a person of ordinary skill in the railroad industry in North America. Following from decision of the CAFC in Phillips v. A WH Corp., the Applicant expressly excludes all interpretations that are inconsistent with this specification, and, in particular, to confine the rule of broadest reasonable interpretation to interpretations that are consistent with actual usage in the industry as understood by persons of ordinary skill in the art, or that are expressly supported by this specification, the inventor expressly excludes any interpretation of the claims or the language used in this specification such as may be made in the USPTO, or in any other Patent Office, other than those interpretations for which express support can be demonstrated in this specification or in objective evidence of record in accordance with In re Lee, (for example, earlier publications by persons not employed by the USPTO or any other Patent Office), demonstrating how the terms are used and understood by persons of ordinary skill in the art, or by way of expert evidence of a person or persons of at least 10 years experience in the industry.
Brief Description of the Fiiaures The description is accompanied by a set of illustrative Figures in which:
Figure 1 a is a general arrangement, side view of the layout of a manufacturing line for producing multi-strand cables;
Figure lb is a top view of the manufacturing line of Figure la; and Figure 2 is an enlarged view of a portion of the manufacturing line of Figure la.
Detailed Description The description that follows, and the embodiments described therein, are provided by way of illustration of an example, or examples, of particular embodiments of the principles, aspects or features of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention.
In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are generally to scale unless noted otherwise. The terminology used in this specification is thought to be consistent with the customary and ordinary meanings of those terms as they would be understood by a person of ordinary skill in the railroad industry in North America. Following from decision of the CAFC in Phillips v. A WH Corp., the Applicant expressly excludes all interpretations that are inconsistent with this specification, and, in particular, to confine the rule of broadest reasonable interpretation to interpretations that are consistent with actual usage in the industry as understood by persons of ordinary skill in the art, or that are expressly supported by this specification, the inventor expressly excludes any interpretation of the claims or the language used in this specification such as may be made in the USPTO, or in any other Patent Office, other than those interpretations for which express support can be demonstrated in this specification or in objective evidence of record in accordance with In re Lee, (for example, earlier publications by persons not employed by the USPTO or any other Patent Office), demonstrating how the terms are used and understood by persons of ordinary skill in the art, or by way of expert evidence of a person or persons of at least 10 years experience in the industry.
This description incorporates by reference the text and illustrative Figures of US
Patent 4,212,151 of Schauffelle et al., which issued July 15, 1980, and, in particular, column 1, line 13 to column 3, line 5, and also column 4, line 48 to column 7, line 61. The description also incorporates by reference the text and illustrative Figures of US Patent 4,599,853 of Varga-Papp issued July 15, 1986, and, in particular, column 1, line 10 to column 2, line 30, and column 2, line 65 to column 6, line 40.
By way of terminology, the number of layers N, in a conductor, does not for the purposes of this description include the central core wire, N being the number of layers wrapped about that core wire.
Referring to the Figures, a production line apparatus for manufacturing a multi-strand cable is indicated generally in the illustrations as 20. It includes a feedstock portion, indicated generally as 22, a roll forming and closing section indicated generally as 24, and a rotating cage portion 26. It may also include a dielectric coating application stage, indicated schematically as 28.
At the input end of the line, feedstock portion 22 may include a gang, or battery, or array 30, of spools or bobbins or reels 32 of feedstock. In some embodiments the wire feedstock is copper or a copper alloy wire, or aluminum, or an aluminum alloy wire, as may be. In this instance, the feedstock is a single input wire, i.e., all of the reels 32 carry feedstock of the same wire diameter, such that the eventual resultant product may be refened to as a single input wire (SIW) conductor. The use of input wires of a single diameter may tend to facilitate both inventory and resupply. Reels 32 are individually replaceable, and a new reel may be installed without stopping production of the cable. Rather, the leading end of the new reel is spliced into the trailing end of feedstock of the old reel.
Thus the input feedstock reels do not have to be replaced all at the same time. For the purposes of compactness of illustration, array 30 has been truncated in Figures la and lb, such that only a representative portion of the array is shown. The number of reels in array 30 may be 37, or more, where a nominally 3 layer conductor is to be manufactured (1 + 6+ 12 +
18), and 61 or more where a four layer conductor is to be manufactured (1 + 6 + 12 + 18 +
24). The illustrations should be understood to be generally representative of a large number of reels, and, without further duplication in the illustrations, should be understood also of being representative of a sufficient number of reels from which to form a four layer, nominally 61 strand conductor (e.g., there may be 62, or more reels and mountings for those reels).
Deployment of these reels in an orientation in which their axes are vertical is convenient.
Patent 4,212,151 of Schauffelle et al., which issued July 15, 1980, and, in particular, column 1, line 13 to column 3, line 5, and also column 4, line 48 to column 7, line 61. The description also incorporates by reference the text and illustrative Figures of US Patent 4,599,853 of Varga-Papp issued July 15, 1986, and, in particular, column 1, line 10 to column 2, line 30, and column 2, line 65 to column 6, line 40.
By way of terminology, the number of layers N, in a conductor, does not for the purposes of this description include the central core wire, N being the number of layers wrapped about that core wire.
Referring to the Figures, a production line apparatus for manufacturing a multi-strand cable is indicated generally in the illustrations as 20. It includes a feedstock portion, indicated generally as 22, a roll forming and closing section indicated generally as 24, and a rotating cage portion 26. It may also include a dielectric coating application stage, indicated schematically as 28.
At the input end of the line, feedstock portion 22 may include a gang, or battery, or array 30, of spools or bobbins or reels 32 of feedstock. In some embodiments the wire feedstock is copper or a copper alloy wire, or aluminum, or an aluminum alloy wire, as may be. In this instance, the feedstock is a single input wire, i.e., all of the reels 32 carry feedstock of the same wire diameter, such that the eventual resultant product may be refened to as a single input wire (SIW) conductor. The use of input wires of a single diameter may tend to facilitate both inventory and resupply. Reels 32 are individually replaceable, and a new reel may be installed without stopping production of the cable. Rather, the leading end of the new reel is spliced into the trailing end of feedstock of the old reel.
Thus the input feedstock reels do not have to be replaced all at the same time. For the purposes of compactness of illustration, array 30 has been truncated in Figures la and lb, such that only a representative portion of the array is shown. The number of reels in array 30 may be 37, or more, where a nominally 3 layer conductor is to be manufactured (1 + 6+ 12 +
18), and 61 or more where a four layer conductor is to be manufactured (1 + 6 + 12 + 18 +
24). The illustrations should be understood to be generally representative of a large number of reels, and, without further duplication in the illustrations, should be understood also of being representative of a sufficient number of reels from which to form a four layer, nominally 61 strand conductor (e.g., there may be 62, or more reels and mountings for those reels).
Deployment of these reels in an orientation in which their axes are vertical is convenient.
The payoff of each reel is carried upward to a payoff sheave, 34, which may be an overhead sheave. The outputs of the various sheaves 34 are fed around idlers 33 toward a gang of sheaves 36 mounted on an horizontal axis that feed the various strands in an array, in this case a substantially planar array, toward the next section of the apparatus, namely the forming and closing section 24.
The first stage of the forming and closing section 24 includes roll forming dies, such as may be termed roll forming elements 37, a lay plate 38, and may include a closing die 39.
There are different possible arrangements but, in each case, the individual strands are formed to the shape of the section they are to take in the conductor, and are then passed to the lay plate 38, at which their angular position relative to the central core wire 35 is established, and then to the closing plate, or closing die 39 at which the compacted (i.e., pre-roll-formed) elements are compressed, or not, as may be. Compression is not a necessary step. In some embodiments, the forming and spacing may occur in a single location at the lay plate as illustrated in US Patent 4,212,151. Assuming the central core wire to be a single round wire that forms the datum of the construction, the other wires of the various subsequent layers may be taken as having a generally triangular or trapezoidal shape corresponding to a sector of an annulus of the same number of portions as the number of strands in the layer. In some embodiments the corners of those elements may nonetheless retain a fairly rounded or radiused edge in keeping with the relatively modest area reduction of a passive roll forming process in which the strand is of sufficient cross-sectional area after forming that the force required to drive the forming process is provided in the tension in the strand itself.
In one embodiment, in the first stage 40, up to 8 aluminum or copper wire strands may enter at the level of core wire 35. (In another embodiment, all strands may be carried at this level). The first layer, of nominally 6 strands, (which may be 5, 6 or 7, for example) is wound about the core wire 35. In the second stage 42 the next layer is formed at forming station 43, and lay plate 44 and closing die 45, where the next layer is formed, oriented and then compressed onto the endless advancing central core and first layer.
Again, while the second layer has nominally 12 strands, it may have slightly more or fewer depending on the construction being formed. In the third stage there is a roll forming station 46, a lay plate 47, and a closing die 48 at which the nominally18 strand third layer is twisted onto the advancing core construction, that already includes the core and the first and second layers.
In the fourth stage, should it be used, there is a roll forming station 49, a lay plate 50, and a closing die 51 at which the nominally 24 strand fourth layer is twisted onto the advancing core and the first, second and third layers. The uncoated, twisted resultant raw four layer conductor product 52 exits the forming section, and is drawn toward the rotating cage portion 26. In each case, at each stage the filaments of that stage or layer are fed in on a set of sheaves 55 from the overhead supply as appropriate. As a matter of definition, the "workpiece" at any given stage may be thought of as the continuous feed from the previous stage, i.e., the core wire plus any layers of conductor strands twisted about the core wire in the preceding stages.
In contrast to earlier driven roll forming sections, the first, second, third and fourth roll forming stages indicated are passive. That is, they do not include roll forming drives, and they do not include, i.e., are free of, metering elements or sensors. The output section of the strand is of sufficient strength to draw the strand through the forming die.
In the rotating cage portion 26 there is a single twist apparatus that includes a hollow spindle 54, rotating frame 56, capstans 58, winding feed members, and an output reel, or take-up reel 60 upon which the output product is collected pending further steps, such as the coating of the raw cable with a dielectric coating or encapsulant or encapsulating layer. The twisting section may tend not to be a double twist section given the large number (nominally 37 for a three layer, and 61 for a four layer) number of strands of the constructed cable.
Given that the stationary infeed positions permit continuous feed, the output reel may be quite iarge. For example, the output reel may have a diameter of greater than 72 inches. The diameter may be 76, 84 or 96 inches.
The roll forming, (and compression, if any), may be in the range of less than 15 %
reduction in area, and more than 5 % reduction in area. In one embodiment, the reduction in area is in the range of between 10 and 14 % overall, and may be in the range of 12 -14 %., and may be about 13 %. As may be understood, the roll forming dies provided at each of the stages will have an output section shape that has a reduction in area from the input round wire section corresponding to the reduction in area of the strands.
The layer forming apparatus is passive. That is, it does not include, i.e., is free of, powered stage drives for driving the roll forming elements, and, likewise, it is also free of metering systems for the drives it doesn't have. This reduction of complexity may tend to facilitate the construction of a four layered, nominally 61 strand cable, as described herein.
The resulting cable is then a single input wire, unilay, continuous feed cable, and the apparatus is a single twist, rigid strander, or rigid stranding machine. The machine need only stop to remove, and replace, the output reel. As far as the inventor is aware, such a product has not been seen heretofore. In this instancer the drive is provided by the tension from the capstan. As is customary, the rate of capstan advance is proportional to the rate ofrevolution of the frame, and therefore the twist of the conductor. Inasmuch as the resultant conductor may be a heavy, high power conductor, the machine is a singe twist machine, i.e., it is free of a revolving bow.
In earlier times, there may have been a perception that a multi-layer unilay cable would be structurally unstable, and that the structure would be prone to collapse in manufacture. A reverse lay cable will tend not to be as prone to this phenomenon in light of the alternating criss-crossing of the elements of its various layers. However, the inventor has found that, contrary to conventional wisdom, the multilayer unilay structure, employing roll-formed elements is sufficiently structurally stable for many uses. That is, the strand elements of the 61 (nominal) strand SIW unilay single twist product made by this process have been has been stretched longitudinally elastically during manufacture, and have also been twisted under tension. To the extent that the elements of the outermost layer (or other layers) have the trapezoidal or keystone shape, and inasmuch as they follow helices, the resultant structure may tend to be self-tightening where the sides of the keystone shape of the elements tend to bind against each other and form a stable structure.
As may be noted, the apparatus provides all of the power for the roll forming reduction of area through the tension applied to the workiece by the capstan apparatus. Only the displacement (or speed) of the capstan need be monitored and metered, thus tending to eliminate the need to monitor or meter either speed or displacement at any of the layer forming apparatus stages.
In an alternate embodiment, it may be that while most of the roll forming stations are passive, one or more stations may employ a conventional driven roll forming set of dies.
The area reduction of the passive roll forming stations may be in the range of 10 - 14 %, whereas the active roll forming stations, if any, may have an area reduction in the range of up to about 19 %. Although the disclosure shows and describes a four layer conductor, passive roll forming may be used in conductors with a larger number of layers.
In summary, then the apparatus described herein can be used to make a single input wire, four layer multi-strand unilay conductor in a single twist rigid strander. The conductor may have a dielectric coating. As noted, the conductor may have roll formed strands having a reduction in area in roll forming of between 10 % and 15 %. Alternatively, it may have strands that have a reduction in area of between 12 and 14 %. Alternatively still, it may be between 10 % and 13 %. The conductor may be made of (a) copper; (b) a copper alloy; (c) aluminum; and (d) an aluminum alloy. The conductor has an outer layer of electrically conductive strands, said outer layer of conductive strands includes strands formed in a keystone shape, and the outer layer has a residual elastic stress therein tending to bind said strands together.
The apparatus itself may include a feedstock section, a forming section, and a winding section. The feedstock section includes accommodations for an array of conductor strand reels, and paying off sheaves mounted to carry the feedstock strands from the feedstock section to said forming section. The forming section includes a core wire feed apparatus, a first layer feed apparatus, a second layer feed apparatus, a third layer feed apparatus, and a fourth layer feed apparatus. The first, second third and fourth feed layer apparatus are positioned, or aligned, in series. At least one of the feed layer apparatus includes roll forming dies through which feedstock strands are drawn. All of the feed layers include a respective lay plate for positioning the strands of its respective layer about the core wire and any preceding layers. The winding, or reeling, or take-up section includes a rotating cage. The rotating cage having a capstan apparatus mounted therewithin. The capstan apparatus is mounted to draw the core wire and the respective layers of strands through the layer feed apparatus. The winding section includes an output cable accumulation reel mounted carried by the frame member of the rotating cage. The taken up output cable drawn through the capstan apparatus is accumulated on the output reel. All of the lay plates and rolling dies are sized to handle a single input wire diameter. At least a majority of the roll forming dies are passive roll forming dies. The apparatus may include a coating station for applying a dielectric coating to the output cable. In one embodiment, all of the roll forming dies are passive roll forming dies. In one embodiment each of the first, second, third and fourth feed layer apparatus includes roll forming dies.
In that apparatus, the first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire. The second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including acconunodations for between 9 and 14 strands. The third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands. The fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands. In one embodiment, the first, second, third and fourth lay plates have accommodations for 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. In the apparatus, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 15 %. In one embodiment, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 12 and 14 %. In another embodiment, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 13 %. The output cable accumulation reel is greater than 72 inches in diameter. The apparatus is free of rate metering equipment at the first, second, third and fourth layer feed apparatus. Rather, only the capstan has a rate metering control.
The production of the cable involves a method or process of using the apparatus. The method includes supplying feedstock from an array of reels equal to the number of strands in the conductor, one of the strands being a core wire, all of the strands being of the same diameter; conveying feedstock strands to each of a serially positioned set of first layer feed apparatus, a second feed layer apparatus, a third feed layer apparatus and a fourth feed layer apparatus; passively roll forming a plurality of the strands in at least a majority of the first, second, third, and fourth layer feed apparatus; orienting the strands for closure about the core wire and any previous layers of strands; closing the roll formed strands about the core wire and about any preceding layer of strands closed about the core wire; pulling the closed strands and core wire through the first, second, third and fourth layer feed apparatus with a capstan apparatus to form the twisted cable; and accumulating the twisted cable on a take-up reel mounted in a rotating cage.
The method may also include the subsequent step of encasing the twisted cable in a dielectric coating. Further, it may include replacing or replenishing an empty reel of the array of feedstock reels with a full reel of feedstock while the capstan apparatus is in operation. The method includes feeding strands to the various lay plates in appropriate numbers. The first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire and the method includes feeding a number of strands equal to the number of accommodations to the first layer lay plate; the second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including accommodations for between 9 and 14 strands, and the method includes feeding a number of strands equal to the number of accommodations to the second layer lay plate; the third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands and the method includes -feeding a number of strands equal to the number of accommodations to the third layer lay plate; and the fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands and the method includes feeding a number of strands equal to the number of accommodations to the fourth layer lay plate. In one embodiment, the first, second, third and fourth lay plates receive 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. The method includes providing all roll forming power through the tension applied by the capstan apparatus. It also includes monitoring at least one of (a) displacement and (b) velocity, of the workpiece in the method other than at the first, second, third and fourth later feed apparatus, namely monitoring at least one of (a) displacement, and (b) velocity, of the workpiece only at the capstan apparatus.
Various embodiments have been described in detail. Since changes in and or additions to the above-described examples may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited to those details.
The first stage of the forming and closing section 24 includes roll forming dies, such as may be termed roll forming elements 37, a lay plate 38, and may include a closing die 39.
There are different possible arrangements but, in each case, the individual strands are formed to the shape of the section they are to take in the conductor, and are then passed to the lay plate 38, at which their angular position relative to the central core wire 35 is established, and then to the closing plate, or closing die 39 at which the compacted (i.e., pre-roll-formed) elements are compressed, or not, as may be. Compression is not a necessary step. In some embodiments, the forming and spacing may occur in a single location at the lay plate as illustrated in US Patent 4,212,151. Assuming the central core wire to be a single round wire that forms the datum of the construction, the other wires of the various subsequent layers may be taken as having a generally triangular or trapezoidal shape corresponding to a sector of an annulus of the same number of portions as the number of strands in the layer. In some embodiments the corners of those elements may nonetheless retain a fairly rounded or radiused edge in keeping with the relatively modest area reduction of a passive roll forming process in which the strand is of sufficient cross-sectional area after forming that the force required to drive the forming process is provided in the tension in the strand itself.
In one embodiment, in the first stage 40, up to 8 aluminum or copper wire strands may enter at the level of core wire 35. (In another embodiment, all strands may be carried at this level). The first layer, of nominally 6 strands, (which may be 5, 6 or 7, for example) is wound about the core wire 35. In the second stage 42 the next layer is formed at forming station 43, and lay plate 44 and closing die 45, where the next layer is formed, oriented and then compressed onto the endless advancing central core and first layer.
Again, while the second layer has nominally 12 strands, it may have slightly more or fewer depending on the construction being formed. In the third stage there is a roll forming station 46, a lay plate 47, and a closing die 48 at which the nominally18 strand third layer is twisted onto the advancing core construction, that already includes the core and the first and second layers.
In the fourth stage, should it be used, there is a roll forming station 49, a lay plate 50, and a closing die 51 at which the nominally 24 strand fourth layer is twisted onto the advancing core and the first, second and third layers. The uncoated, twisted resultant raw four layer conductor product 52 exits the forming section, and is drawn toward the rotating cage portion 26. In each case, at each stage the filaments of that stage or layer are fed in on a set of sheaves 55 from the overhead supply as appropriate. As a matter of definition, the "workpiece" at any given stage may be thought of as the continuous feed from the previous stage, i.e., the core wire plus any layers of conductor strands twisted about the core wire in the preceding stages.
In contrast to earlier driven roll forming sections, the first, second, third and fourth roll forming stages indicated are passive. That is, they do not include roll forming drives, and they do not include, i.e., are free of, metering elements or sensors. The output section of the strand is of sufficient strength to draw the strand through the forming die.
In the rotating cage portion 26 there is a single twist apparatus that includes a hollow spindle 54, rotating frame 56, capstans 58, winding feed members, and an output reel, or take-up reel 60 upon which the output product is collected pending further steps, such as the coating of the raw cable with a dielectric coating or encapsulant or encapsulating layer. The twisting section may tend not to be a double twist section given the large number (nominally 37 for a three layer, and 61 for a four layer) number of strands of the constructed cable.
Given that the stationary infeed positions permit continuous feed, the output reel may be quite iarge. For example, the output reel may have a diameter of greater than 72 inches. The diameter may be 76, 84 or 96 inches.
The roll forming, (and compression, if any), may be in the range of less than 15 %
reduction in area, and more than 5 % reduction in area. In one embodiment, the reduction in area is in the range of between 10 and 14 % overall, and may be in the range of 12 -14 %., and may be about 13 %. As may be understood, the roll forming dies provided at each of the stages will have an output section shape that has a reduction in area from the input round wire section corresponding to the reduction in area of the strands.
The layer forming apparatus is passive. That is, it does not include, i.e., is free of, powered stage drives for driving the roll forming elements, and, likewise, it is also free of metering systems for the drives it doesn't have. This reduction of complexity may tend to facilitate the construction of a four layered, nominally 61 strand cable, as described herein.
The resulting cable is then a single input wire, unilay, continuous feed cable, and the apparatus is a single twist, rigid strander, or rigid stranding machine. The machine need only stop to remove, and replace, the output reel. As far as the inventor is aware, such a product has not been seen heretofore. In this instancer the drive is provided by the tension from the capstan. As is customary, the rate of capstan advance is proportional to the rate ofrevolution of the frame, and therefore the twist of the conductor. Inasmuch as the resultant conductor may be a heavy, high power conductor, the machine is a singe twist machine, i.e., it is free of a revolving bow.
In earlier times, there may have been a perception that a multi-layer unilay cable would be structurally unstable, and that the structure would be prone to collapse in manufacture. A reverse lay cable will tend not to be as prone to this phenomenon in light of the alternating criss-crossing of the elements of its various layers. However, the inventor has found that, contrary to conventional wisdom, the multilayer unilay structure, employing roll-formed elements is sufficiently structurally stable for many uses. That is, the strand elements of the 61 (nominal) strand SIW unilay single twist product made by this process have been has been stretched longitudinally elastically during manufacture, and have also been twisted under tension. To the extent that the elements of the outermost layer (or other layers) have the trapezoidal or keystone shape, and inasmuch as they follow helices, the resultant structure may tend to be self-tightening where the sides of the keystone shape of the elements tend to bind against each other and form a stable structure.
As may be noted, the apparatus provides all of the power for the roll forming reduction of area through the tension applied to the workiece by the capstan apparatus. Only the displacement (or speed) of the capstan need be monitored and metered, thus tending to eliminate the need to monitor or meter either speed or displacement at any of the layer forming apparatus stages.
In an alternate embodiment, it may be that while most of the roll forming stations are passive, one or more stations may employ a conventional driven roll forming set of dies.
The area reduction of the passive roll forming stations may be in the range of 10 - 14 %, whereas the active roll forming stations, if any, may have an area reduction in the range of up to about 19 %. Although the disclosure shows and describes a four layer conductor, passive roll forming may be used in conductors with a larger number of layers.
In summary, then the apparatus described herein can be used to make a single input wire, four layer multi-strand unilay conductor in a single twist rigid strander. The conductor may have a dielectric coating. As noted, the conductor may have roll formed strands having a reduction in area in roll forming of between 10 % and 15 %. Alternatively, it may have strands that have a reduction in area of between 12 and 14 %. Alternatively still, it may be between 10 % and 13 %. The conductor may be made of (a) copper; (b) a copper alloy; (c) aluminum; and (d) an aluminum alloy. The conductor has an outer layer of electrically conductive strands, said outer layer of conductive strands includes strands formed in a keystone shape, and the outer layer has a residual elastic stress therein tending to bind said strands together.
The apparatus itself may include a feedstock section, a forming section, and a winding section. The feedstock section includes accommodations for an array of conductor strand reels, and paying off sheaves mounted to carry the feedstock strands from the feedstock section to said forming section. The forming section includes a core wire feed apparatus, a first layer feed apparatus, a second layer feed apparatus, a third layer feed apparatus, and a fourth layer feed apparatus. The first, second third and fourth feed layer apparatus are positioned, or aligned, in series. At least one of the feed layer apparatus includes roll forming dies through which feedstock strands are drawn. All of the feed layers include a respective lay plate for positioning the strands of its respective layer about the core wire and any preceding layers. The winding, or reeling, or take-up section includes a rotating cage. The rotating cage having a capstan apparatus mounted therewithin. The capstan apparatus is mounted to draw the core wire and the respective layers of strands through the layer feed apparatus. The winding section includes an output cable accumulation reel mounted carried by the frame member of the rotating cage. The taken up output cable drawn through the capstan apparatus is accumulated on the output reel. All of the lay plates and rolling dies are sized to handle a single input wire diameter. At least a majority of the roll forming dies are passive roll forming dies. The apparatus may include a coating station for applying a dielectric coating to the output cable. In one embodiment, all of the roll forming dies are passive roll forming dies. In one embodiment each of the first, second, third and fourth feed layer apparatus includes roll forming dies.
In that apparatus, the first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire. The second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including acconunodations for between 9 and 14 strands. The third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands. The fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands. In one embodiment, the first, second, third and fourth lay plates have accommodations for 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. In the apparatus, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 15 %. In one embodiment, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 12 and 14 %. In another embodiment, the roll forming dies of any of the layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 13 %. The output cable accumulation reel is greater than 72 inches in diameter. The apparatus is free of rate metering equipment at the first, second, third and fourth layer feed apparatus. Rather, only the capstan has a rate metering control.
The production of the cable involves a method or process of using the apparatus. The method includes supplying feedstock from an array of reels equal to the number of strands in the conductor, one of the strands being a core wire, all of the strands being of the same diameter; conveying feedstock strands to each of a serially positioned set of first layer feed apparatus, a second feed layer apparatus, a third feed layer apparatus and a fourth feed layer apparatus; passively roll forming a plurality of the strands in at least a majority of the first, second, third, and fourth layer feed apparatus; orienting the strands for closure about the core wire and any previous layers of strands; closing the roll formed strands about the core wire and about any preceding layer of strands closed about the core wire; pulling the closed strands and core wire through the first, second, third and fourth layer feed apparatus with a capstan apparatus to form the twisted cable; and accumulating the twisted cable on a take-up reel mounted in a rotating cage.
The method may also include the subsequent step of encasing the twisted cable in a dielectric coating. Further, it may include replacing or replenishing an empty reel of the array of feedstock reels with a full reel of feedstock while the capstan apparatus is in operation. The method includes feeding strands to the various lay plates in appropriate numbers. The first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about the core wire, the lay plate having accommodations for between 5 and 8 strands in the first layer apart from the core wire and the method includes feeding a number of strands equal to the number of accommodations to the first layer lay plate; the second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about the first layer of strands, the lay plate of the second layer feed apparatus including accommodations for between 9 and 14 strands, and the method includes feeding a number of strands equal to the number of accommodations to the second layer lay plate; the third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about the second layer of strands, the lay plate of the third layer feed apparatus including accommodations for between 15 and 21 strands and the method includes -feeding a number of strands equal to the number of accommodations to the third layer lay plate; and the fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about the third layer of strands, the lay plate of the fourth layer feed apparatus including accommodations for between 20 and 28 strands and the method includes feeding a number of strands equal to the number of accommodations to the fourth layer lay plate. In one embodiment, the first, second, third and fourth lay plates receive 6, 12, 18 and 24 strands to be roll formed and twisted, respectively. The method includes providing all roll forming power through the tension applied by the capstan apparatus. It also includes monitoring at least one of (a) displacement and (b) velocity, of the workpiece in the method other than at the first, second, third and fourth later feed apparatus, namely monitoring at least one of (a) displacement, and (b) velocity, of the workpiece only at the capstan apparatus.
Various embodiments have been described in detail. Since changes in and or additions to the above-described examples may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited to those details.
Claims (32)
1. A single input wire, four layer multi-strand unilay conductor.
2. The conductor of claim 1 wherein said conductor has an external dielectric coating.
3. The conductor of any one of claims 1 and 2 wherein said conductor has roll formed strands having a reduction in area in roll forming of between 10 % and 15 %.
4. The conductor of claim 3 wherein said strands have a reduction in area of between 12 and 14 %.
5. The conductor of any one of claims 1 to 4 wherein said conductor is made from one of (a) copper; (b) a copper alloy; (c) aluminum; and (d) an aluminum alloy.
6. The conductor of any one of claims 1 to 5 wherein said conductor has an outer layer of electrically conductive strands, said outer layer of conductive strands includes strands formed in a keystone shape, and said outer layer has a residual elastic stress therein tending to bind said strands together.
7. An apparatus for making a four layered, single input wire, multi-strand unilay conductor, said apparatus comprising:
a feedstock section, a forming section, and a winding section;
said feedstock section including accommodations for an array of conductor strand reels, and paying off sheaves mounted to carry feedstock strands from said feedstock section to said forming section;
said forming section including a core wire feed apparatus, a first layer feed apparatus, a second layer feed apparatus, a third layer feed apparatus, and a fourth layer feed apparatus, said first, second third and fourth feed layer apparatus being aligned in series;
at least one of said feed layer apparatus including roll forming dies through which feedstock strands are drawn, all of said feed layers including a respective lay plate for positioning the strands of its respective layer about said core wire and any preceding layers;
said winding section including a rotating cage, said rotating cage having a capstan apparatus mounted therewithin, said capstan apparatus being mounted to draw said core wire and the respective layers of strands through said layer feed apparatus;
said winding section including an output cable accumulation reel mounted to be carried by said rotating cage, and upon which to take up output cable drawn through said capstan apparatus;
all of said lay plates and rolling dies being sized to handle a single input wire diameter; and at least a majority of said roll forming dies being passive roll forming dies.
a feedstock section, a forming section, and a winding section;
said feedstock section including accommodations for an array of conductor strand reels, and paying off sheaves mounted to carry feedstock strands from said feedstock section to said forming section;
said forming section including a core wire feed apparatus, a first layer feed apparatus, a second layer feed apparatus, a third layer feed apparatus, and a fourth layer feed apparatus, said first, second third and fourth feed layer apparatus being aligned in series;
at least one of said feed layer apparatus including roll forming dies through which feedstock strands are drawn, all of said feed layers including a respective lay plate for positioning the strands of its respective layer about said core wire and any preceding layers;
said winding section including a rotating cage, said rotating cage having a capstan apparatus mounted therewithin, said capstan apparatus being mounted to draw said core wire and the respective layers of strands through said layer feed apparatus;
said winding section including an output cable accumulation reel mounted to be carried by said rotating cage, and upon which to take up output cable drawn through said capstan apparatus;
all of said lay plates and rolling dies being sized to handle a single input wire diameter; and at least a majority of said roll forming dies being passive roll forming dies.
8. The apparatus of claim 7 wherein said apparatus includes a coating station for applying a dielectric coating to the output cable.
9. The apparatus of any one of claims 7 and 8 wherein all of said roll forming dies are passive roll forming dies.
10. The apparatus of any one of claims 7 to 9 wherein each of said first, second, third and fourth feed layer apparatus includes roll forming dies.
11. The apparatus of any one of claims 7 to 9 wherein:
said first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about said core wire, said lay plate having accommodations for between 5 and 8 strands in said first layer apart from said core wire;
said second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about said first layer of strands, said lay plate of said second layer feed apparatus including accommodations for between 9 and 14 strands;
said third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about said second layer of strands, said lay plate of said third layer feed apparatus including accommodations for between 15 and 21 strands; and said fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about said third layer of strands, said lay plate of said fourth layer feed apparatus including accommodations for between 20 and 28 strands.
said first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about said core wire, said lay plate having accommodations for between 5 and 8 strands in said first layer apart from said core wire;
said second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about said first layer of strands, said lay plate of said second layer feed apparatus including accommodations for between 9 and 14 strands;
said third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about said second layer of strands, said lay plate of said third layer feed apparatus including accommodations for between 15 and 21 strands; and said fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about said third layer of strands, said lay plate of said fourth layer feed apparatus including accommodations for between 20 and 28 strands.
12. The apparatus of claim 11 wherein said first, second, third and fourth lay plates have accommodations for 6, 12, 18 and 24 strands to be roll formed and twisted, respectively.
13. The apparatus of any of claims 7 to 12 wherein said roll forming dies of any of said layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 15 %.
14. The apparatus of any of claims 7 to 12 wherein said roll forming dies of any of said layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 12 and 14 %.
15. The apparatus of any of claims 7 to 12 wherein said roll forming dies of any of said layer feed apparatus include dies having an output geometry that has a reduction of area as compared to input wire size of between 10 and 13 %.
16. The apparatus of any of claims 7 to 15 wherein said output cable accumulation reel is greater than 72 inches in diameter.
17. The apparatus of any one of claims 7 to 16 wherein said apparatus is free of rate metering equipment at said first, second, third and fourth layer feed apparatus.
18. The apparatus of any one of claims 7 to 17 wherein only said capstan has a rate metering control.
19. A method of making a four layered, single input wire, multi-strand unilay conductor, said apparatus comprising:
supplying feedstock from an array of reels equal to the number of strands in the conductor, one of said strands being a core wire, all of said strands being of the same diameter;
conveying feedstock strands to each of a serially positioned set of first layer feed apparatus, a second feed layer apparatus, a third feed layer apparatus and a fourth feed layer apparatus;
passively roll forming a plurality of said strands in at least a majority of said first, second, third, and fourth layer feed apparatus;
orienting said strands for closure about said core wire and any previous layers of strands;
closing said roll formed strands about said core wire and about any preceding layer of strands closed about said core wire;
pulling said closed strands and core wire through said first, second, third and fourth layer feed apparatus with a capstan apparatus to form the twisted cable; and accumulating the twisted cable on a take-up reel mounted in a rotating cage.
supplying feedstock from an array of reels equal to the number of strands in the conductor, one of said strands being a core wire, all of said strands being of the same diameter;
conveying feedstock strands to each of a serially positioned set of first layer feed apparatus, a second feed layer apparatus, a third feed layer apparatus and a fourth feed layer apparatus;
passively roll forming a plurality of said strands in at least a majority of said first, second, third, and fourth layer feed apparatus;
orienting said strands for closure about said core wire and any previous layers of strands;
closing said roll formed strands about said core wire and about any preceding layer of strands closed about said core wire;
pulling said closed strands and core wire through said first, second, third and fourth layer feed apparatus with a capstan apparatus to form the twisted cable; and accumulating the twisted cable on a take-up reel mounted in a rotating cage.
20. The method of claim 19 wherein said method includes the subsequent step of encasing the twisted cable in a dielectric coating.
21. The method of any one of claims 19 and 20 wherein said method includes replacing an empty reel of said array of feedstock reels with a full reel of feedstock while said capstan apparatus is in operation.
22. The method of any one of claims 19 to 21 wherein said method includes reducing the area of a plurality of said strands between 10 and 15 %.
23. The method of any one of claims 19 to 21 wherein each of said first, second, third and fourth layer feed apparatus includes passive roll forming dies operable to shape strands of feedstock passed therethrough, and said method includes roll forming the strands passed through said first, second, third and fourth layers.
24. The method of claim 23 wherein said roll forming includes a reduction of area of between 10 and 15 %.
25. The method of claim 23 wherein said roll forming includes a reduction of area of between 12 and 14 %.
26. The method of claim 23 wherein said roll forming includes a reduction of area of between 10 and 13 %.
27. The method of any one of claims 19 to 26 wherein:
said first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about said core wire, said lay plate having accommodations for between 5 and 8 strands in said first layer apart from said core wire and said method includes feeding a number of strands equal to said number of accommodations to said first layer lay plate;
said second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about said first layer of strands, said lay plate of said second layer feed apparatus including accommodations for between 9 and 14 strands, and said method includes feeding a number of strands equal to said number of accommodations to said second layer lay plate;
said third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about said second layer of strands, said lay plate of said third layer feed apparatus including accommodations for between 15 and 21 strands and said method includes feeding a number of strands equal to said number of accommodations to said third layer lay plate; and said fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about said third layer of strands, said lay plate of said fourth layer feed apparatus including accommodations for between 20 and 28 strands and said method includes feeding a number of strands equal to said number of accommodations to said fourth layer lay plate.
said first layer feed apparatus includes a lay plate and dies for a core wire and a first layer of strands to be twisted about said core wire, said lay plate having accommodations for between 5 and 8 strands in said first layer apart from said core wire and said method includes feeding a number of strands equal to said number of accommodations to said first layer lay plate;
said second layer feed apparatus includes a lay plate and dies for a second layer of strands to be twisted about said first layer of strands, said lay plate of said second layer feed apparatus including accommodations for between 9 and 14 strands, and said method includes feeding a number of strands equal to said number of accommodations to said second layer lay plate;
said third layer feed apparatus includes a lay plate and dies for a third layer of strands to be twisted about said second layer of strands, said lay plate of said third layer feed apparatus including accommodations for between 15 and 21 strands and said method includes feeding a number of strands equal to said number of accommodations to said third layer lay plate; and said fourth layer feed apparatus includes a lay plate and dies for a fourth layer of strands to be twisted about said third layer of strands, said lay plate of said fourth layer feed apparatus including accommodations for between 20 and 28 strands and said method includes feeding a number of strands equal to said number of accommodations to said fourth layer lay plate.
28. The method of any one of claims 19 to 26 wherein said method includes feeding said first, second, third and fourth lay plates 6, 12, 18 and 24 strands to be roll formed and twisted, respectively.
29. The method of any one of claims 19 to 28 wherein said method includes providing roll forming dies having an output shape having a reduction in area of between 10 and 15 %.
30. The method of any one of claims 19 to 29 wherein said method includes providing all roll forming power through the tension applied by said capstan apparatus.
31. The method of any one of claims 19 to 30 wherein said method includes monitoring at least one of (a) displacement and (b) velocity, of the workpiece in said method other than at said first, second, third and fourth later feed apparatus.
32. The method of any of claims 19 to 30 wherein said method includes monitoring at least one of (a) displacement, and (b) velocity, of the workpiece only at said capstan apparatus.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2627840 CA2627840A1 (en) | 2008-03-31 | 2008-03-31 | Multilayer unilay cable, manufacturing apparatus and process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2627840 CA2627840A1 (en) | 2008-03-31 | 2008-03-31 | Multilayer unilay cable, manufacturing apparatus and process |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2627840A1 true CA2627840A1 (en) | 2009-09-30 |
Family
ID=41161194
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2627840 Abandoned CA2627840A1 (en) | 2008-03-31 | 2008-03-31 | Multilayer unilay cable, manufacturing apparatus and process |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2627840A1 (en) |
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- 2008-03-31 CA CA 2627840 patent/CA2627840A1/en not_active Abandoned
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