Field of the Invention

[1 ] This invention relates generally to a type of vulcanising apparatus used for cable repair.

Background of the Invention

[2] Cable vulcanising machines are used to repair electrical cables. More specifically, once a cable has been cut to repair a core thereof, the surrounding sheath is repaired by wrapped uncured rubber tape which is then compressed at the affected section between heating platens of the vulcanising machine. The vulcanising machine compresses and heats the affected section to cause the rubber tape to cure to form a protective covering contiguous with the sheath.

[3] The vulcanising machines often comprise manually operated clamping and latching arrangements wherein the platens are compressed together and a manually operated threaded turn screws and latching systems and the like.

[4] The present invention seeks to provide Cable repair vulcanising apparatus, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[5] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Disclosure

[6] There is provided herein vulcanising apparatus comprising a pair of heating platens defining respective semicylindrical voids which encircle to house the cable and having respective heater elements and at least one linear actuator acting on at least one of the platens to configure the platens between open and closed configurations. The cylinder platen void size may be varied with the addition of various changeable alternate sized flanged sleeve sets to vary the void size subject to cable sizes. [7] The platens may be reliably positioned and may move vertically between the opened and closed configurations along at least one linear rail and linear carriage system.

[8] The apparatus may comprise a vertical frame defined by a pair of columns supporting respective side linear rails and linear carriage systems which engage a movable platen bracket either side.

[9] The lower platen may be static whereas the upper platen may move vertically along the side linear rails.

[10] The at least one actuator may comprise a linear actuator that pull the platens together. In a preferred embodiment, the at least one actuator comprises a pair of actuators pulling the platens together either side of the upper platen bracket, thereby ensuring even symmetrical compression along the length of the platens.

[11 ] The actuators may comprise electromechanical actuators controllable by a controller. The actuators may apply more than 8000N of load pressure, a pressure difficult to achieve with the afore described manually operated turn screws systems.

[12] The controller may further take temperature readings from the platens and control the application thereof and cook the uncured rubber according to the configured time periods. The controller may further have built-in safety alarms in case of malfunction.

[13] The apparatus may define an operator stage in front of the platens for loading and unloading cable. Furthermore, the apparatus may define a user interface which is operable behind the platens to safely keep the operator away from the platens.

[14] The apparatus may comprise a wireless interface for remote-control safety. Where the apparatus comprises a control box having a user interface thereon, the user interface may be replicated on a mobile device in wireless communication with the apparatus.

[15] Other aspects of the invention are also disclosed. Brief Description of the Drawings

[16] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[17] Figure 1 shows a perspective view of vulcanising apparatus in accordance with an embodiment;

[18] Figure 2 shows a side elevation view of the apparatus;

[19] Figure 3 shows a front elevation view of the apparatus;

[20] Figure 4 shows an exemplary user interface displayed by the apparatus;

[21 ] Figure 5 shows an interior cross-sectional view of the apparatus in accordance with an embodiment;

[22] Figure 6 shows control circuitry of the apparatus in accordance with an embodiment;

[23] Figure 7 shows a top elevation view of a half section of a flanged sleeve set ;

[24] Figure 8 shows a bottom elevation view of a half section of a flanged sleeve set;

[25] Figure 9 shows a removable cable support bracket in accordance with an embodiment; and

[26] Figure 10 shows the removable cable support bracket attached to the apparatus.

Description of Embodiments

[27] Vulcanising apparatus 100 comprises a pair of heating platens 101 defining respective semicylindrical voids therebetween and having respective heater elements 102 to heat the platens 101 . Preferably, flanged sleeve sets 142 of different sizes may be inserted between the platens 101 to adjust for the cable size being vulcanized.

[28] The vulcanising apparatus 100 comprises at least one actuator 103 acting on at least one of the platens 101 to configure the platens 101 between an open configuration wherein the cable can be laid between the platens 101 and any added flanged sleeve set 142 and a closed configuration wherein the platens 101 close together to compress and heat the cable. [29] The platens 101 may be aluminium. Furthermore, the heater elements 102 may be concealed within an interior thereof. The heater elements 102 may be electro resistive heating elements. The heater elements 102 may run substantially along the entire length of each platen 101 to ensure uniform heating therealong.

[30] In the embodiment shown, the platens 101 are horizontal and at least one of the platens 101 moves vertically between the open and closed configurations. The platens 101 may comprise an upper platen 101 A and a lower platen 101 B. As such, a cable (which may weigh in excess of 100 kg per metre) may be conveniently laid across the lower horizontal platen 101 B prior closing the platens 101 together.

[31 ] The lower platen 101 may remain static whereas the upper platen 101 may move vertically with respect to the lower platen 101.

[32] The apparatus 100 may comprise a vertical frame 104 and at least one of the platens 101 may move along a linear rail and carriage system 105 of the vertical frame 104. With reference to Figure 5, the lower platen 101 may be held static by a lower platen bracket 106 whereas the upper platen 101 A may move vertically with respect to the lower platen 101 B by an upper platen bracket 107 moving along the linear rail and carriage system 105.

[33] In the embodiment shown, the vertical frame 104 may be defined by a pair of columns 106 each defining a respective side linear rail and carriage system 105 and wherein the upper platen bracket 107 is engaged between the side linear rails and carriage system 105.

[34] As shown in Figure 5, the actuator 103 may be a linear actuator 103. Furthermore, the actuator 103 may be an electromechanical actuator.

[35] The linear actuator 103 may be configured to pull the platens 101 together. The linear actuator 103 may be configured to provide more than 8000N of load pull forceof pressure between the platens 101.

[36] As is shown in Figure 5, the linear actuator 103 may pull between a lower attachment point 108 of the vertical frame 104 or a base 110 of the apparatus 100 and an upper platen bracket attachment point 109 to pull the upper platen 101 A down towards the lower platen 101 B. As can be seen, the linear actuator 103 may go past the lower platen 101 B.

[37] In embodiments, the apparatus 100 comprises a pair of linear actuators 103 acting either side of the upper platen bracket 107.

[38] The base 101 may define a stage 1 1 1 on which an operator may stand whilst handling cable between the platens 101. The base 101 may define forklift tine pockets 141 for manoeuvring the apparatus 100. The apparatus 100 may further comprise a control box 1 13 having a controller 1 14 therein.

[39] With reference to Figure 6, the controller 1 14 may comprise a processor 1 15 for processing digital data. A memory device 1 16 in operable communication with the processor across a system bus 1 17 is configured for storing digital data including computer program code instructions. In use, the processor 1 15 fetches these computer program code instructions and associated data 1 18 for interpretation and execution of the control functionality described herein. The computer program code instructions may be logically divided into a plurality of computer program code instruction controllers 1 19. The controller 1 14 may take the form of a ruggedised industrial PLC device or the like.

[40] The controller 1 14 may have a video interface 120 operably controlling a digital display 121 . The processor 1 15 may control the digital display 121 to display a user interface 1 13. Figure 4 shows an exemplary user interface 1 13.

[41 ] The user interface 1 13 may be operative behind the platens 101 so that the operator is safely out of the way whilst operating the actuators. In this regard, the control box 1 12 may be located atop the vertical frame 104 and wherein the user interface 1 13 is exposed from a rear thereof.

[42] In embodiments, the controller 1 14 is a wireless interface for remote-control using a wirelessly connected electronic device, such as a mobile com munication device executing a software application thereon. In accordance with this embodiment, the user interface displayed by the mobile communication device may replicate the user interface 1 13 shown in Figure 4. [43] As shown in Figure 6, the controller 114 may interface a I/O interface 122 for interfacing with various peripherals, including controlling the actuators 103. As such, the controller 1 14 may open and close the platens 101 by controlling the actuators 103.

[44] In embodiments, the controller 1 14 may interface a positional transducer 123 to gauge the position of at least one of the platens 101. The transducer 123 may comprise mechanical trip switches which close when the upper platen 101 A is at the upper or lower travel limit. Alternatively, the positional transducer 123 may comprise the actuator 103 comprising a rotary transducer from which the revolutions are indicative of the extension of the actuator 103.

[45] The controller 114 may control actuators 1 13 according to positions determined by the positional transducer 123.

[46] In embodiments, a pressure transducer 123 may measure pressure applied between the platens 101. For example, the pressure transducer 123 may take the form of a strain gauge between the actuator 103 and the lower or upper attachment points 108, 109 to measure the amount of pressure applied between the platens 101. Similarly, the controller 1 14 may control the actuators 113 according to pressure sensed by the transducer 123.

[47] As is further shown in Figure 6, the controller 114 may control a high-power switch 124 to supply electrical power to the heating elements 102. Furthermore, the controller 1 14 may interface at least one thermocouple 125 to read the temperatures of at least one of the platens 101. In a preferred embodiment, the controller 1 1 4 interfaces a respective switch 114 and thermocouple 125 for each platen 101. The controller 114 may control the heating elements 102 according to a temperature setpoint and temperature readings engaged by the thermocouple 125.

[48] The controllers 119 may comprise a timer controller wherein the controller 1 14 controls the actuators 103 and heating elements 102 for a predetermined time period.

[49] For example, with reference to Figure 4, the user interface 1 13 may display timing options of 35, 45 and 60 minutes. For example, if the operator were to select the 35-minute timing interval, the controller 1 14 may be configured to close the platens 101 and heat the cable for 35 minutes. The selected time 132 may be displayed by the interface 1 13.

[50] More specifically, once the appropriate time interval is chosen, a start button 135 of the interface 113 may be operated whereafter the controller 1 14 may use the thermocouples 125 to detect when the platens 101 are heated to a temperature setpoint and the positional transducers 123 to detect that the platens 101 are in the closed configuration whereafter the timer commences to ensure that the cable is heated appropriately for the entire chosen duration.

[51 ] In alternative embodiments, the interface 1 13 may accept the cable type and wherein the controller 114 comprises a lookup table of appropriate temperatures and durations according to cable type. For example, an operator may input a cable diameter wherein the controller 114 ascertains the appropriate temperature setpoint and duration for the given diameter of cable.

[52] As is shown in Figure 14, the user interface 113 may display a process value temperature 127 and a setpoint temperature 128 for each element 102.

[53] The controllers 119 may further comprise an overtemperature alarm controller wherein an overtemperature alarm indication 129 is displayed on the interface 113 should the controller 114 detect using the thermocouples 125 that the platen 101 temperature is substantially over a temperature setpoint.

[54] The controllers 1 19 may further comprise a timer alarm controller wherein a timer alarm indication 130 is displayed within the interface 1 13 when the controller 114 determines that the set cooking time for the cable repair has been reached at which point the controller 1 14 stop the elements 102 heating.

[55] The controllers 119 may further comprise an overtime alarm controller wherein an overtime alarm indication 130 is displayed within the interface 113 if the controller 114 detects using the transducers 123 that the platens 101 have remained closed for too long.

[56] The interface 113 may display the remaining time indication 131.

[57] The interface 113 may further display manual actuator controls 133 wherein the user may use the open or close buttons to operate the movement of the platens 101 manually. Furthermore, the interface 1 13 may comprise a platen reset control which resets the platens 101 to an open position.

[58] The interface 1 13 may comprise a settings control 136 wherein various settings may be configured, including pressure applied between the platens 101 . The interface 1 13 may further comprise a timer reset button 137 which resets the timer.

[59] In embodiments, the controller 1 14 is configured to store job history within the data 1 18 of the memory device 1 16. Such job history may be viewed from the interface 1 13 using the job history button 138.

[60] More specifically, each time a cable is vulcanised, an identifier of the cable may be input into the user interface 1 13. Thereafter, the controller may record at least one of the operator name, job number, cable identifier, date, start time, end time, duration, minimum, maximum or average temperatures, temperature trend, minimum, maximum or average pressures or pressure trend and the like.

[61 ] In embodiments, the controller 1 14 may only allow the opening or closing of the platens 101 under dead man control. For example, the controller 1 14 may require the start button 135 to be held down whilst the controller 1 14 opens or closes the platens 101. Similarly, the manual actuator controls 133 may be required to be held down for the platen 101 to be moved by the controller 1 14.

[62] In embodiments, the controller 1 14 may be configured to slightly open the platens 101 following manual closing thereof using the manual controls 133. For example, repeated closing of the platens 101 by repeated pressing of the close button of the manual controls 133 may result in excessive force being applied by the actuator 103. For example, whereas the actuator 103 may be rated to 7000N of pressure, repeated pressing of the actuator 103 may result in the actuator 103 applying up to 15000N of pressure which may break the apparatus 100.

[63] As such, following manual closing of the platens 103, the controller 1 14 may reverse the actuator 103, such as for 3 seconds. As such, repeated pressing of the close button of the manual controls 133 would not result in excessive force being applied by the actuator 103. [64] Similarly, following opening of the platens 103, the controller 1 14 may reverse the actuator 103 to close the platens 101 . In this regard, the apparatus 100 may comprise a limit switch to detect an open position of the platens 101. Following opening of the platens 101 , such as by using the open button of the manual controls 133, the controller 144 may reverse the actuator 103. Preferably, the controller 1 14 is configured to reverse the actuator 103 for more than when reversing the closing of the platens 101 .

[65] For example, when closing the platens 103, the controller 1 14 may reverse the actuator 103 for three seconds wherein , when opening the platens 101 , the controller 1 14 may reverse actuator 103 for 7 seconds.

[66] The reversal of the actuator 103 when opening the platens 103 for more than when reversing actuator 103 when closing the platens 103 positions the platens 103 so that the actuator 103 can still perform the closing reversal. In other words, when opening the platens, the controller 1 14 may reverse the actuator 103 for 7 seconds to position the actuator 103 away from the maximum open position of the limit switch. At this position, if the close button of the manual controls 133 were operated, the position of the actuator 103 would have enough tolerance to perform the closing reversal of three seconds.

[67] As shown in Figure 7 and 8, the apparatus 100 can utilise various changeable additional flanged sleeve sets 142 which have alternate internal diameter sizes to vary the platen 101 cylindrical void size and accommodate various sized cables within the Vulcanising apparatus 100.

[68] The sleeve set 142 may comprise separate semicylindrical pieces 143 comprising a semicylindrical midsection 144 and locating semicircular flanges 145 with locating and locking pins at both ends thereof.

[69] The flanges with locating and locking pins 145 ensure proper alignment within the platens 101 and prevent the sleeves from falling out from the platens 101 during opening and closing operations.

[70] As shown in Figures 9 and 10, the apparatus 100 may also have a removable cable support bracket 146 having side arms 147 supporting semicylindrical saddles 149 positioned by the side arms 147 adjacent to the heating platens 101 to provide additional cable support requirements when the apparatus 100 is in use. The arms 147 may be slidably engaged within corresponding sleeves 150 to provide length adjustment thereof and therefore offset the saddles 149 from the sides of the platens 101.

[71 ] The sleeves 150 may be held removed by removable attachment plates 151 which may attach under the lower platens 101.

[72] The apparatus 100 may further comprise a wheeled base (not shown) to assist the manoeuvrability of the apparatus 100. The base may have a quadrant of castor wheels with lockout functionality. The wheeled base may define a lower step up to access the control box 1 12.

[73] Handles (also not shown) may be attached to the vertical frame 104 to assist manual repositioning of the apparatus 100 using the wheeled base. The handles may comprise a pair of handles located beneath the control box 1 12, and on the opposite side of the platens 101 .

[74] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed as obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.