Cable Fairing System

Abstract

A cable fairing system is disclosed which contains a rotatable cable strand pening die connected to a rotatable cable strand closing die by means of a hollow, slotted tube. Bearings respectively connected to brackets attached to a bench support said dies for rotation therein. A feed reel supplies multi-strand cable for threading through said dies and hollow tube, and a take-up reel receives the reconstructed cable after thrums have been inserted between the opened strands thereof by a human or other operator. A controlled motor drives said take-up reel at such speed as to pull the multi-strand cable through the aforesaid dies and tube and still allow the aforementioned thrums to be installed therein immediately prior to the reconstruction thereof.

Description

STATEMENT OF GOVERNMENT INTEREST

The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.

FIELD OF THE INVENTION

The present invention relates, in general, to multi-strand cable and rope making machinery and, in particular, is a unique system for inserting ribbon fairing in previously constructed multi-strand wire cable.

DESCRIPTION OF THE PRIOR ART

Heretofore, numerous methods and means have been employed to insert various and sundry types of fairing along the length of stranded cables and ropes.

For example, simple methods such as opening the strands with a marlin spike or other knife-like devices and inserting ribbons or other filaments under the strands were used. Of course, such method was slow, cumbersome, and usually resulted in an inferior product, due to the manual strength, dexterity, and skill required.

Another method used to insert fairing in cables was to use a single die to open the strands as a result of forcing the respective strands to pass through suitably disposed passageways therein. Unfortunately, this method does not allow for the expansion of the center core of the cable, especially when long segments of faired cable are being fabricated, thereby effecting a non-uniform, deformed, rough, unwieldy, product.

Although satisfactory for some purposes, all of the known prior art cable fairing machinery leaves a great deal to be desired, particularly from the construction and use standpoints.

SUMMARY OF THE INVENTION

The present invention overcomes most of the disadvantages heretofore encountered with the prior art. It incorporates a pair of spatially disposed rotatable dies that are connected together by means of a tube that forces both dies to rotate at the same time and at the same speed. Part of said tube is cut away to allow the center core of the cable being faired to protrude therethrough during the fairing operation. The dies are mounted in bearings in such manner as to allow them to rotate freely therein, and the bearings are, in turn, preferably mounted on brackets having sufficient height to prevent hindrance thereof with ambient objects. Said brackets are, of course, mounted on a table or bench, or on any other suitable support means, as desired.

The cable strands are opened by the first die and stay open through the second die. Ribbon or other type fairing is placed under the outer layer of strands after they pass through the second die (while they are still unlayed) and just before they are again reassembled (or re-layed) as a stranded cable. The cable is automatically unlayed and re-layed by simply pulling it through the dies and at the same time, the fairing is inserted therein, either manually by a human operator automatically by any suitable shuttle type inserter means. Thus, it may readily be seen that ordinary commercially available stranded cable or rope may be converted to faired cable or rope in an expeditious manner without damaging either thereof, and that it may be easily accomplished in situ, wherever the need therefor arises. Accordingly, the subject invention constitutes a new and useful system which, for most practical purposes, is a vast improvement over those of the prior art.

It is, therefore, an object of this invention to provide an improved method and means for installing fairing in stranded cables, lines, or ropes, etc.

Another object of this invention is to provide a unique system which facilitates the conversion of conventional and other stranded cables, lines, or ropes that have fairing installed therein; regardless of whether said fairing is one or more thrums, filaments, hair-like fibers, ribbon, or the like.

Still another object of this invention is to provide an expeditious method and means for constructing faired cables, lines, ropes, and other stranded objects in such manner that no deformation or weakening condition of consequence exists therein.

A further object of this invention is to provide a system for installing fairing in stranded cables and the like that is portable and, thus, easily transported and used in the field or anywhere else faired cables are needed or constructed.

Another object of this invention is to provide a method and means for installing fairing in a stranded cable at a greater rate than heretofore possible.

Another object of this invention is to install fairing in stranded cables having cores without deforming the core, even through considerable lengths thereof are involved, regardless of the type and size of fairing employed.

Another object of this invention is to provide a method and means for installing fairing in a stranded cable, either automatically or by a single, relatively unskilled, human operator.

Another object of this invention is to provide an improved system for fairing a cable, rope, line, etc., that is easily and economically constructed, operated, maintained, transported, and stored.

Other objects and many of the attendant advantages will be readily appreciated as the subject invention becomes better understood by reference to the following detailed description, when considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a block diagram depicting the system constituting the subject invention;

FIG. 2 is an elevational view, partially in cross-section, of the cable strand spreader mechanism of FIG. 1;

FIG. 3 is a side elevational view of the cable opening die of FIGS. 1 and 2;

FIG. 4 is a right end view of the cable opening die of FIG. 3;

FIG. 5 is a side elevational view of the cable closing die of FIGS. 1 and 2;

FIG. 6 is a right end view of the cable closing die of FIG. 5;

FIG. 7 is a plan view of an exemplary manual thrum inserter that may be used in the system of FIG. 1; and

FIG. 8 is a right end view of the thrum inserter of FIG. 7.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the system of FIG. 1, there is shown a feed reel 11 which contains a cable, line, or rope 12 through which fairing is to be inserted.

For the purpose of keeping this disclosure as simple as possible, reel 11 will be considered to contain a conventional twisted strand wire cable of whatever length is necessary to convert it to whatever length of faired cable is desired. In addition, the cable involved may have any number of strands and a core, the latter of which may be either another single wire strand, or it may include one or more internally disposed insulated electrical conductors, as desired.

In this particular embodiment of the subject invention, an adjustable brake 13 is connected to feel reel 11 in such conventional manner as to control the rotation thereof, as the stranded cable is pulled therefrom.

The strands of the front end of cable 12 are manually opened and supplied as a plurality thereof 14 to a cable strand spreader mechanism 15. Said cable spreader mechanism 15 is generally shown in FIG. 1 and more specifically shown in FIG. 2; hence, as appropriate, both of said figures will contain like reference numerals for like parts, and both will now be described concomitantly.

After being opened, cable strands 14 are respectively threaded through die holes 16 in rotatable opening die 17, with the central core, of course, being threaded through a center core hole 18.

A hollow tube 19 is connected between the exit side of rotatable opening die 17 and the entrance side of a rotatable closing die 20 in such manner that said opening and closing dies are rigidly connected together for simultaneous rotation thereof as a unit. Located along practically the entire length of tube 19 is an elongated slot 21 which extends through the wall thereof, thereby effecting an elongated passageway through which the slack portion of the cable core may hang, so as to prevent the deformation thereof and the entire cable upon the subsequent re-laying thereof, as will be described in more detail during the discussion of the operation of the invention presented below. Consequently, it should be understood that the aforesaid tube 19 and especially elongated slot 21 are key elements in the construction of cable strand spreader mechanism, and that the ultimate success of cable reconstruction with the thrums installed therein is contingent upon said key elements being incorporated in the unique combination of elements constituting this invention.

While the core of the cable passes through the center core hole 22, the remaining outer strands of cable 12 pass along the outside of tube 19 and are threaded through die holes 23 of rotatable closing die 20 which are essentially in line with the comparable die holes 16 and 18 of rotatable closing die 17, respectively.

For the purpose of allowing dies 17 and 20 to freely rotate, they are respectively mounted in a pair of bearings 24 and 25 which are, in turn, effectively mounted on a bench stand 26, or on any other suitable support means.

As best seen in FIG. 2, the aforesaid tube 19 is secured within the inside diameter of an exit end pipe portion 27 of die 17 and entrance end pipe portion 28 of die 20, respectively, by means of a pair of set screws 29 and 30 that are screwed tightly into compatibly threaded holes 31 and 32. In addition, it may also be seen that bearings 24 and 25 are, in the instant preferred embodiment of the invention, depicted as being ball bearings with inner and outer races, the former of which holds dies 17 and 20, the latter of which is optionally connected to flanged brackets 33 and 34, respectively, which, in turn, are mounted on the top of bench 26, as by bolts 35 and 36, respectively, or by any other suitable means. However, it should be understood that any other bearing means may be so employed, as bearings 24 and 25, as long as they allow dies 17 and 20 to rotate freely. Dies 17 and 20 will also be described in greater detail in conjunction with FIGS. 3 through 6 subsequently.

Again referring to FIGS. 1 and 2, a thrum inserted 38 is employed to install ribbon or other fairing 39 between the strands of cable 12 prior to closure or re-laying thereof. Said thrum inserter 38 may be a human being who manually inserts sections of ribbons in the cable and then breaks or cuts them off at predetermined lengths from a roll thereof obtained from any suitable thrum supply 41. To facilitate the cutting of said ribbon thrums at some desired length, the supply ribbon preferably has precuts or perforations 42, so that it may be easily broken or cut at such locations. On the other hand, thrum inserter 38 may be a machine that automatically inserts the ribbon in the cable and cuts it off at the lengths that are optimum for any give purpose. The ribbon thrums, of course, may be inserted at any desired angle or angles and in such quantities as to provide any predetermined densities thereof, either partially or entirely around the circumference of the cable. Hence, they may be spaced so as to be a single line of thrums, so as to be several lines of thrums, so as to constitute fairing around the entire circumference of the cable, or so as to effect any other desired geometrical configuration.

After cable strands 14 are again brought together (re-layed), in the beginning they are preferably held in their normal twisted position by a cable clamp 43. Of course, the subsequent pulling of the cable causes the plurality of open strands to be drawn together or re-layed after they leave rotatable closing die 20, and so doing causes each thrum to be firmly held in place by the strands adjacent thereto.

For the purpose of pulling the cable through the strand spreader mechanism and storing the faired cable, a take-up reel 44 is used. It is driven by motor 45, the stopping, starting, and speed of which is regulated by a variable motor control 46. Obviously, many combinations of arrangements may be used; but, for example, if thrum inserter 38 is a human being, motor control 46 may be merely a foot or other operated switch. On the other hand, in the event thrum inserter 38 is an automatic machine, motor control 46 might be a computer which is programmed to cause motor 45 to drive take-up reel 44 at whatever speed is necessary for the optimum operation of thrum inserter 38. Obviously, it would be well within the purview of one skilled in the art having the benefit of the teachings presented herewith to design the thrum inserter - take-up reel-motor-motor control combination to be whatever is necessary for any given operational circumstances.

All of the foregoing elements represented in block form, with the exception of cable strand spreader mechanism 15, are well known and conventional per se. Hence, it should be understood that it is their unique interconnections and interactions with said unique cable strand spreader mechanism that effects the system constituting the subject invention and causes it to produce the improved results herein indicated.

Referring now to FIGS. 3 and 4, there are shown side and front views of the preferred embodiment of rotatable opening die 17 of FIGS. 1 and 2, and especially of FIG. 2. Again, to effect simplicity of disclosure, as appropriate, like parts thereof will be referenced by like reference numerals.

Die 17, in this particular instance, has a cone-like protrusion 51 with a rounded front end 52. Extending through the entire die 17 is the aforementioned core hole 18, which is disposed at the center thereof in such manner that it parallels strand holes 16 that surround it. Protrusion 51, of course, may have any desired configuration, as long as it facilitates the opening of the cable strands as the cable is pulled from right to left. Said protrusion 51 connected to a journal 53, which is that portion of die 17 that is secured by friction or any other suitable means within the inside diameter of the aforementioned bearing 24. A flange 54 is integrally attached to journal portion 53, and the aforesaid pipe 27 is attached thereto for the purpose of holding tube 19 in place therein.

FIGS. 5 and 6 illustrate side and front views of the preferred embodiment of rotatable closing die 20 of FIGS. 1 and 2. Again, as appropriate, like parts thereof will be referenced by like reference numerals.

Entrance end pipe 28 has an inside diameter with threaded hole 32 in the wall thereof, as previously explained. Pipe 28 is integrally connected to a stop flange 55 which is, in turn, integrally connected to bearing journal portion 56, that portion thereof which is supported by the aforementioned bearing 25.

Again, as best seen in FIG. 2, the bearing 25 that holds journal 56 is disclosed as being a ball bearing assembly having inner and outer races; however, it should be understood that any other bearing that is appropriately designed to allow free rotation of closing die 20 as a unit may be substituted therefor without violating the spirit and scope of this invention.

The exit end of die 20 has a base 57 attached to journal 56. Of course, the aforesaid strand holes 23, as well as a core hole 22 extends through the entire die, with the latter mentioned core hole 22 being in alignment with the hollow in tube 19 and the aforesaid core hole 18 of opening die 17.

Because, in its simpliest form, the subject invention is operated by manually inserting ribbon fairing 39 through strands 14 of cable 12 as said strands are being re-layed after passing through closing die 20, an exemplary embodiment of an inserted 38 that may be employed for such purpose is depicted in FIGS. 7 and 8. Said inserter 38 has a hollow blade 61 through which ribbon fairing is threaded. In one wall of blade 61 is a thumbhole or aperture 62 which allows a human thumb to press ribbon 39 against the inside surface of the opposite wall at such times as no relative movement between inserter and ribbon is desired, such as at the time when the ribbon fairing is being thrust through the re-laying strands of cable 12.

MODE OF OPERATION

The operation of the invention will now be discussed briefly in conjunction with all of the figures of the drawing.

The operation, of course, is exceedingly simple, which is one of the advantages of the invention, since it allows unskilled labor to be trained to use it in just a few minutes.

Multiple strand cable 12 is partially unrolled from feed reel 11, the forward strands separated and threaded through a like plurality of holes in open die 17. The center strand or core of cable 12 is threaded through hole 18. The outer strands are pulled along the outside of hollow tube 19 and assume representative positions 63 and 64, say, for an exemplary twisted two strand cable, as illustrated in FIG. 2. Obviously, the more strands the cable has, the more strand positions that occur.

The pulling of the outer cable strands along tube 19 causes the core to be pulled through the hollow thereof; and as such pulling occurs during actual faired cable construction, said core will usually hang out of slot 21 and acquire a position 65 -- as, likewise, best seen in FIG. 2 -- in order to take up the slack therein caused by the relative shortening of the outer strands, when the thrums are inserted therebetween.

The open strands and core of cable 12 are, of course, threaded through holes 23 and 22, respectively, of closing die 20, after which the pulling force thereon as a clamped strand cable causes the strands and core to automatically close. But just before strand closure or re-laying occurs, the ribbon thrums segments are inserted therebetween, and after strand closure occurs, said thrum segments are cut or broken off by the human or other thrum inserter. The normal cable interstrand squeezing force, of course, holds the thrums in their respective places in the finished faired cable.

The aforementioned pulling force is effected by take-up reel 44, once actual construction commences. Motor 45 drives take-up reel 44 at whatever speed is optimum for proper thrum insertion. Of course, it may be started and stopped and/or speed controlled by manually or computer operated motor control 46, as the case may be.

The taughtness of the cable at any predetermined stage within the subject system may also be regulated by properly braking feed reel 11 with brake 13 in conjunction with start-stop speed control 46. Hence, considerable operational versatility within the system can be effected.

Take-up reel 44 may be used as a storage means for the constructed faired cable, and when ready for use, said faired cable may be unreeled therefrom.

From the foregoing, it may readily be seen that the subject invention constitutes a very simple but effective means for installing fairing in any preconstructed multi-strand cable, rope, line, or the like, and, in addition, could be incorporated in the initial production thereof merely by making those design choices which would be necessary to add it as an accessory to presently used systems for the construction thereof.

Obviously, other embodiments and modifications of the subject invention will readily come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing description and the drawings. It is, therefore, to be understood that this invention is not to be limited thereto and that said modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

What is claimed is:

1. A system for installing fairing thrums in a multi-strand cable, comprising in combination:

rotatable means for containing a multi-strand cable in which said fairing thrums are to be installed;

means spatially disposed from said rotatable multi-strand cable containing means for receiving, opening, separating, and closing the strands of said multi-strand cable as a result of said cable being pulled therethrough; and

means connected to said cable for the pulling thereof through said multi-strand cable receiving, opening, separating, and closing means.

2. The device of claim 1, wherein said rotatable means for containing the multi-strand cable in which said fairing thrums are to be installed comprise a rotatable feed reel.

3. The device of claim 1, wherein the means spatially disposed from said rotatable multi-strand cable containing means for receiving, opening, separating, and closing the strands of said multi-strand cable as a result of said cable being pulled therethrough comprises:

a first rotatable die having an axis of revolution, a journal disposed equidistantly around said axis of revolution, a core hole disposed through said first die along said axis of revolution, and a plurality of strand holes disposed through said first die in such manner as to be substantially equidistant from said axis of revolution;

a first bearing disposed around the journal of said first die in such manner as to effectively allow relative rotation therebetween;

a second rotatable die having an axis of revolution substantially in alignment with the axis of revolution of said first rotatable die, a journal disposed equidistantly around said axis of revolution, a core hole disposed through said second die along the axis of revolution thereof, and a plurality of strand holes disposed through said second die in such manner as to be equidistant from the axis of revolution thereof;

a second bearing disposed around the journal of said second die in such manner as to effectively allow relative rotation therebetween;

a slotted hollow pipe connected between said first and second rotatable dies along extensions of the axes of revolution thereof in such manner as to effect rotation thereof as a unit; and

means connected to said first and second bearings for the support thereof at a predetermined location.

4. The device of claim 3, wherein said means connected to said first and second bearing for the support thereof at a predetermined location comprises:

a pair of brackets respectively connected to said first and second bearings; and

a bench connected to said pair of brackets in such manner as to effect the rigid holding thereof at said predetermined location.

5. The device of claim 1, wherein said means connected to said cable for the pulling thereof through said multi-strand cable receiving, opening, separating, and closing means comprises:

a rotatable take-up reel; and

a motor connected to said rotatable take-up reel for the rotational driving thereof.

6. The device of claim 1, wherein said means connected to said cable for the pulling thereof through said multi-strand cable receiving, opening, separating, and closing means comprises:

a rotatable take-up reel;

a motor connected to said rotatable take-up reel for the rotational driving thereof; and

an adjustable motor control connected to said motor for starting, stopping, and regulating the speed thereof.

7. The invention of claim 1, further characterized by means disposed adjacent to said multi-strand cable receiving, opening, separating, and closing means for inserting fairing thrums between the strands of said cable immediately prior to the closing thereof.

8. The device of claim 1, further characterized by adjustable brake means connected to said rotatable multi-strand cable containing means for regulating the speed and tension at which the cable contained thereby is received by the aforesaid cable strand receiving, opening, separating, and closing means.

9. A system for installing fairing thrums in a multi-strand cable, comprising in combination:

a rotatable feed reel upon which is wound the multi-strand cable in which fairing thrums are to be installed;

a first rotatable die having an axis of revolution, a journal disposed equidistantly around said axis of revolution, a center core hole disposed through said first die along said axis of revolution, and a plurality of outer strand holes disposed through said first die in such manner as to be substantially equidistant from said axis of revolution;

a second rotatable die having an axis of revolution substantially in alignment with the axis of revolution of said first rotatable die, a journal disposed equidistantly around said axis of revolution, a center core hole disposed through said second die along the axis of revolution thereof, and a plurality of outer strand holes disposed through said second die in such manner as to be equidistant from the axis of revolution thereof;

a hollow pipe connected between said first and second rotatable dies along extensions of the axes of revolution thereof in such manner as to be in alignment with the center core holes thereof and to effect rotation thereof as a unit;

an elongated slot located in the wall of the aforesaid hollow pipe;

a first bearing disposed around the journal of said first die in such manner as to effectively allow relative rotation therebetween;

a second bearing disposed around the journal of said second die in such manner as to effectively allow relative rotation therebetween;

a pair of mounting brackets respectively attached to said first and second bearings;

a bench connected to said pair of mounting brackets for support thereof;

a clamp attached to said multi-strand cable after the center core strand and the outer strands thereof have been threaded through the aforesaid core and outer plurality of holes in said first die, said hollow pipe, and said second die, respectively, for effecting the urging thereof toward a closed multi-strand cable condition as it is pulled along;

a rotatable take-up reel connected to the clamped end of said closed multi-strand cable for the pulling and storing thereof thereon;

a motor connected to said take-up reel for the rotational driving thereof, so as to effect the pulling and storing of said closed multi-strand cable thereon; and

a motor control connected to the aforesaid motor for starting, stopping, and speed regulation thereof.

10. The invention of claim 9 further characterized by a thrum inserter disposed adjacent to said multi-strand cable at a position where the multi-strands thereof are closed for the timely insertion of fairing thrums between the strands of said cable immediately prior to the closing thereof; and

means effectively connected to said thrum inserter for supplying fairing thrums thereto.