The Related Art

Invention relates to cable production system enabling weaving and outer casing process application and thus making diameter smaller without use of piping or filling thank to round structure formed by means of combining cores in twisting process.

Invention particularly relates to cable production system providing reduction in diameter by means of round structure in twisting process by means of achieving a angular form of 120 ° in 3-core cables, 90 ° in 4-core cables, 72 ° in 5-core cables for conductors and round structure by combining cones together upon passing through twisting space formed between slab a and slab b in insulation production process.

Background of the Invention

Today conductive cables are used to transmit electric energy from one point to another. The biggest novelty experienced after invention of and actively starting to use electricity is the change made in inner structure of electric cables. Use of copper wire in said cables as conductor is common because it is easy to find it. Basic components of an electric cable are conductivity and insulation. Conductor transmit current through cable and insulation protects electricity in the conductor. Further additional coatings are made to cables in order to protect and make use life longer. The material mostly as conductor in an electric cable is copper but in some cases aluminium can also be used.

The first manufacture process of a conductor is wiring process. This includes reduction of copper wire diameter to the last diameter gradually in order to increases conductivity and reduce skin effect. Copper wires are delivered to cable factories in standard thickness and in bobbin. Copper wires delivered to factory in standard thickness and ready for processing are conveyed to thinning machines at factory subject to need or thickness of cable to be produced. Thinning machines contain rolling mill capable to be thinned from 1.8 mm to 0.2 mm. Copper wires of bobbin shape is processed at required thinness by processing at thinning machine. Copper wires thinned at desired thickness are sent to machine called tampering machine and hardness of the copper is softened here and brightness is examined. Copper wire undergoes tampering process in order to obtain bright color. Copper not undergoing tampering process is rigid. Copper wires delivered to factory in raw forms undergo stages such as thinning, softening and polishing and are made ready for processing. Thinness or thickness of the cable is fixed on basis of need. Copper wires of which operation is finished are sent to coating machine. Required chemicals are melted by heating according to feature of the product. After cables are cooled down at cooling machine, they are sent to a control system to check for any errors in coating of cable at a higher voltage machine. Chemicals used in coating of copper in cable manufacturing may show difference subject to area of use. If a cable to be laid under floor is to be manufactured, PVC-PE is used in outer coating of cable. Different chemicals are used in cables used in indoor or small house appliances. Type of chemicals in the coating part of cable varies because of causes such as humidity; dryness of the area where cable is laid If cable is to be laid in an area to taken strike, form of chemical to be used is produced in a resistant structure and at high temperature. Insulation material of high temperature resistance used in cables permits conductor to conduct more power from same area and an insulation of lower temperature resistance. Full length of cable is subjected to a voltage test for no failure in insulation coating. Electric coatings insulate signals transmitted through cable against potential external interactions. It also protects power cables in order to prevent intervention to adjacent signal circuits. Mechanic covers also called armor protects cable against stroke, rodents and other external damages arising from potentially damaging causes. In general an outer polymer coating is applied to protect cables. This coating is called outer sheath. The sheath protects conductors and insulation against outer factors such as humidity and mechanical aggressions that might affect electrical features.

In the cable production system in use today, conductor is twisted in round form and then extrusion is applied to provide insulation. In current method cable cores are brought together by twisting process but spaces remain between them. Said spaces are coated by extrusion when making cable in the next process or inner coating is made to provide round form, This method causes bigger cable diameter. Bigger cable diameter causes less cable laying in small areas in particular, use of more materials during extrusion stage and thus increase in cost.

One of the methods applied in cable production today is disclosed under the invention numbered EP2785968B1 entitled “Method for producing a cable core having a conductor surrounded by an insulation for a cable, in particular for an induction cable, and cable core and cable”. The invention is a production method for producing a cable core for an induction cable in a simple and simultaneously reliable manner, in which a raw conductor is fed continuously to a processing machine and separated in a recurring manner at specified length positions at a separating point so that there are two wire ends. Said ends are then pulled apart from each other in the longitudinal direction of the cable and then connected again by a connector which has an insulating spacer which separates the wire ends from each other by a specified distance. The connector is preferably designed as an injection moulded part, in particular using the online process. A plurality of such cable cores are connected to each other via a cabling process and then enclosed by a cable sleeve to produce the induction cable.

As a result, the need for cable production system eliminating the disadvantages available in the related art and inadequacy of existing solutions have necessitated development in the related art.

Brief Description of the Invention

Invention relates to Class5 - Class 6 conductive flexible cable production system enabling weaving and outer casing process application and thus making diameter smaller without use of piping or filling thank to round structure formed by means of combining cores in twisting process, and meeting the needs mentioned above, eliminating all disadvantages and providing some additional advantages.

From background of the related art, the purpose of the invention is to provide obtaining a round structure and reduction in cable diameter without use of piping or filling to make weaving and outer sheath process by help of using slab set in Class5 - Class 6 conductive flexible cable production system.

Purpose of invention is to obtain round structure when cores are brought together by help of passing conductor through twisting space formed between slab a and slab b forming slab set and giving triangle form in Class5 - Class 6 conductive flexible cable production system.

Another purpose of invention is to provide application of woven and outer sheath process thanks to production of round structure in twisting process without need for use of pipe or filling in Class5 - Class 6 conductive flexible cable production system.

A further purpose of the invention is to provide laying more cable in smaller areas, using less material in extrusion, facilitating mounting, reducing total cable weight thanks to reducing diameter and thus reducing sheath, filling, weaving screen amount and thus providing cost advantage in Class5 - Class 6 conductive flexible cable production system.

Another purpose of the invention is to provide sector (triangle) form at 72° 90°and 120° to round conductors by means of sector machine used in Class5 - Class 6 conductive flexible cable production system.

A further purpose of the invention is to provide obtaining round surface by help of slab b contained in slab set used in Class5 - Class 6 conductive flexible cable production system.

Another purpose of the invention is to provide protection of form during production of flex copper insulation converted into sector (triangle) form thanks to conductor twisting end used in Class5 - Class 6 conductive flexible cable production system.

The structural and characteristics features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account the said figures and detailed explanations.

Brief Description of Figures

In order to make the embodiment and additional members being subject of the present invention as well as the advantages clearer for better understanding, it should be assessed with reference to the following described figures.

Figure 1 - work flow chart of cable production system

Figure 2 - schematic general view of slab set a.

Figure 3 - schematic general view of slab set b.

Figure 4 shows general schematic view of the twisting end

Figure 5 is schematic general view of copper given sector (triangle) form

Figure 6 shows general schematic view of insulation coated copper.

Figure 7 shows general schematic view of the twisting core formed

Figure 8 shows general schematic view of the cable cross-section.

Reference Numbers

10. Cable 1 1. Copper

12. Insulation

13. Core

14. Outer sheath 20. Slab a set

30. Slab b set

40. Twisting end

Detailed Description of the Invention

In this detailed description, Class5 - Class 6 conductive flexible cable production system enabling weaving and outer casing process application and thus making diameter of cable (10) smaller without use of piping or filling thank to round structure formed by means of combining cores (13) in twisting process, being subject of the invention has been disclosed only as an illustrative example for the purpose of better understanding of the subject and described in a manner not causing any restrictive effects

In the cable production system developed for obtaining cables having thin wire conductor copper (11 ) and shown in figure 1 , copper (1 1 ) passing through twisting end (40) located in space form formed between slab set a (20) and slab set b (30) is given triangle form at 120° in 3-core(13), in 4-core (13) cables (10) 90° angle triangle form, in 5-core (13) cable (10) 72° angle triangle . When co res (13) in said triangle form are brought together, a round structure is obtained and diameter of cable (10) in twisting process is reduced thanks to this round structure. In said cable production system, round copper (1 1 ) firstly reaches copper twisting line. Slab set a (20) and slab set b (30) located in sector machine on said copper twisting line close onto each other and gives angular triangle (sector) shape to the copper (1 1 ). Said sector machine gives sector (triangle) forms in three different angles namely, 72° 90°and 120°to round conductors thanks to slab set a (20) and slab set b (30) it contains. Said conductor is given spring shape form on two edges having angle with each other in internal part of cores (13) facing each other and outer surface facing insulation material opposite two edges in a manner to form round structure when brought together. Said slab set a (20) shown in figure 2 is in three different angels in order to give sector (triangle) form to conductors at different angles to conductors, 72° 90°and 120“angles. Said slab set (b) (30) shown in figure 3 provides obtaining round surface on angular corners of conductors. Twisting end (40) formed upon closure of said slab set a (20) and slab set b (30) onto each other and shown in figure 4 has round form on one surface and angular form on the other. Said twisting end (40) provides protection of form of flex copper (1 1 ) concerted into sector (triangle) form during insulation process. On said sector machine, two edges having angles with each other and given spring form on surface opposite said edges as shown in figure 5 the copper (1 1 ) comes to insulation line later. Said triangle copper (1 1 ) is coated with insulation material in insulation line and thus cores (13) are formed. Insulation machine used in said insulation line is mainly extrusion machine and coats copper (1 1 ) with PVC, XLPE, PE, HFFR, EPDM, TPU, TPE or a similar material. PVC (Poly vinyl chloride) is a Polyvinyl chloride based special thermoplastic insulation agent used in low and medium voltage cables. Thermoplastic insulators are the plastics getting hardened by repeatable cooling at a certain temperature range and getting soft by heating and not transforming when softened without any external effect and keeping its insulation feature. XLPE is a Thermoset insulation material with developed mechanic features and obtained by applying polyethylene having high insulation features through various methods and cross-bonding thereof. Thermoset insulators do not melt and deform at high temperatures. PE (Polyethylene) is a thermoplastic used in many various products. It takes its name from ethylene of monomer form and is produced by use of ethylene. FIFFR (Flalogen Free Flame Retardant) is compound consisting of Ethylene Vinyl Acetate (EVA), Aluminum Tri Flydroxide (ATH) and Polyethylene (PE). EPDM (Ethylene Propylene Diene Monomer) provides perfect resistance against external environment conditions and environments of low temperature thanks to its natural features as elastomeric material. EPDM is a kind to polymer material produced by copolymerization of rubber propylene and unsaturated diene. TPU (Thermoplastic Polyurethane) has feature of easy to process at thermal processes such as extrusion, injection because of its features allowing softening when heated and hardened when cooling. Thermoplastic is general name of elastomer and is also called thermoplastic rubber. TPE is a rubber like material and can be treated by thermoplastic technologies such as injection forming, 2K forming or extrusion. The cores (13) coated with the insulation materials shown in figure 6 come to drum twisting machine line and are twisted and brought together at fixed tension and fixed steps by drum twisting machine. The cores (13) shown in figure 7, brought together come to taping and metal weaving line, Flere twisted cores (13) are screened thereon by conducting wires of different diameters by weaving machine. Metal woven or not woven twisted cores (13) are taken to sheath line and coated with outer sheath (14) made from PVC, HFFR, XLFIFFR, PE, TPU, CPE, CR or similar material thereon by sheath machine. Resistance of XLFIFFR (Crosslinkable Flalogen Free Flame Retardant) against flame is up to PVC material. When subjected to flame, it burns but when flame is removed, it extinguishes. CPE (Chlorinated Polyethylene) is a high molecule elastomeric material chlorinated with high intensity polyethylene. It is of structure inflammable, resistant against weather conditions, capable to work at low temperatures and bendable with rubbers. Mainly PVC is used as resistant increasing agent. Following completion of outer sheath process, the cable (10) shown in figure 7 is obtained.

The most important feature of said cable production system is that the space between cores (13) is minimized in twisting stage. Thus diameter of cable (10) is reduced and not only easy mounting but also reduction in production costs is achieved. Because said cores (13) go into twisting line after being rounded need for extra sheath, filling or weaving screen is eliminated. In said cable production system wires of 0.2-0.3 and 0,4 mm diameter are brought together in conductor twisting process and sector form is given by means o slab set a (20) and slab set b (30). Sector form given comers (13) are coated of nature meeting international standards with extrusion in insulation process. Conductor is subject to sector forms in order to prevent damage to sector form given during insulation process.

In a preferred embodiment of the invention, round form copper conductors of EN 60228 CL5-CL6 which is the thinnest wine are made into sector conductor in triangle form in 120° 90° 72° and then this form is insulated in t riangle form without damaging in insulation extrusion process. With drum twisting, weaving and outer sheath processes, cables (10) of round feature with smaller diameter provide easy use and mounting.

In a preferred embodiment of the invention, copper (1 1 ) conductors of round form with too thin wires, meeting EN 60228 CL5 are provided with conductor twisting operation in conductor twisting process and conductor of 35 mm ² , 50 mm ² , 70 mm ² , 95 mm ² , 120 mm ² , 150 mm ² , 185 mm ² , 240 mm ² are obtained. In insulation process, said round conductor is made sector conductor in triangle form at 120° 90° 72° angles and insulated in triangle form without damaging this form at extrusion process. With drum twisting, weaving and outer sheath processes, cables (10) of round feature with smaller diameter provide easy use and mounting.