GB2036119A - Method of Manufacturing Twisted Wire Product and Product Made by this Method - Google Patents

Abstract

Wires 2 are wound and simultaneously laid directly on the core 1 of the product to form a wound layer 3 between the adjacent wires of which there are peripheral spaces 4 constituting from 15 to 70 per cent of the wire diameter. The partly finished twisted wire product made in this manner is subjected to compression so as to cause its plastic deformation in order to obtain the desired shape and size. The wires of the wound and compressed layer 7 of the finished product have a contact with the core substantially along the surface thereof as a result of compression applied to the product so as to cause its plastic deformation to produce the desired shape and size. <IMAGE>

Description

SPECIFICATION Method for Manufacturing Twisted Wire Products and Product Made by This Method The present invention relates to twisted wire products and more particularly to methods of manufacturing twisted wire products and to constructions of products, such as ropes, made by these methods.

The invention is most suited for manufacturing rope strands and cores, wire armouring of the electric cables, overhead bimetallic power cables and the like.

The present invention contemplates the provision of a method for manufacturing twisted wire products, wherein wires are wound and simultaneously laid on the core to form a wound layer between the wires of which there are provided peripheral spaces, whereupon a partly finished product is subjected to compression so as to cause a plastic deformation thereof so that it acquires over its cross-section the desired shape and size.

It is possible to wind and lay the adjacent wires of the layer being wound with peripheral spaces therebetween. Such spaces between the adjacent wires of the wound layer permit the range of the wire-core ratio to be increased and, consequently, the number of wire sizes to be considerably reduced.

It is also possible that wires of the layer being wound be wound and laid so as to form groups of wires each such group containing at least two wires, with peripheral spaces being provided between adjacent groups. Such method makes it possible to manufacture twisted wire products, such as ropes, having a higher degree of flexibility, which ensures improved reliability and durability of the product.

It is expedient that the spaces between the wires of the wound layer be in the order of 1 5 to 70 per cent of the diameter of these wires. The peripheral spaces constituting less than 1 5 per cent of the diameter of the wires are not advisable since in such a case the effect of the present method is not attainable, whereas the spaces constituting more than 70 per cent of the wire diameter necessitate a considerable compression force which perhaps may cause the shape of the outer layer wires to change, bringing down reliability and durability of the twisted wire product.

The wires of the layer being wound may be laid so that part of them will protrude radially above the rest of wires, the protruding wires being in contact with one of the core wires, whereas the rest of wires having a contact with two core wires. The product is then radially compressed until every wire of the wound layer get in contact substantially with one wire of the core.

It is advantageous that in manufacturing twisted wire products comprising a plurality of wire layers, winding and laying on the wires over the previously wound layer be done successively, with the peripheral spaces being provided between the wires, applying compression to the produced twisted wire product after the wound layer has been laid with the peripheral spaces between the adjacent wires.

According to the present invention there is also proposed a twisted wire product made by the proposed method, comprising a core with at least one layer of wires wound thereon and having the desired shape and size obtained as a result of its having been radially compressed, the wires of the wound layer, according to the invention, have a contact with the core substantially throughout the surface thereof.

The adjacent wires of the wound layer in the spun wire product may be laid with respect to each other so as to form between them peripheral spaces constituting from about 1 to 10 per cent of the product diameter. The peripheral spaces permit peripheral movement of the wires of the wound layer when the product is bent to a small radius, for example, on the drums, fleet wheels, and the like means having a small diameter.

It is advisable to lay the adjacent wires of the wound layer in the twisted wire product, such as a rope, so that they be in contact with each other along the helical lines, which permits the wires to turn about their axes without deforming the shape of the product.

It is advantageous to lay the adjacent wires of the wound layer in the twisted wire product, such as a rope, so that they have a contact with each other along the helical planes, which enables manufacture of a durable and compact product.

It is expedient that the adjacent wires of the wound layer in the twisted wire product, such as a rope, be laid in groups containing each at least two wires. It is also advisable that there be peripheral spaces between the groups of wires, the adjacent wires in each group being in contact with each other.

The invention will now be described in greater detail with reference to specific embodiments thereof, taken in conjunction with the accompanying drawings, wherein: Fig. 1 is a cross-sectional view showing laying of wires of the wound layer over the core of the product before compression according to the invention; Fig. 2 is a view similar to that shown in Fig. 1, illustrating the position and shape of the wires of the wound layer after compression; Fig. 3 is a cross-sectional view 7 a 1+5 construction before (thin line) and after (solid line) compression; Fig. 4 is a cross-sectional view of a 1+6+6+6+12 construction before (thin line) and after (solid line) compression; Fig. 5 is a cross-sectional view of a 1+8+8 construction before (thin line) and after (solid line) compression;; Fig. 6 is a cross-sectional view of a 1+6+6 construction before (thin line) and after (solid line) compression; Fig. 7 is a cross-sectional view of a 1+5+12 construction before (thin line) and after (solid line) compression; Fig. 8 is a cross-sectional view of a 4+8 construction before (thin line) and after (solid line) compression; Fig. 9 is a cross-sectional view of a 1+6+12+12 construction before (thin line) and after (solid line) compression; Fig.10 is a cross-sectional view of a 1+6+12+12 multi-layer construction before (thin line) and after (solid line) compression; Fig. 11 is a cross-sectional view of a 1+6+12+12+24 multilayer construction before (thin line) and after (solid line) compression;; Fig. 1 2 is a cross-sectional view of a 1+6+12+18+12/6 construction before (thin line) and after (soiid line) compression; Fig. 1 3 is a cross-sectional view of a 1+6+12+18+24+12/12 construction before (thin line) and after (solid line) compression; Fig. 14 is a cross-sectional view of a product wherein the core is formed from a material having a lower strength than wires of the wound layer; Fig. 1 5 is a cross-sectional view of a product made from wires of different size; Figs. 1 6, 1 7 are crosssectional views of a product having an oval and trihedral shapes.

According to the requirements that a twisted wire product is to meet one prepares a required number of wires having corresponding size, shape and mechanical properties.

Wires 2 (Fig. 1) are wound and laid directly on a core 1 of the wire product being manufactured to form a wound layer 3, winding and laying being done so as to form peripheral spaces 4 between the adjacent wires 2. A partly finished twisted wire product made in this manner is compressed with the aid of a reducing means (not shown) which may be a reducing die, rolls, etc.

When the product is compressed, the wires of the wound layer under action of the compression force F of the reducing means, deform and, due to their being free from contact with each other, transfer this force onto the core 1 providing for a uniform reduction of the product over its cross section.

As the core 1 reduces counteracting to the compression force, the metal of wires redistributes along the periphery due to the presence of the peripheral spaces between the wires of the wound layer. An unimpeded transfer of the pressure force P onto the core can take place only when the metal of wires 5 (Fig. 2) of the wound layer redistributes peripherally until said wires get in contact 6 with each other along helical surfaces, i.e. until a tightly compressed circular layer 7 is formed.

The core 1 is a central member of the product.

In general, the core may comprise one or plurality of wires, one-layer or multilayer twisted wires strands, and other similar twisted wire products of different sizes and shapes.

Since compressed circular layer 7 is formed after the reduction of the product over its cross section a high strength and durability of the finished twisted wire product are ensured.

At the same time, since there is no necessity to overcome a resistance of the compressed circular layer the compression force necessary for the reduction of the product is considerably reduced, which simplifies reducing means and the process of reduction.

Presence of the spaces between wires of the wound layers permits the range of the ratio between the wires of this layer and the core, to be increased whereby bringing down the number of standard sizes used in the product. In some products this ratio may be equal to 1, that is all the wires making up the product have the same diameter.

It is necessary, however, to take into consideration that the spaces between said wires, constituting less than 1 5 per cent of the diameter thereof, are not advisable as the tight circular layer starts to form, in fact, at the very beginning of the reduction. On the other hand, when these spaces are larger than 70 per cent of the wire diameter, there arises the necessity to increase the compression force in order to provide for the maximum diminishing of the initial spaces to form a finished product.

Given below are examples of application of the present method for manufacturing twisted wire products.

Example 1 Fig. 3 represents a cross section of an alternative product of the 1+5 construction, comprising a core 1 (central wire) and five wires 2 of the wound layer. According to the proposed method the adjacent wires 2 were wound and laid so as to form peripheral space 4 constituting about 15 per cent of the wire diameter (Fig. 3, left). The product made in this way was subjected to compression to initiate its plastic deformation (Fig. 3, right). As a result of compression the wires acquired substantially trapezoidal shape. The adjacent wires got in contact with each other and with the core 1 along helical surfaces 6 and 8, respectively.

Provision of spaces of about 1 5 per cent on the similar products allows manufacture thereof from wires of the same diameter.

Example 2 Fig. 4 represents a cross section of an alternative product of the 1+6+6/6+12 construction (6/6 means that the wires are of different diameters), comprising a core 1 having a central wire and two layers made up of wires 2 and 10 with different diameters. Twelve wires 2 were wound and directly laid on the core 1 to form a wound layer 3. The wires were wound and laid so as to form between them spaces of about 35 per cent of the diameter thereof. As the wires making up the core may be of different diameters, the wires of the layer being wound may be laid with different spaces 4 and 41 successively following each other and varying in size from each other by 50 per cent.

The product obtained as a result of compression is uniformly reduced, with deformed wires 5 of the wound layer contacting each other along the helical surfaces 9 and the core along the helical surfaces 8.

Thus, owing to the presence of the peripheral spaces between adjacent wires, of about 35 per cent of the diameters thereof, it was possible to manufacture the product from wires 2 and 10 of two different diameters. To make a product having then same characteristics by known methods, wires of four different diameters, as a minimum, are needed.

Example 3 Fig. 5 represents a cross section of an alternative product of the 1+8+8 construction, comprising a core 1 consisting of a central wire 11 and a layer of eight wires 12. Eight wires 2 were wound and laid directly on the core 1 up to the contact therebetween to form a wound layer.

The wires were wound and laid so as to form spaces of about 70 per cent of the wire diameter between them.

The product obtained as a result of compression was uniformly reduced with deformed wires 5 having a contact with each other along the helical lines 1 3 and with the core along the helical surfaces 8.

The uniform deformation of the product over its whole cross section improves its compactness, strength and durability owing to the increased contacts along the helical surfaces 8 between the wires of the wound layer and the core. In addition peripheral spaces of about 70 per cent of the wire diameter enable the manufacture of a product the layers of which are made up to wires 2 and 12 which are close in their size. At the same time manufacturing similar products by known methods requires either the wires with considerably different sizes or more wires with different diameters.

Example 4 Fig. 6 represents an alternative product of a 1+6+6 construction. The product comprises a core 1 including a central wire 11 and six wires 12 of the first layer. Six wires 2 were wound and laid over the core 1 to form a layer with peripheral spaces of more than 70 per cent of the wire diameter.

In the product obtained as a result of compression between deformed wires 5 of the wound layer there were formed peripheral spaces 14, the wires being in contact with a core along the helical surfaces 8.

It can be seen from the above example (Fig. 6) that with the increase of the peripheral spaces the shape of the wires of the wound layer greatly deforms as a result of compression, which, in some cases, may be not desirable, in particular, when the product has to bent to a small radius.

Example 5 Fig. 7 represents an alternative multilayer product of a 1 + 5+12 construction. Said product was manufactured in the following way. Wires were wound and laid over a core 1 represented by a central wire to form the first layer in which the adjacent wires are located with peripheral spaces (as shown in Fig. 3). The product was then subjected to compression. Wires 2 of the next layer 3 were laid upon the previous layer on the deformed wires 5 to form peripheral spaces 4 and then subjected to compression to form the finished product, in which the deformed wires 51 were in contact with each other along the helical surfaces 6 and with the core along the helical surfaces 8.

As can be seen from the above example, compression to each layer of the product was applied after laying of the wound layer in which there were peripheral spaces between adjacent wires.

This permits manufacture of products higher compactness and strength with decreased contact stresses between layers, which ensures their better durability.

Example 6 Fig. 8 represents an alternative multilayer product of a 4+8 construction, comprising a core 1 including four wires. The product was manufactured in the following way. Wires 2 and 21 were wound and laid over the core 1 so that some of them, namely wires 21, radially protruded above the rest of the wires namely wires 2. The protruding wires 2' were in contact with one wire of the core whereas the wires 2 were each in contact with two wires of the core 1.

Products made in this way are not, substantially, round in cross section which permits their manufacture using wires the lesser number of standard sizes. As a rule, the number of the protruding wires 2' and wires 2 may be not equal. Compression was applied to the product until each wire 5 of the wound layer as a result of a peripheral shift got in contact with only one wire of the core.

Owing to the above arrangement of the wires the finished product features, practically, uniform deformation of wires 5 and more uniform mechanical properties over its cross section. This enables manufacturing of such a product from wires of the same diameter.

Example 7 Fig. 9 represents a cross-sectional view of an alternative multilayer product of a 1+6+12+12 construction comprising a core 1 including a central wire and two layers formed from wires 2 having the same diameter. The product was made by winding and laying over the core 1 up to the contact therewith twelve wires 2 of the same diameter as the core wires, to form a wound layer 3, the wires being wound and layed so as to form groups containing two wires, with spaces 4 being provided between said groups, constituting 80 per cent of their diameter.

As a result of compression there was made a finished product (solid lines) wherein a uniform deformation was obtained all the way to the contact of the deformed wires 5 of the wound layer with each other along the helical surfaces 9 and with the core along the helical lines 3, with peripheral spaces 4 of about 10 per cent of the product diameter being formed between the adjacent wire groups of the finished product.

Thus, owing to the initial peripheral spaces of about 80 per cent between the adjacent wire groups, it was possible to make a product utilizing wires of the same diameter. To manufacture a product of such a quality by the known methods, four different wire sizes, as a minimum, are needed. Besides, the finished product having peripheral spaces of about 10 per cent between the groups of wires, features improved flexibility ensuring a higher durability of the product used on the load-lifting mechanisms with a ratio of D/d < 1 5, where D is a diameter of a fleet wheel or drum (not shown), and d is a diameter of the product, i.e. rope.

Example 8 Fig. 10 represents a cross-sectional view of an alternative multilayer product a 1+6+12+12 construction, comprising a core 1 including a central wire and two layers of wires 16 of the same diameter. Wires 2,17 were wound and laid over the core 1 (thin lines) so as to form a layer made up of wire groups between which there were formed spaces 4 of about 90 per cent of the wire diameter. Some of the wires, say wires 2, protruded radially above the rest, i.e. the wires 17, said wires 2 being in contact with one wire of the core 1, and the wires 1 7 having a contact with two wires of the core 1. The twisted wire product obtained was not round in cross-section and was similar to that in example 7.

The product was compressed so that the wire 5 of the wound layer had a contact, as a result of the peripheral shift, with two wires of the core 1.

With above arrangement of wires, the resulting product features a practically uniform deformation of the wires 5 and more uniform mechanical properties of the wires over the crosssection of the product, which permits manufacture of a durable and compact product utilizing wires of two diameters.

Example 9 Fig. 11 represents another alternative multilayer product of a 1+6+12+12+24 construction, which was made in the following way. Wires were wound and laid over a core 1 of the twisted product of the 1+6+12 construction to form a wire layer wherein the wires were arranged in groups with peripheral spaces therebetween (as shown in Fig. 10). The obtained product was subjected to compression, whereafter on the previously laid layer of wires 5 there was wound and laid a next layer of wires 18 and 1 9 so that they were arranged in groups with peripheral spaces therebetween constituting about 1 5 per cent of the wire diameter, some of the wires, namely wires 19, protruding radially above the rest of the wires, namely wires 1 8.As a result, the wires 19 has a contact with one wire of the core 1, whereas the wires 1 8 had a contact with two wires of the core 1. The twisted wire product obtained was not round in cross-section and was similar to that in examples 7 and 8.

Compression to the product was applied so as to cause every wire of the wound layer to have a contact with one wire of the core. Thus, the finished product was substantially a plastically deformed one obtained as a result of its being compressed layer by layer. As can be seen from the above example, compression to each wire layer of the product was applied after laying of the wound wire layer wherein there were peripheral spaces between the adjacent groups of wires, which permits manufacture of a durable and compact product featuring reduced contact stresses between layers, which in turn ensures its longer service life.

Thus, owing to the initial peripheral spaces 26 of about 40 per cent between the adjacent groups of wires, it became possible to make a product with more uniform mechanical properties over its cross-section.

In addition, the finished product having peripheral spaces of about 2 per cent between the wire groups features better flexibility ensuring increased durability of the product used on the load-lifting mechanisms with a ratio of D/d < 1 5, where D is a diameter of the drum of a lifting mechanism, and d is a diameter of the product.

Example 10 Fig. 12 represents still another alternative product of a 1+6+12+18+12/6 construction, comprising a core 1 having a central wire and three layers formed from wires of the same diameter, which was produced by winding and laying over and the core twelve wires 20 and six wires 21 of different diameters up to the contact with to form a wound layer 3. The wires 20 and 21 were wound and laid so as to form wire groups of three wires each, and spaces 4 of about 90 percent of the diameter of the wires 21 between said groups.

As a result of compression there was made the finished product wherein there was obtained a uniform deformation all the way to the contact of the deformed wires 20 and 21 of the wound layer with each other along the helical surfaces 9, and with the core 1 along the helical surfaces 8, with the peripheral spaces of about 5 of the product diameter being provided between the adjacent wire groups of the finished product.

Thus, owing to the initial peripheral spaces of about 90 per cent between the adjacent wire groups, it became possible to make a product featuring more uniform mechanical properties over its cross-section.

In addition, the finished product having peripheral spaces of about 5 per cent between wire groups features improved flexibility ensuring increased durability of the product used on the lifting mechanisms with a ratio of D/d < 20, where D is a diameter of the drum of a lifting mechanism and d is a diameter of the product.

Example 11 Fig. 1 3 represents a cross-sectional view of a further alternative product of a 1+6+12+18+24+12/12 construction, comprising a core 1 having a central wire and four wire layers formed from wires 22 of the same diameter. The product was made by winding and laying over the core 1 twelve wires 23 and twelve wires 24 up to the contact therewith, to form a wound layer 3. The wires were wound and laid so that they formed wire groups 25 each containing four wires, and between which there were provided peripheral spaces 26 of about 40 per cent of the joint diameter of the wires 24 and 23.

As a result of compression there was made a product wherein a uniform deformation was obtained all the way to the contact of wires 23 and 24 of the wound layer with each other over the helical surfaces 9 and with the core 1 over the helical surfaces 8, with peripheral spaces of about 2 per cent of the product diameter being provided between the adjacent groups of wires.

The proposed method can be applied for manufacturing products, such as ropes, wherein the wires of the wound layer have a surface contact with the core substantially the surface thereof. The following modifications of the above product are possible.

Fig. 4 illustrates a product, such as a rope, in which the contact 8 between the wires 5 of the wound layer and the core along a helical surface is larger than contact 9 between wires 5 along a helical surface.

Fig. 5 illustrates a product such as a rope, in which the contact 8 between the wires 5 and the core along a helical surface is larger than the contact 1 3 between the wires 5 along a helical line.

Fig. 6 illustrates a product, such as a rope, in which the contact 8 between the wires 5 and the core along a helical surface is prevailing one as between the wires 5 there is a space 14.

Such construction of products provide relative shift of wires of the wound layer with respect to each other when above products are in use without deforming distorting the shape thereof, which increases their durability.

The above examples relate to the cases when the core and the wound layer are made from wires having about the same ultimate strength. It is advantageous in some cases to use a milder core, i.e. with a lesser ultimate strength than that of the wires of the wound layer. In such a case, under the action of the compression force the wires 5 of the wound layer are pressed in the core 1 without substantially changing their shape at the point of contact therewith (Fig. 14).

In the above examples of manufacturing products the wires of the wound layer are of the same size. There may be cases when the wires 5 and 5' of the wound layer differ in size. In this case the wires of the wound layer may acquire a shape like that shown in Fig. 1 5.

Other shapes of wires of the wound layer after compression are also possible, which depends on the material used for the core and wires of the wound layer, and on the degree of the product reduction.

It is possible to make, applying this method, products not only of a circular shape but of other shapes as well, and, in particular, of an oval one (Fig. 16) when wires 5 and 51 are laid on the core having an oval shape, trihedral shape (Fig. 17) when wires 5 and 51 are laid on the core of a trihedral shape and other shapes.

Initial shape of the cross-section of wires of the wound layer may also differ from a round one and may be oval or other one.

While particular embodiments of the invention have been shown and described, various modifications thereof will be apparent to those skilled in the art and therefore it is not intended that the invention be limited to the disclosed embodiments or to the details thereof and the departures may be made therefrom within the spirit and scope of the invention as defined in the

Claims (14)

claims. Claims

1. A method for manufacturing twisted wire products of a desired shape and size in crosssection, wherein wires are wound and simultaneously laid on the core to form a partly finished product having spaces between its adjacent wires, and the partly finished product is compressed to cause it to plastically deform so that it acquires the desired shape and size.

2. A method as claimed in claim 1, wherein adjacent wires of the layer being wound are wound and laid so as to form peripheral spaces between them.

3. A method as claimed in claim 1, wherein the wires of the layer being wound are wound and laid so as to form wire groups each comprising at least two wires, with peripheral spaces being provided between said wire groups.

4. A method as claimed in claim 2 or claim 3, wherein the peripheral spaces constitute from about 15 to about 70 per cent of the diameter of the wound wires.

5. A method as claimed in claims 1 and 2 or 3 and 4, wherein wires of the layer being wound are laid so that some of them protrude radially above the rest of wires, the protruding wires being in contact with one wire of the core, whereas the rest of wires are in contact with two wires of the core, and compression is applied to the partly finished product until the wires of the wound layer come into contact substantially with one wire of the core.

6. A method as claimed in any preceding claim, wherein twisted wire products comprising a plurality of wire layers are manufactured by successively winding a layer of wires on a previously wound layer, with compression being applied to the partly finished product after the successive layer of wires has been completely laid with peripheral spaces between its adjacent wires.

7. A twisted wire product, such as a rope, manufactured by the method claimed in claim 2, comprising a core and at least one wound layer of wires in contact with the core substantially along the surface thereof, the product having in crosssection a desired shape and size.

8. A twisted wire product, such as a rope, wherein between the adjacent wires of the wound layer there are provided spaces constituting from about 1 to 10 per cent of the product diameter.

9. A twisted wire product, such as a rope, as claimed in claim 7, wherein adjacent wires of the wound layer are in contact with each other along helical lines.

10. A twisted wire product, such as a rope, as claimed in claim 7, wherein adjacent wires of the wound layer are in contact with each other along helical surfaces.

11. A twisted wire product, such as a rope, manufactured by the method of claim 5, wherein wires of the wound layer are arranged in groups comprising at least two wires, with spaces provided between said groups, the adjacent wires in each group, being in contact with each other.

12. A method of manufacturing twisted rope products, substantially as described hereinabove with reference to any one embodiment shown in the accompanying drawings.

13. A method of manufacturing twisted wire products, substantially as herein described with reference to any one of the foregoing Examples.

14. A twisted wire product, substantially as herein described, with reference to any one embodiment shown in the accompanying drawings.

1 5. A twisted wire product, substantially as herein described, with reference to any one of the foregoing Examples.