JP7327226B2 - Cable manufacturing method - Google Patents

Description

The present invention relates to a cable manufacturing method.

Generally, cables are known which have at least an inner conductor, a shield member covering the inner conductor, and a sheath covering the shield member. The shield member shields noise from entering the internal conductor from the outside.

As the shield member, a braided shield in which a plurality of conductive strands are braided, a copper tape formed in a tape shape, and the like are known. It is known that, depending on the cable laying conditions and deterioration over time, the strands constituting the braided shield may be cut, or the copper tape may be displaced to create gaps. Various methods have been proposed for detecting defects and abnormalities in the shielding member caused by deterioration over time (see Patent Documents 1 to 3, for example).

JP 2009-281850 A JP 2012-058049 A JP 2016-121922 A

Patent Literatures 1 to 3 disclose techniques for detecting defects or the like occurring in a shield member using radio waves. However, the techniques described in Patent Literatures 1 to 3 are intended to detect defects in the shielding member due to deterioration over time, etc., and are not intended to detect defects in the shielding member during the manufacture of the cable.
For example, during cable manufacture, the shield member may be damaged due to excessive bending or twisting when the cable is wound around a bobbin, contact or rubbing between wires, and the like. There is a problem that the techniques described in Patent Literatures 1 to 3 cannot meet the demand for detecting defects or the like in manufacturing the cable.

As a method of detecting a defect or the like occurring in a shield member, there is also known a method of confirming by a transmission image of a cable acquired using X-rays or ultrasonic waves. However, since these methods require a large-sized device for detection, it is difficult to incorporate an inspection device into a cable manufacturing device. In other words, there is a problem that in-line inspection is difficult.

SUMMARY OF THE INVENTION An object of the present invention is to provide a cable manufacturing method that enables in-line inspection of a manufactured cable.

In order to achieve the above object, the present invention provides the following means.
A method of manufacturing a cable according to the present invention is a method of manufacturing a cable having at least a conductor, a covering layer covering the conductor, a shield layer covering the covering layer, and a sheath covering the shield layer, wherein A coating forming step of providing the coating layer around the outer circumference of the conductor, a shield forming step of spirally winding a wire around the outer circumference of the moving covering layer to form the shield layer, and an insulating outer circumference of the moving shield layer. and an inspecting step of inspecting the direction in which the wire is wound from above the sheath of the moving cable, wherein the inspecting step includes the moving from the antenna A radio wave emitting step of emitting radio waves toward a shield layer, a reflected wave detecting step of detecting a reflected wave reflected from the shield layer, and a direction in which the wire is wound based on the intensity of the detected reflected wave. and a determination step of determining whether it is within a predetermined allowable range.

According to the cable manufacturing method of the present invention, since the moving cable is subjected to the inspection process including the radio wave radiation process, the reflected wave detection process, and the judgment process, the cable to be manufactured can be inspected in-line. Effective.

It is a sectional view explaining composition of a cable manufactured by a manufacturing method of the present invention. It is a flowchart explaining each process in the manufacturing method of this invention. FIG. 3(a) is a schematic diagram for explaining the internal semiconducting process, the insulating process, and the external semiconducting process, FIG. 3(b) is a schematic diagram for explaining the shield forming process, and FIG. It is a schematic diagram explaining a formation process, and FIG.3(d) is a schematic diagram explaining an inspection process. 1 is a schematic diagram for explaining the configuration of an inspection device used in an inspection process; FIG. FIG. 4 is a schematic diagram for explaining the positional relationship between the wires of the shield wire and the dipole antenna; FIG. 10 is a schematic diagram illustrating another positional relationship between the wires of the shield wire and the dipole antenna; FIG. 4 is a schematic diagram for explaining the positional relationship between the wire of the shield wire and the slot antenna; FIG. 10 is a schematic diagram illustrating another positional relationship between the wire of the shield wire and the slot antenna;

A cable manufacturing method according to an embodiment of the present invention will be described with reference to FIGS. 1 to 6. FIG. The cable 10 manufactured in this embodiment is used for power supply to a vehicle line. As shown in FIG. 1, the cable 10 has an inner conductor (conductor) 11, an inner semiconductive layer (covering layer) 12, an insulator (covering layer) 13, and an outer semiconducting layer (covering layer) 14 from the center to the outside. , a shield wire (shield layer) 15, and a sheath 17 are arranged.

The internal conductor 11 is a stranded wire in which a plurality of tinned annealed copper wires are twisted together. The internal semiconductive layer 12 is a layer provided on the outer periphery of the internal conductor 11, and is a layer composed of a semiconductive tape and a semiconductive compound such as semiconductive rubber.

The insulator 13 is a layer provided on the outer periphery of the internal semiconductive layer 12, and is a layer made of a rubber-based resin such as ethylene propylene rubber. The external semiconductive layer 14 is a layer provided on the outer periphery of the insulator 13, and is a layer composed of a semiconductive tape and a semiconductive compound such as semiconductive rubber.

The shield wire 15 is a layer formed by winding the wire 16 laterally, in other words, spirally, around the outer circumference of the external semi-conductive layer 14 . Wire 16 is tinned annealed copper wire. The sheath 17 is a layer provided on the outer circumference of the shield wire 15, and is a layer made of polyolefin resin.

Next, a method for manufacturing the cable 10 having the above configuration will be described with reference to FIGS. 2 to 5. FIG.
As shown in FIG. 2, first, an internal semiconducting step (coating forming step, S11) is performed to form the internal semiconducting layer 12 on the outer periphery of the internal conductor 11 . After the inner semiconductive layer 12 is provided, an insulating step (coating forming step, S12) is performed to provide an insulator 13 around the outer periphery of the inner semiconductive layer 12 . After the insulator 13 is provided, an outer semiconducting step (coating forming step, S13) is performed to provide an outer semiconducting layer 14 on the outer periphery of the insulator 13 .

In this embodiment, the steps from S11 to S13 are applied to an example in which the steps are performed as a series of steps as shown in FIG. 3A. The inner conductor 11 is sent out at a predetermined speed from the bobbin 21A around which the inner conductor 11 is wound. A semiconducting tape forming an internal semiconducting layer 12 is wound around the outer periphery of the sent out internal conductor 11 . After that, an insulator 13 made of rubber-based resin is provided on the outer periphery of the inner semi-conductive layer 12 . Furthermore, a semiconductive tape forming an external semiconductive layer 14 is wound around the insulator 13 . The cable 10 provided up to the outer semi-conductive layer 14 is wound around the bobbin 21B.

After the outer semi-conductive layer 14 is provided, as shown in FIG. 2, a shield forming step (S14) is performed to provide a shield wire 15 around the outer periphery of the outer semi-conductive layer 14. FIG.
In the present embodiment, an example in which the process of S14 is performed as shown in FIG. 3B will be described. The cable 10 provided from the bobbin 21B to the outer semi-conductive layer 14 is sent out at a predetermined speed. A shield wire 15 is provided by laterally winding a wire 16 around the outer periphery of the outer semi-conductive layer 14 of the cable 10 sent out. The cable 10 provided up to the shield wire 15 is wound around the bobbin 21C.

After the shield wire 15 is provided, a sheath forming step (S15) is performed to provide a sheath 17 around the outer circumference of the shield wire 15, as shown in FIG.
In the present embodiment, an example in which the process of S15 is performed as shown in FIG. 3C will be described. Cable 10 provided from bobbin 21C to shield wire 15 is sent out at a predetermined speed. A sheath 17 made of polyolefin resin is provided on the outer circumference of the shield wire 15 of the cable 10 sent out. The thickness of the sheath 17 can be exemplified from 3 mm to 4 mm. The cable 10 provided up to the sheath 17 is wound around the bobbin 21D.

The device and method for providing the inner semiconductive layer 12, the insulator 13, the outer semiconductive layer 14, the shield wire 15, and the sheath 17 can be known devices and methods, and the device and method are particularly limited. not something to do.

After the sheath 17 is provided, each step of inspecting the shield wire 15 using the inspection device 30 is performed as shown in FIG. Specifically, a radio wave emitting step (inspection step, S21) of emitting radio waves from above the sheath 17 toward the shield wire 15, and a reflected wave detecting step of detecting a reflected wave reflected from the shield wire 15 from which the radio waves have been emitted. (inspection step, S22), a determination step (inspection step, S23) of determining the direction in which the wire 16 is wound based on the intensity of the detected reflected wave is performed.

The inspection device 30 repeats each step from S21 to S23. The period required to perform these series of steps can be exemplified, for example, in the range of 0.4 seconds to 0.5 seconds. In other words, the inspection device 30 can perform 150 to 120 inspections per minute.

In the present embodiment, an example in which the inspection apparatus 30 that performs the steps from S21 to S23 is arranged as shown in FIG. 3D will be described. The cable 10 provided from the bobbin 21D to the sheath 17 is sent out at a predetermined speed. Predetermined characters, symbols, and the like are printed by the printing device 25 on the outer circumference of the sheath 17 of the cable 10 sent out. The printed cable 10 is inspected by the inspection device 30 . The inspected cable 10 is wound on the bobbin 21E.

For example, a mark is attached to a location determined by the inspection by the inspection device 30 that the direction in which the wire 16 is wound exceeds a predetermined range of directions. The marked cable 10 location is discarded.

As shown in FIG. 4, the inspection apparatus 30 includes a dipole antenna 31, an oscillator 32, a coaxial cable 33, a directional coupler 34, a traveling wave receiver 35, a reflected wave receiver 36, and a determiner 37. and is provided.

The dipole antenna 31 has two elements 31A and 31B. The elements 31A and 31B are rod-shaped members, and the two elements 31A and 31B are arranged to extend side by side on a straight line. An example of the length of the dipole antenna 31 is 30 mm.

In this embodiment, as shown in FIG. 5, an example in which the direction in which the two elements 31A and 31B of the dipole antenna 31 extend and the direction in which the wire 16 of the cable 10 is wound is substantially parallel will be described. Here, "substantially parallel" means that the angle between the direction in which the two elements 31A and 31B of the dipole antenna 31 extend and the direction in which the wire 16 is wound is in the range of -5° to 5°.

The oscillator 32 oscillates at the resonance frequency of the dipole antenna 31 and outputs radio waves to be input to the dipole antenna 31 . Approximately 5 GHz can be exemplified as the resonance frequency emitted by the oscillator 32 . A coaxial cable 33 is a feed line connecting the dipole antenna 31 and the oscillator 32 . Radio waves directed from the oscillator 32 to the dipole antenna 31 are transmitted to the coaxial cable 33 as traveling waves. Further, radio waves directed from the dipole antenna 31 toward the oscillator 32 are transmitted to the coaxial cable 33 as reflected waves.

A directional coupler 34 is provided on the coaxial cable 33 . The directional coupler 34 has a function of outputting, to the traveling wave receiver 35 , a traveling wave traveling from the oscillator 32 toward the dipole antenna 31 among radio waves transmitted on the coaxial cable 33 . The directional coupler 34 has a function of outputting a reflected wave from the dipole antenna 31 toward the oscillator 32 among the radio waves transmitted on the coaxial cable 33 to the reflected wave receiver 36 .

The traveling wave receiver 35 has a function of receiving the traveling wave output from the directional coupler 34 and outputting its reception level to the determiner 37 . The reflected wave receiver 36 has a function of receiving the reflected wave output from the directional coupler 34 and outputting the received level to the determiner 37 .

The determiner 37 has a function of obtaining the ratio of the reception level of the reflected wave and the reception level of the traveling wave, and comparing the obtained ratio with a predetermined threshold value. If the determined ratio is equal to or greater than the threshold, the determiner 37 determines that the direction in which the wire 16 is wound in the cable 10 is within a predetermined allowable range. It is determined that the direction in which the -21 dB can be exemplified as the predetermined threshold. Note that the determination device 37 may have an alarm function of notifying with light, sound, or the like when it is determined that the direction in which the wire 16 is wound exceeds the allowable range.

Inspection device 30 radiates radio waves from dipole antenna 31 toward cable 10 moving from bobbin 21D toward bobbin 21E (S21). In other words, radio waves are radiated toward the shield wire 15 . At this time, the distance between the dipole antenna 31 and the outer circumference of the shield wire 15 of the cable 10 is, for example, 6 mm. When the thickness of the sheath 17 is 4 mm, the distance from the dipole antenna 31 to the outer circumference of the sheath 17 is 2 mm.

After that, the reflected wave reflected from the shield wire 15 from which the radio wave was radiated is detected by the inspection device 30 (S22). Then, the determiner 37 of the inspection device 30 determines whether or not the direction in which the wire 16 is wound is within a predetermined allowable range (S23).

In this embodiment, the manufacturing process of the cable 10 has been described by applying it to an example in which it is divided into four processes shown in FIGS. 3(a) to 3(d). may be divided into less than four steps.

According to the manufacturing method described above, since the moving cable 10 is inspected by the radio wave radiation step S21, the reflected wave detection step S22, and the determination step S23, the cable 10 to be manufactured can be inspected in-line. Become.

For example, since the inspection device 30 that performs the inspection is smaller than in the case of inspection by a method of checking with a transmission image of the cable 10 acquired using X-rays or ultrasonic waves, in-line (in the line that manufactures the cable 10) can be inspected. In addition, when inspecting the moving cable 10, the time required for one inspection is shorter than when inspecting by a method of checking with a transmission image of the cable acquired using X-rays or ultrasonic waves. Therefore, it is easy to increase the density of locations where inspection is performed.

In addition, since the shield wire 15 is horizontally wound, excessive bending and twisting when winding the cable 10 around the bobbin 21C, contact (rubbing) between the wires 16, excessive bending and twisting when winding the cable around the bobbin 21D, etc. Sixteen angular deviations can occur. That is, the helically wound wire 16 moves such that the helically wound angle of the wire 16 with respect to the axis of the cable 10 deviates from the desired angle, or the spacing between the wires deviates from the desired spacing. sometimes According to the manufacturing method described above, it is possible to inspect defects such as the helical winding angle of the wire 16 with respect to the axis of the cable 10 deviating from the desired angle and the spacing between the wires deviating from the desired spacing. becomes.

By setting the angle formed by the direction in which the elements 31A and 31B of the dipole antenna 31 extend and the direction in which the wire 16 is wound to be -5° or more and 5° or less, the intensity of the reflected wave is increased compared to other angles. tend to be high. If the direction in which the wire 16 is wound is different from the direction in which the elements 31A and 31B of the dipole antenna 31 extend, the intensity of the reflected wave decreases. Therefore, it becomes easier to determine the direction in which the wire 16 is wound.

The technical scope of the present invention is not limited to the above embodiments, and various modifications can be made without departing from the scope of the present invention.
For example, as shown in FIG. 6, the direction in which the two elements 31A and 31B of the dipole antenna 31 extend may be substantially perpendicular to the direction in which the wire 16 of the cable 10 is wound. Here, "substantially perpendicular" means that the angle between the direction in which the two elements 31A and 31B of the dipole antenna 31 extend and the direction in which the wire 16 is wound is in the range of 85° or more and 95° or less.

By setting the angle between the direction in which the elements 31A and 31B of the dipole antenna 31 extend and the direction in which the wire 16 is wound to be 85° or more and 95° or less, the intensity of the reflected wave is lower than in the case of other angles. Prone. If the direction in which the wire 16 is wound is out of the range of 85° or more and 95° or less with respect to the direction in which the elements 31A and 31B of the dipole antenna 31 extend, the intensity of the reflected wave increases. Therefore, it becomes easier to determine the direction in which the wire 16 is wound. In this case, if the ratio obtained from the reflected wave and the traveling wave is equal to or less than a predetermined threshold value, the determiner 37 determines that the direction in which the wire 16 is wound in the cable 10 is within a predetermined allowable range. If the threshold value is exceeded, it is determined that the direction in which the wire 16 is wound exceeds the allowable range. In this case, -24 dB can be exemplified as the predetermined threshold.

For example, a slot antenna 131 may be used instead of the dipole antenna 31, as shown in FIG. The direction in which the slot 131A of the slot antenna 131 extends may be substantially parallel to the direction in which the wire 16 of the cable 10 is wound. Here, "substantially parallel" means that the angle between the direction in which the slot 131A extends and the direction in which the wire 16 is wound is in the range of −5° or more and 5° or less.

By setting the angle between the direction in which the slot 131A extends and the direction in which the wire 16 is wound to be -5° or more and 5° or less, the intensity of the reflected wave tends to be higher than in the case of other angles. If the direction in which the wire 16 is wound is different from the direction in which the slot 131A extends, the intensity of the reflected wave decreases. Therefore, it becomes easier to determine the direction in which the wire 16 is wound.

Also, the direction in which slot 131A of slot antenna 131 extends may be substantially perpendicular to the direction in which wire 16 of cable 10 is wound. Here, "substantially perpendicular" means that the angle between the direction in which the slot 131A extends and the direction in which the wire 16 is wound is in the range of 85° or more and 95° or less.

By setting the angle between the direction in which the slot 131A extends and the direction in which the wire 16 is wound to 85° or more and 95° or less, the intensity of the reflected wave tends to be lower than in the case of other angles. If the direction in which the wire 16 is wound is different from the direction in which the slot 131A extends, the intensity of the reflected wave increases. Therefore, it becomes easier to determine the direction in which the wire 16 is wound.

For example, if the determiner 37 of the inspection device 30 determines that the winding direction of the wire 16 is not within the predetermined allowable range, various parameters in the shield forming step (S14) may be changed. good. For example, the linear speed of the cable 10 (moving speed of the cable 10) may be changed, or the tension and rotation speed of the wire 16 during horizontal winding may be changed.

DESCRIPTION OF SYMBOLS 10... Cable, 11... Inner conductor (conductor), 12... Inner semi-conductive layer (covering layer), 13... Insulator (covering layer), 14... Outer semi-conducting layer (covering layer), 15... Shield wire (shield layer ), 17...Sheath 31...Dipole antenna 31A, 31B...Element 131...Slot antenna 131A...Slot S11...Internal semiconducting step (coating forming step) S12...Insulating step (coating forming step) S13... External semiconducting step (coating forming step) S14 Shield forming step S15 Sheath forming step S21 Radio wave radiation step (inspection step) S22 Reflected wave detection step (inspection step) S23 Determination step (inspection step )

Claims (5)

A method for manufacturing a cable having at least a conductor, a covering layer covering the conductor, a shield layer covering the covering layer, and a sheath covering the shield layer,
a covering forming step of providing the covering layer on the outer periphery of the moving conductor;
a shield forming step of providing the shield layer by spirally winding a wire around the outer periphery of the moving covering layer;
A sheath forming step of providing the sheath having insulating properties around the outer circumference of the moving shield layer;
an inspection step of inspecting the direction in which the wire is wound from above the sheath of the moving cable;
has
The inspection step includes:
a radio wave radiating step of radiating radio waves from the antenna toward the moving shield layer;
a reflected wave detection step of detecting a reflected wave reflected from the shield layer;
a determination step of determining whether the direction in which the wire is wound is within a predetermined allowable range based on the intensity of the detected reflected wave ;
the antenna is a slot antenna,
In the inspection step, the slot antenna is arranged such that an angle formed by a direction in which the slot in the slot antenna extends and a direction in which the wire of the shield layer is spirally wound is -5° or more and 5° or less. A method of manufacturing a cable. A method for manufacturing a cable having at least a conductor, a covering layer covering the conductor, a shield layer covering the covering layer, and a sheath covering the shield layer,
a covering forming step of providing the covering layer on the outer periphery of the moving conductor;
a shield forming step of providing the shield layer by spirally winding a wire around the outer periphery of the moving covering layer;
A sheath forming step of providing the sheath having insulating properties around the outer circumference of the moving shield layer;
an inspection step of inspecting the direction in which the wire is wound from above the sheath of the moving cable;
has
The inspection step includes:
a radio wave radiating step of radiating radio waves from the antenna toward the moving shield layer;
a reflected wave detection step of detecting a reflected wave reflected from the shield layer;
a determination step of determining whether the direction in which the wire is wound is within a predetermined allowable range based on the intensity of the detected reflected wave;
The antenna is a dipole antenna,
In the inspection step, the dipole antenna is arranged such that an angle between the direction in which the element of the dipole antenna extends and the direction in which the wire of the shield layer is helically wound is -5° or more and 5° or less. A method of manufacturing a cable. A method for manufacturing a cable having at least a conductor, a covering layer covering the conductor, a shield layer covering the covering layer, and a sheath covering the shield layer,
a covering forming step of providing the covering layer on the outer periphery of the moving conductor;
a shield forming step of providing the shield layer by spirally winding a wire around the outer periphery of the moving covering layer;
A sheath forming step of providing the sheath having insulating properties around the outer circumference of the moving shield layer;
an inspection step of inspecting the direction in which the wire is wound from above the sheath of the moving cable;
has
The inspection step includes:
a radio wave radiating step of radiating radio waves from the antenna toward the moving shield layer;
a reflected wave detection step of detecting a reflected wave reflected from the shield layer;
a determination step of determining whether the direction in which the wire is wound is within a predetermined allowable range based on the intensity of the detected reflected wave;
The antenna is a dipole antenna,
In the inspection step, the dipole antenna is arranged such that an angle between a direction in which the elements of the dipole antenna extend and a direction in which the wire of the shield layer is spirally wound is 85° or more and 95° or less. , cable manufacturing method. A method for manufacturing a cable having at least a conductor, a covering layer covering the conductor, a shield layer covering the covering layer, and a sheath covering the shield layer,
a covering forming step of providing the covering layer on the outer periphery of the moving conductor;
a shield forming step of providing the shield layer by spirally winding a wire around the outer periphery of the moving covering layer;
A sheath forming step of providing the sheath having insulating properties around the outer circumference of the moving shield layer;
an inspection step of inspecting the direction in which the wire is wound from above the sheath of the moving cable;
has
The inspection step includes:
a radio wave radiating step of radiating radio waves from the antenna toward the moving shield layer;
a reflected wave detection step of detecting a reflected wave reflected from the shield layer;
a determination step of determining whether the direction in which the wire is wound is within a predetermined allowable range based on the intensity of the detected reflected wave;
the antenna is a slot antenna,
In the inspection step, the slot antenna is arranged such that an angle formed by a direction in which the slot in the slot antenna extends and a direction in which the wire of the shield layer is spirally wound is 85° or more and 95° or less. , cable manufacturing method. When it is determined in the determining step that the direction in which the wire is wound is not within a predetermined allowable range, the wire is wound in a helical shape in the shield forming step so as to be within the allowable range. The cable manufacturing method according to any one of claims 1 to 4 , wherein various parameters for winding are changed.

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