EP0646674B1 - Verfahren zum Herstellen von Kabeln - Google Patents

Verfahren zum Herstellen von Kabeln Download PDF

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Publication number
EP0646674B1
EP0646674B1 EP93115843A EP93115843A EP0646674B1 EP 0646674 B1 EP0646674 B1 EP 0646674B1 EP 93115843 A EP93115843 A EP 93115843A EP 93115843 A EP93115843 A EP 93115843A EP 0646674 B1 EP0646674 B1 EP 0646674B1
Authority
EP
European Patent Office
Prior art keywords
wire
wires
closing die
panel plates
cable manufacturing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP93115843A
Other languages
English (en)
French (fr)
Other versions
EP0646674A1 (de
Inventor
Kenji Ito
Kouki Kusakai
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tokyo Rope Manufacturing Co Ltd
Original Assignee
Tokyo Rope Manufacturing Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tokyo Rope Manufacturing Co Ltd filed Critical Tokyo Rope Manufacturing Co Ltd
Priority to EP93115843A priority Critical patent/EP0646674B1/de
Priority to DE69322510T priority patent/DE69322510T2/de
Publication of EP0646674A1 publication Critical patent/EP0646674A1/de
Application granted granted Critical
Publication of EP0646674B1 publication Critical patent/EP0646674B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
    • E01D19/00—Structural or constructional details of bridges
    • E01D19/16—Suspension cables; Cable clamps for suspension cables ; Pre- or post-stressed cables
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B3/00—General-purpose machines or apparatus for producing twisted ropes or cables from component strands of the same or different material
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B5/00—Making ropes or cables from special materials or of particular form
    • D07B5/002—Making parallel wire strands
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
    • D07B7/02—Machine details; Auxiliary devices
    • D07B7/021—Guiding means for filaments, strands, ropes or cables

Definitions

  • This invention relates to a method for manufacturing a cable used as a stay in a cable-stayed bridge.
  • a Parallel Wire Strand cable (PWS) is used as a stay in a cable-stayed bridge.
  • the PWS consists of a bundle of plural wires arranged parallel with one another, and has a high breaking-load strength and a high elastic coefficient.
  • the PWS has superior properties for use as a stay in a cable-stayed bridge.
  • Such a PWS is carried from a manufacturing plant to a bridge-construction site, wound on a reel. It is difficult to wind the PWS onto a reel neatly and a substantial amount of time and labor are required to do so, since the bundled parallel wires of the PWS can easily deform.
  • each of the wires may be deformed plastically, since it is stranded about its axis, causing the so-called "reduction in breaking strength due to stranding" (i.e. reduction in strength resulting from multiplying a linear wire strength by a spining factor).
  • This breaking strength reduction decreases the breaking-load strength and elastic coefficient of the cable, making it difficult to maintain the best properties of a cable to be used as a stay in a cable-stayed bridge.
  • a method and an apparatus for laying up elongated members, particularly hoses and electrical cable cores is disclosed in US-A-4 151 704.
  • the hoses and cores are initially laid out horizontally and threaded through tubes extending between a plurality of lay plates.
  • the hoses and cores are pulled from the tubes while the lay plates are rotated synchronously to form a laid-up unit.
  • the tubes are arranged with a linear shape.
  • a cable manufacturing method comprising the steps of, arranging a closing die and a plurality of panel plates in this order, on a pass-line having a curved zone and a linear zone, from the side of a front end of the pass-line; inserting all wires, to be stranded, through an opening of the closing die, and inserting each wire through a hole formed in a corresponding one of the panel plates; guiding the wires such that the wires are substantially parallel with one another and each wire is loose of the panel plates; rotatably supporting the panel plates, respectively; and passing each wire through the curved zone and the linear zone while rotating the panel plates in the same direction, thereby stranding the wires with a large pitch so as not to plastically deform the wires.
  • the pass-line has a curved zone P3
  • a cable can be manufactured in a space having a length shorter than the cable to be obtained.
  • the radius R of the curved zone P3 of the pass-line PL is set to a value 100 times or more the diameter d of each wire. This is because if R ⁇ 100d, the wire may be plastically curved (bended) while it passes the curved zone P3.
  • a first guide pipe is interposed between each adjacent two panel plates, a plurality of relay pipes are attached to each panel plate in the curved zone, one end of a second guide pipe is coupled with a small-diameter portion of each relay pipe, and the other end of the second guide pipe is inserted into a large-diameter portion of the relay pipe, thereby enabling the wires to be guided through the first and second guide pipes and the relay pipes.
  • the rotation of the panel plates is not interfered by the guide pipes and is performed smoothly.
  • each wire passes the pass-line while it is guided by a corresponding guide pipe, the wire is prevented from slacking or contacting adjacent wires. Thus, there is no possibility of tangling of wires, resulting in smooth wire feeding.
  • a cable manufacturing apparatus comprises a wire feed mechanism 5 and a wire stranding mechanism 10.
  • the wire feed mechanism 5 is provided in the vicinity of a first closing die 11 of the wire stranding mechanism 10, and has a plurality of wire holders 7 on an endless track 6.
  • the wire feed mechanism 5 has pairs of pinch rolls 66 and guide rolls 67, and is disposed to set a wire 2 on a pass-line PL from the side of the first closing die 11 to the side of panel plates 15.
  • a plurality of wires 2 are fed on the pass-line PL, and stranded by means of closing dies 11 and 13 to produce a cable 3 as a stay in a cable-stayed bridge.
  • the wire stranding mechanism 10 can strand approximate five hundreds wires 2 at maximum.
  • the produced cable 3 is wound on a reel 8.
  • the pass-line PL of the wire stranding mechanism 10 has linear zones P1 and P2 and a curved zone P3.
  • the linear zones P1 and P2 are parallel with each other, and spaced 12 m.
  • the linear zone P1 has a length L1 of about 260 m, and the linear zone P2 a length L2 of about 221 m.
  • the curved zone P3 is a semi-circular line with a radius of 6 m, and one end of the curved zone P3 connects the linear zone P1, and other end of the curved zone P3 connects the linear zone P2.
  • the linear zone P1 has the first and second closing dies 11 and 13 and a plurality of panel plates 15, and the linear and curved zones P2 and P3 have a plurality of panel plates 15.
  • the pitch of the panel plates 15 is 2 - 5 m in the linear zones P1 and P2, and about 1.2 m (i.e., an angle between each adjacent pair of the panel plates 15 is about 11.25°) in the curved zone P3.
  • the wires 2 are inserted from the side of the linear zone P1, and pulled out the side of the linear zone P1.
  • a radius R of the curved zone P3 it is desirable to set a radius R of the curved zone P3 to a value 100 times or more higher than the diameter d of the wire 2, and to set the lengths L1 and L2 to 150 - 300 m and 150 - 250 m, respectively.
  • the lengths L1 and L2 are set to 260 m and 221 m, respectively, and the diameter R 6 m.
  • the curved zone P3 has seventeen panel plates 15 arranged in regular intervals. The distance between each adjacent pair of the plates 15 in the curved zone P3 is shorter than that in the linear zone P1 or P2.
  • Each panel plate 15 is rotatably housed in a bearing case 30.
  • Rotary mechanisms 20 are provided at the inlet and outlet side panel plates 15 and every third panel plates 15. These plates 15 are coupled to one another by means of universal joints 29. Thus, when one of the plates 15 is rotated by a corresponding one of the rotary mechanisms 20, the torque is transmitted to the other plates 15 successively.
  • each rotary mechanism 20 has a cycloidal decelerator 23 and the bearing case 30 located with a constant level on a floor 99.
  • Each bearing case 30 is supported by a plurality of bases 31 having an anti-vibration function.
  • Each cycloidal decelerator 23 is secured to a base 21, and has an input gear engaged with the driving-shaft gear of a motor 22. The motor is controlled by a controller 35.
  • the output gear of the decelerator 23 is coupled with a sprocket 24.
  • Each bearing case 30 houses a gear 28 and a sprocket 27 arranged coaxial with the gear 28.
  • the gear 28 is engaged with a gear 16 on the side of the panel plate 15.
  • a chain 25 connects the sprocket 24 to the sprocket 27.
  • the gear 16 is coaxial with the panel plate 15, and is supported by a shaft (not shown).
  • Each panel plate 15 is supported by a plurality of bearings (not shown), and has a diameter of 800 ⁇ 50 mm and a thickness of 25 ⁇ 10 mm.
  • the first closing die (fixed closing die) 11 has a casing (not shown), and two semi-circular ring members 11a are housed in the casing. 421 wires are inserted in the closing inlet 12 of the first closing die 11 in a tight manner.
  • the casing of the first closing die 11 is fixed to a frame (not shown) by means of bolts (not shown).
  • the second closing die (rotary closing die) 13 consists of a casing (not shown) and three arc ring members 13a received in the casing.
  • the closing inlet 14 of the second closing die 13 is a little larger than the inlet 12 of the first closing die 11.
  • the second closing die 13 is rotatably supported by a rotary mechanism (not shown). This rotary mechanism is substantially identical to the rotary mechanism 20 of the panel plate 15, but is controlled by the controller 35 to rotate through 180 degrees while the panel plate 15 rotates through 360 degrees.
  • the panel plate 15 is shaped like a disk, and has 421 guide holes 17a and 17b.
  • One wire 2 is inserted in each guide hole 17a or 17b.
  • wires 2 are inserted one by one into the guide holes 17a and 17b of the panel plate 15 from the outlet side of the first closing die 11 by the use of the wire feed mechanism 5 (step S1).
  • Plural wire holders 7 such as bobbins or T carriers are attached to the wire feed mechanism 5, and wires 2 are pulled one by one with the use of the pinch rolls 66 while the wire holders 7 are moved on the endless track 6, and are successively guided by means of the guide rolls 67 toward the guide holes 17a and 17b of the plate 15.
  • the ring members 11a and 13a are loosened, and hence the diameters of the first and second closing dies 11 and 13 are widened.
  • the wire 2 can easily be inserted into the dies 11 and 13.
  • the wire 2 is inserted into the guide holes 17a and 17b of the panel plate 15 located remotest to the closing dies 11 and 13.
  • the wires 2 are set parallel to one another in the wire stranding mechanism 10.
  • a guide tube is provided between each adjacent pair of the panel plates 15 for guiding the wires 2.
  • the time period required to insert 421 wires into the guide holes 17a and 17b of all the panel plates 15 is about four hundreds minutes.
  • the wires 2 After insertion of the wires 2 into the guide holes 17a and 17b of all the panel plates 15, the wires 2 are cut between the first closing die 11 and the pinch rolls 66 located closest to the die 11. Then, the tip ends of the wires 2 projecting from the inlet 12 of the die 11 is fastened by means of a socket (not shown). In this state, the wires 2 are pulled along the pass-line PL and wound on the reel 8 by means of a jack (not shown), while the second closing die 13 and all the panels 15 are rotated in the same direction (step S2). At this time, setting of the wires 2 has been completed, where the length of each wire 2 is 500 m or more.
  • the pulling device 9 has a plurality of hydraulic chucks (not shown) which performs pulling operation.
  • the second closing die 13 and all the panel plates 15 are rotated at a speed of 1 - 10 rmp, preferably 3 - 6 rpm (step S4).
  • the controller 35 controls the rotary mechanism of the die 13 and the motor 22 of the plates 15 such that the die 13 rotates through 180 degrees while the plates 15 rotate through 360 degrees.
  • the first closing die 11 and the panel plates 15 are indispensable elements in the invention, the second closing die 13 is dispensable. Further, although it is preferable to rotate the second closing die 13 more slowly than the panel plate 15, they may be rotated at the same speed.
  • the rotation of the panel plates 15 and the second closing die, and the pulling of the wires enable the wires 2 to be stranded with a large pitch, for example, of about 7.6 m.
  • the outermost wires 2 have a strand angle falling within a range of 3 - 4 degrees.
  • each wire 2 is loaded with a strand torque.
  • the torque exerted on the wire to plastically deform the same i.e., a torsional yielding torque T, is 370 kgf ⁇ cm from the above equation.
  • step S6 After the rear ends of the wires 2 pass the second closing die 13 and the panel plate 15 closest to the die 13, the die 13 and all the plates 15 stop rotating (step S6). Then, the cable 3 thus produced is wound up onto the reel 8, and a new reel is prepared (step S7). The next cable 3 is produced by inserting the next wires into the guide holes 17a and 17b of the panel plates 15 (step S8) and then repeating the above-described steps 2 - 7.
  • Fig. 13 shows the wire-pulling force and torque properties obtained when a linear process line is employed (a comparative case), whereas Fig. 14 shows those obtained when a process line having a curved zone is employed (the embodiment).
  • the wires have the same length, the wire-pulling force and torque are larger in a curved zone than in a linear zone.
  • the torsional yielding torque T of the wire 2 is 370 kgf ⁇ , which is greatly smaller than the torque Q exerted on the wire 2 in the embodiment.
  • each wire Since in the embodiment the torque exerted on each wire is smaller than a value which causes the wire 2 to be plastically deformed, the wire is only elastically deformed even when it is stranded between the first closing die 11 and the panel plate 15 closest thereto.
  • the strand torque applied to the portion of the wire 2 between the die 11 and the plate 15 is elastically transferred toward a rear end portion of the wire, so that the wire 2 is elastically stranded about its axis without being plastically deformed.
  • the wire 2 is stranded with a sharp angle and hence can be plastically deformed, as is shown in Fig. 10.
  • the overall wire 2 is loosely stranded without being plastically deformed, as is shown in Fig. 11.
  • one circumferential surface faces a line TWL every one pitch, and in other words, one circumferential surface and the other circumferential surface alternately face the line TWL every 1/2 pitch.
  • the cable 3 produced by the use of the method of the invention has mechanical properties substantially identical to the conventional parallel cable (PWS).
  • PWS parallel cable
  • the cable 3 consists of 421 wires stranded, and has a maximum outer diameter of 154 mm.
  • the length of a facility required to produce the cable 3 can be as short as about 60% of the conventionally required length, which means that the plant site can be more effectively utilized.
  • the wire 2 can be always efficiently set by the feed mechanism 5 without changing the wire feeding position, even when the pass-line length set for the wire 2 is changed.
  • the method of the invention is advantageous to be applied, in particular, to production of cables used as stays for a cable-stayed bridge, which include different kinds of cables of different lengths.
  • a resin tape may be coated on the outer periphery of the cable 3.
  • the guide pipe 40 consists of a linear pipe of a synthetic resin, and is provided for guiding the wires 2.
  • the guide pipe 40 may be made of a metal.
  • relay pipes 41 extend through each panel plate 15.
  • the pipe 41 is made of a metal such as carbon steel, stainless steel, or an aluminum alloy, and is fixed to the panel plate 15.
  • a guide pipe 42 connects each adjacent pair of relay pipes 41.
  • One end of the guide pipe 42 is fixed to a small-diameter portion of the relay pipe 41, and the other end is loosely inserted in a large-diameter portion of the pipe 41 such that it can move therein.
  • the guide pipe 42 is made of a wear-resistible and flexible synthetic resin such as super high-polymer polyethylene.
  • the large-diameter portion of the relay pipe 41 has an inner diameter of 16 mm, an outer diameter of 20 mm, and a length of 250 mm, while the guide pipe 42 has an inner diameter of 11 mm, an outer diameter of 15 mm, and a length of 1050 mm.
  • the distance between each adjacent pair of panel plates 15 on the radially inner side varies in accordance with rotation of the panel plates 15 in the curved zone P3 (the same can be said of the distance between the same plates 15 on the radially outer side).
  • the guide pipe 42 slides in the relay pipe 41. This prevents the rotation of each panel plate 15 from being interfered by a corresponding guide pipe 42.
  • each wire 2 is guided by corresponding guide pipes 40 and 42, which prevents the wire from slacking or contacting adjacent wires to each other. Thus, there is no possibility of tangling of wires 2, resulting in smooth wire feeding.
  • the curved zone P3 may be interposed between the first and second linear zones P1 and P2 such that the first and second linear zones P1 and P2 intersect each other.
  • a facility for producing a cable can be made shorter than the cable, and therefore the overall site of a manufacturing plant be effectively used.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ropes Or Cables (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)

Claims (10)

  1. Kabelherstellungsverfahren, enthaltend die Schritte:
    Anordnen einer Verseildüse (11) und einer Vielzahl von Lochplatten (15) auf einer Seilerbahn in dieser Reihenfolge von der Seite eines vorderen Endes der Seilerbahn;
    Einbringen aller zu verseilender Drähte (2) durch eine Öffnung (12) der Verseildüse (11) und Einbringen jedes Drahtes (2) durch ein Loch (17a, 17b), das entsprechend in jedem Exemplar der Lochplatte (15) gebildet ist;
    derartiges Führen der Drähte (2), daß die Drähte (2) im wesentlichen parallel zueinander sind und jeder Draht (2) lose gegenüber den Lochplatten (15) ist;
    drehbares Lagern der einzelnen Lochplatten (15), und
    Hindurchbewegen jedes Drahtes (2) durch die Seilerbahn,
       dadurch gekennzeichnet, daß
    die Seilerbahn einen gebogenen Bereich (P3) und einen geradlinigen Bereich (P1, P2) hat und der Schritt des Hindurchbewegens ein Hindurchbewegen jedes Drahtes (2) durch den gebogenen Bereich (P3) und den geradlinigen Bereich (P1, P2) beinhaltet, während die Lochplatten (15) in gleicher Richtung gedreht und dadurch die Drähte (2) mit einer großen Ganghöhe verseilt werden, derart daß die Drähte (2) nicht plastisch verformt werden.
  2. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß es ferner den Schritt enthält, einen Drahtzufuhrmechanismus (5) in der Nähe der Verseildüse (11) vorzusehen für eine Zufuhr der Drähte (2) von der Seite der Verseildüse (11) zur Seite der Lochplatten (15), um die Drähte (2) auf die Seilerbahn zu setzen.
  3. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß es ferner den Schritt enthält, eine drehbare Verseildüse (13) zwischen der Verseildüse (11) und der am nächsten an der Verseildüse (11) liegenden Lochplatte (15) vorzusehen und diese drehbare Verseildüse (13) in der selben Richtung wie die Lochplatten (15) zu drehen und die Verseildüse (11) festzulegen, so daß sie sich nicht dreht.
  4. Kabelherstellungsverfahren nach Anspruch 3, dadurch gekennzeichnet, daß die drehbare Verseildüse (13) mit der Hälfte der Drehgeschwindigkeit der Lochplatten (15) rotiert.
  5. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß der geradlinige Bereich (P1) auf der Seite des vorderen Endes der Seilerbahn vorgesehen ist.
  6. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Verseildüse (11) im geradlinigen Bereich (P1) vorgesehen ist.
  7. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß es ferner den Schritt enthält, im geradlinigen Bereich (P1, P2) ein erstes Führungsrohr (40) zwischen jedem Paar benachbarter Lochplatten (15) anzuordnen, im gebogenen Bereich (P3) eine Vielzahl von Zwischenrohren (41) an jeder Lochplatte (15) zu befestigen, mit einem einen kleinen Durchmesser aufweisenden Teil jedes Zwischenrohres (41) ein Ende eines zweiten Führungsrohres (42) zu verbinden und das andere Ende des zweiten Führungsrohres (42) in einen mit großem Durchmesser ausgebildeten Teil des Zwischenrohres (41) einzusetzen, so daß die Drähte (2) durch die ersten und zweiten Führungsrohre (40, 42) und die Zwischenrohre (41) geführt werden können.
  8. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß jede Lochplatte (15) drehbar in einem Lagergehäuse (30) aufgenommen ist und immer zwei benachbarte Lochplatten (15) mittels eines Universalgelenkes (29) miteinander gekuppelt sind, so daß ein Drehmoment von einer der Lochplatten (15) über das Universalgelenk (29) auf die andere übertragen wird.
  9. Kabelherstellungsverfahren nach Anspruch 8, dadurch gekennzeichnet, daß im gebogenen Bereich (P3) jede dritte Lochplatte (15) gedreht wird.
  10. Kabelherstellungsverfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Krümmungsradius R des gebogenen Bereiches (P3) auf das 100-fache oder mehr des Durchmessers d jedes Drahtes (2) eingestellt ist.
EP93115843A 1993-09-30 1993-09-30 Verfahren zum Herstellen von Kabeln Expired - Lifetime EP0646674B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP93115843A EP0646674B1 (de) 1993-09-30 1993-09-30 Verfahren zum Herstellen von Kabeln
DE69322510T DE69322510T2 (de) 1993-09-30 1993-09-30 Verfahren zum Herstellen von Kabeln

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP93115843A EP0646674B1 (de) 1993-09-30 1993-09-30 Verfahren zum Herstellen von Kabeln

Publications (2)

Publication Number Publication Date
EP0646674A1 EP0646674A1 (de) 1995-04-05
EP0646674B1 true EP0646674B1 (de) 1998-12-09

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP93115843A Expired - Lifetime EP0646674B1 (de) 1993-09-30 1993-09-30 Verfahren zum Herstellen von Kabeln

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EP (1) EP0646674B1 (de)
DE (1) DE69322510T2 (de)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108214250B (zh) * 2018-03-06 2023-09-19 柳州桂桥缆索有限公司 钢丝和钢绞线共用除锈刷机

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4151704A (en) * 1978-05-24 1979-05-01 International Standard Electric Corporation Method and apparatus for laying up elongate members
JPH0674554B2 (ja) * 1990-11-09 1994-09-21 東京製綱株式会社 索 体

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Publication number Publication date
EP0646674A1 (de) 1995-04-05
DE69322510D1 (de) 1999-01-21
DE69322510T2 (de) 1999-05-06

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