Patent Application
20190039283
The aspects of the disclosed embodiments relate to elongated objects, such as cables, insulated heating pipes for district heating, oil pipes, such as flexible pipes etc., comprising a central core and a polymeric cladding or sheath being provided around the core, such as by extrusion around the core. Optionally, the cladding can additionally comprise additional layers, such as a layer of metal foil and an outer sheath.
When producing such elongated objects, a start-up length and a shut-down length of the cladding of the elongated objects are frequently of a poor or insufficient quality and must be separated from the rest of the produced object and sold as scrap or reused.
More specifically, the aspects of the disclosed embodiments relates to an apparatus for removing or stripping an especially polymeric cladding or sheath of elongated objects comprising a core, and a polymeric cladding around said core. By removing the cladding from the core and thereby separating the cladding material from the core material, it is possible to dispose separately of the cladding material and the core material. Such a disposal is more environmentally friendly and makes it possible to obtain a higher price for the scrap than by selling said materials as mixed scrap. Additionally, and probably more important, the core can, at least in certain situations, be reused. This is especially the case when producing low, medium or high voltage cables having a cladding comprising a polymeric insulation, such as an insulation of cross-linked polyethylene (XLPE), as will be explained below. It should be noted that in addition to the extruded polymeric layer(s), the cladding may also comprise a metal foil layer arranged outwardly of or on the extruded layer(s) and an outer polymeric sheath arranged outwardly of or on said metallic foil layer.
The aspects of the disclosed embodiments additionally relates to the use of an apparatus according to the present disclosure in connection with an extruder for extruding a polymeric cladding onto a core of an elongated object, especially extruding a cladding comprising a polymeric insulation around a conductor of a voltage cable; a system comprising an apparatus according to the invention and an extruder for extruding a polymeric cladding onto a core of an elongated object, especially extruding a cladding comprising a polymeric insulation around a conductor of a voltage cable; and a method of extruding a cladding around an elongated core, especially extruding a cladding comprising a polymeric insulation around a conductor of a voltage cable and wherein a start-up and/or a shut-down length of the cladding of the produced cable is stripped from the core and the stripped core is separated from the rest of the produced cable and connected to the forward end of a further core with essentially the same diameter and on which a cladding is extruded.
According to the aspects of the disclosed embodiments, an apparatus for stripping an especially polymeric outer cladding on a central essentially circular core of an elongated object, such as a polymeric cladding optionally including an insulation extruded around a central conductor of a voltage cable, the central core having a centre line and an outer surface, comprising:
As the centering element or elements of the centering device centre the centre line of the core of the elongated object to coincide with the rotational axis of the cutting device, the centre line of the core of the elongated object is always arranged on exactly the same position relative to the rotational axis of the cutting device and the tool(s) thereof. Thereby, the cutting tool(s) of the cutting device can be preset or adjusted to a preselected cutting depth in the cladding and remove the cladding exactly up to the outer surface of the core. As a result, a clean core essentially free from any debris of cladding can be provided. Additionally, the centering device can be configured to monitor the diameter of the core, and the cutting device can be configured to adjust or control the cutting depth, i.e. the position of the cutting tool(s) in dependency of the diameter monitored by the centering device, e.g. by means of control means or control system.
As mentioned, the elongated object can be a voltage cable, such as a low voltage cable, a medium voltage cable or a high voltage cable comprising a core in the form of a conductor and a cladding comprising a polymeric insulation layer around the conductor. Additionally, the cladding may comprise a semiconductor polymeric layer between the conductor and the insulation layer, and an outer semiconductor layer outwardly of or on the insulation layer. Further, the cladding may comprise a metal foil layer arranged outwardly of or on the outer semiconductor layer and an outer polymeric sheath arranged outwardly of or on the metallic foil layer. In principle, the apparatus can also be used to remove one or more outer layers of the elongated object, such as the metal foil layer and the outer polymeric sheath of a voltage cable. Thereby, the subjacent layer can serve as the core layer during the stripping of the metal foil layer and the sheath.
The conductor of a voltage cable is typically of a highly or relatively highly conductive material, such as copper or aluminium or alloys thereof.
The insulation of the cable can as mentioned be a layer of cross-linked polyethylene, XLPE, which is often the case for medium and high voltage cables. However, the insulation can also be of another polymeric material such as PVC, especially for low voltage cables.
The scrap length is during the start-up of the production of voltage cables having a cladding comprising XLPE typically a couple of hundred meters and can in worst case be up to 500 meters. The scrap length of the cables during shut down of the production is typically shorter than the scrap length during start-up.
The highly conductive and expensive material, such as cobber or aluminium or alloys thereof, of the conductor of a voltage cable can have a diameter of 60 mm or more. As it will be possible to obtain a considerable higher price for clean metal scrap than for mixed scrap of metal and polymer, large savings can be obtained by selling the conductor and the cladding separately. Further, considerable higher savings can be obtained by reusing the clean conductor a number of times, such at 3 to 10 times or more.
As an example, calculations have shown that great yearly savings can be obtained using a high voltage continuous vulcanization (HV CV) production line producing 110 kV high voltage having a Cu-conductor with a cross-sectional area of 1000 mm2 for 50 days a year, and producing 400 kV High voltage cables having an Al-conductor with a cross-sectional area of 1600 mm2 for 250 days a year, and 300 m start-up and 100 m shut-down length, and reusing said lengths four times.
According to an embodiment of the present disclosure, the cutting device comprises at least one cutting tool being arranged radially moveable and adjustable relative to the table. One or more cutting tools are needed depending of the radial thickness of the cladding layer and also depending of the machinability of the polymeric material of the cladding and additionally depending of the selected rotational speed of the rotatable table.
According to a preferred embodiment of the present disclosure, the cutting device comprises at least two cutting tools arranged in essentially a common plane extending perpendicularly to the central axis of rotation of the cutting device, such as a pair of oppositely arranged cutting tools or three cutting tools arranged circumferentially equally spaced.
At present, two oppositely arranged cutting tools in each essentially plane is considered most appropriate.
According to a further embodiment, the cutting device comprises a number of consecutively arranged cutting tools, such as two or three consecutively arranged cutting tools.
Thereby, it is possible to remove relatively thick cladding layers even when the machinability of the cladding material is relatively low
In an additional embodiment of the apparatus, the cutting device comprises at least two cutting tools arranged in essentially a common plane in each of at least two, such as three consecutive arranged planes extending perpendicularly to the central axis of the central axis of rotation of the cutting device.
At present, two oppositely arranged cutting tools in each of three consecutively arranged planes are considered an advantageous embodiment especially when trimming the polymeric cladding of a medium or high voltage cable comprising a core on which an XLPE is extruded and vulcanized. As seen from the inlet towards the outlet end of the apparatus, the tools are preferably as follows; two oppositely arranged cutting tools carrying out a rough machining of the cladding, two oppositely arranged cutting tools carrying out a medium machining, and two oppositely arranged cutting tools carrying out a fine machining of the cladding up to the surface of the conductor.
According to an, at present, preferred embodiment, at least one and preferably each cutting tool of the cutting device is arranged on a slide guided on a radially extending guide way.
At least one, alternatively each cutting tool of the cutting device can be a turning tool. However, at present, it is according to an embodiment of the invention preferred that the at least one, alternatively each cutting tool of the cutting device is a milling tool, such as a cylindrical cutter or an end mill.
Each cutting tool of the cutting device is preferably configured to be radially movable between a cutting position in cutting engagement with the cladding of the elongated object and an inactive position in which the elongated object, still being provided with the cladding, can pass through the cutting device without interfering with the cutting device and vice versa.
Alternative to the above-described arrangement of cutting tools, the cutting tools, such as end mills, can be arranged such that the shafts thereof extend essentially radially to the rotational axis of the rotatable table and with a mutual spacing seen in the direction from the front end towards the outlet end of the frame.
As seen in said direction, the cutting device can comprise a single rough milling tool or a first and a second mutually spaced rough milling tool, i.e. milling tools for rough milling.
As seen in said direction and consecutive to the above single rough milling tool or the second rough milling tool and spaced therefrom, the cutting device can comprise a single medium milling tool or a first and a second mutually spaced medium milling tool, i.e. milling tools for medium milling.
As seen in said direction and consecutive to the above single medium milling tool or the second medium milling tool and spaced therefrom, the cutting device can comprise a single fine milling tool or a first and a second mutually spaced fine milling tool, i.e. milling tools for fine milling.
The spacing between consecutive milling tools, such as end mills, can advantageously essentially correspond to the diameter of the end mill.
Further, according to an embodiment of the apparatus, the centering device comprises at least one radially moveable and adjustable centering element.
According to an at present preferred embodiment, the centering device comprises a number of circumferentially mutually equally spaced and in radial direction moveable and adjustable centering elements, such as two radially oppositely arranged centering elements or three radially 120° circumferentially mutually spaced centering elements, preferably arranged in a common plane perpendicular to the central rotational axis of the machining/cutting device.
When using two and especially three 120° circumferentially spaced centering elements, an exact centering of the core is readily obtainable in much the same way as a three-jaw chuck can provide an exact centering of an object having a circular outer surface.
According to an additional embodiment, the centering elements are arranged on respective slides arranged on respective radially extending slide ways.
According to an, at present, preferred embodiment, the centering device is provided with means for synchronously radially moving and adjusting the radial position of the centering elements.
The synchronously radial moving and adjustment of the centering elements can be provided by mechanical means in a manner similar to that of a chuck, such as for a three-jaw chuck, or it can be provided by electronic control means, optionally in combination with one or more sensors, or it can be a combination of mechanical means and electronic control means, optionally in combination with one or more sensors.
According to an embodiment, the synchronous means comprises a rotatable guide plate arranged rotatable around an axis coinciding with the central rotational axis of the cutting device and being provided with a number of mutually equally spaced spiral-shaped guide ways, such as grooves or openings, extending spirally outwardly relative to the central rotational axis and on each slide a mating member cooperating slideably with the respective guide way, such as a protruding member or pin extending into the respective groove or opening.
Alternatively, the guide plate could be provided with a number of mutually equally spaced spiral-shaped guide tracks extending spirally outwardly relative to the central rotational axis and on each slide a track follower received on the respective track.
According to a further embodiment, at least one, alternatively each centering element is provided with a roller rotatable about an axis being perpendicular to the radial direction in which the centering element is radially moveable, said roller having and outer roller face forming the engagement surface of the centering element.
The engagement surface of the roller can be a convex curve as seen in an axial sectional view of the roller.
According to an advantageous embodiment, the centering device is configured to move each centering element between an engagement position engaging the core of the elongated object, such as a conductor of a voltage cable, and an inactive position where the engagement surface of each centering element allows the elongated object, still being provided with the cladding, such as a voltage cable including the cladding thereof, to pass freely through the centering device and vice versa.
Moving the centering elements away from the engagement position and into the inactive position is especially important in order to allow the elongated object to pass freely through in case the cladding has not been removed by the cutting device for some reason, e.g. if the cutting tools of the cutting device have been moved to the inactive position thereof.
It should be noted that the apparatus according to the aspects of the disclosed embodiments may additionally comprise an advance or feed device for moving, i.e. pushing and/or pulling the elongated object through the cutting device and centering the device of the apparatus. However, the elongated object can also be pushed and/or pulled through the apparatus by means of a separate advance or feed device or by an apparatus to which the apparatus according to the invention is associated or connected.
Additionally, the aspects of the disclosed embodiments relate to a system comprising an apparatus according to the present disclosure and an extruder configured to extrude a polymeric cladding around a core of an elongated object, such as an insulation around a central conductor of a high voltage cable, the apparatus being optionally arranged downstream of an outlet end of the extruder where the oblong object, such as the voltage cable, leaves the extruder at a predetermined extrusion velocity and enters the apparatus at the inlet end thereof.
The insulation of the mentioned voltage cable can comprise at least one layer of cross-linked polyethylene (XLPE).
The apparatus is preferably and advantageously configured to rotate the table of the cutting device in dependency of the velocity of which the cable is extruded.
Further, the aspects of the disclosed embodiments relates to the use of an apparatus according to the present disclosure in connection with an extruder configured to extrude a polymeric cladding around a central core of an elongated object, such as an insulation around a conductor of a high voltage cable, the apparatus being optionally arranged downstream of an outlet end of the extruder where the elongated object, such as the voltage cable leaves the extruder at a predetermined extrusion velocity and enters the apparatus at the inlet end thereof.
The insulation of the mentioned voltage cable can comprise at least one layer of cross-linked polyethylene (XLPE).
The apparatus is preferably and advantageously configured to rotate the table of the cutting device in dependency of the velocity of which the cable is extruded.
In general, the apparatus according to the aspects of the disclosed embodiments can be configured to rotate the table of the cutting device in dependency of the speed at which the elongated device to be stripped is advanced through the device.
Finally, the aspects of the disclosed embodiments relate to a method of producing elongated objects comprising a central core and a polymeric cladding extruded around the core, said method comprising the following steps:
The oblong object can be a voltage cable, such as a low, medium or high voltage cable, whereby the core is a conductor and the cladding comprises a polymeric insulation. The polymeric insulation can comprise a layer of cross-linked polyethylene (XLPE) being extruded and vulcanized around the conductor.
Thus, the method according to the aspects of the disclosed embodiments can be a method of producing voltage cables comprising a central conductor and a polymeric cladding extruded around the central conductor, said cladding comprising a polymeric insulation, said method comprising the following steps:
When the cladding comprises an insulation comprising a layer of cross-linked polyethylene (XLPE) the cladding is vulcanized in connection with the extrusion.
Embodiments of the present disclosure will be described in more detail in the following with regard to the accompanying figures. The figures show one way of implementing the present disclosure and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.
The aspects of the disclosed embodiments will be described below with reference to an apparatus 1 for stripping a polymer cladding 14 of an elongated object 16 in the form of a voltage cable comprising a core 15 in the form of a conductor and a cladding extruded around the conductor (see
As shown in
As seen in the direction from the inlet end 10 towards the outlet end 11, the apparatus 1 comprises a cutting device 12 configured for stripping, i.e. removing the cladding 14 from the core 15 of the elongated object 16, and a centering device 13 configured for centering the core 15 of the elongated object 16 and thereby also the elongated object relative to the cutting device 12.
As shown in
Additionally, the cutting device 12 comprises a number of cutting tools 31 arranged on the table 22. In the embodiment shown, the cutting tools are milling tools in the form of end mills. As most clearly shown in
Alternative to the above arrangement of the milling tools, the milling tools 31 can be arranged in pairs comprising two oppositely arranged tools arranged essentially in line in a common plane extending perpendicular to the central rotational axis R of the table 22, and the table is provided with tree axially spaced and consecutively arranged pairs of milling tools, each pair comprising two oppositely arranged milling tools 31. In the above alternative arrangement, the table comprises a pair of oppositely arranged rough milling tools, a first spacing, a pair of oppositely arranged medium milling tools, a second spacing, and a pair of oppositely arranged fine milling tools as seen in the direction from the front end towards the outlet end of the frame.
The shaft of each milling tool extends essentially radially to the rotational axis of the table 22 and, as seen in the direction from the front end towards the outlet end of the frame 2, a first pair of oppositely arranged milling tools carries out a rough machining of the cladding, a second pair of oppositely arranged milling tools carries out a medium machining of the cladding and a third pair of oppositely arranged milling tools carries out a fine machining of the cladding up to the core.
As most clearly shown in
The milling units provided with the rough milling tool 31.1 and 31.2, respectively, are denoted 32.1 and 31.2, respectively, the milling units provided with the medium milling tool 31.3 and 31.4, respectively, are denoted 32.3 and 31.4, respectively, and the milling units provided with the fine milling tool 31.5 and 31.6, respectively, is denoted 32.5 and 31.6, respectively.
In the embodiment shown, the centering device 13 comprises three radially movable and adjustable centering elements 37 configured to engage the outer surface 18 of the core 15 of the elongated object 16 by means of an engagement surface 38 of each element 37 in order to centre the core 15 and thereby the elongated object 16 to coincide with the central rotational axis R of the cutting device 12. The centering elements 37 are arranged in a common plane extending perpendicularly to the central rotational axis R of the cutting device 12 and are mutually equally circumferentially spaced, i.e. 120° mutually spaced. Each centering element 37 is arranged on a slide 39 arranged on a radially extending slide way 40. The slide ways are rigidly connected to the rear part 4 of the frame 2. Additionally, the centering device 13 is provided with synchronous means for synchronously radially moving and adjusting the radial position of the centering elements 37 on the slides 39. In the embodiment disclosed, the synchronous means comprises a rotatable guide plate 41. By means of a bearing having an outer bearing ring being rigidly connected to the rear part 4 of the frame 2, the guide plate is rotatable relative to the frame 2 around an axis coinciding with the central rotational axis R of the cutting device 12. The guide plate 41 is provided with three mutually equally spaced, i.e. 120° circumferentially mutually spaced spiral-shaped guide ways 42 extending spirally outwards relative to the central rotational axis R of the cutting device 12. Each centering element slide 39 is provided with an engagement member 43 slidingly engaging a respective guide way and movable along said guide way. In the embodiment shown, the guide ways 42 are grooves in the guide plate 41, the guide plate being arranged between the rear part 4 of the frame 2 and the radially extending slide ways 40, and the engagement members 42 of the respective centering element slides 39 are a pin extending into a respective groove.
The guide plate 41 is rotatable by means of a motor 44 and a drive 45 shown as a belt drive. When rotating the guide plate 41 in a first direction, the engagement of the pins of the slides in the respective grooves of the guide plate 41 entails a radial movement of the slides 39 on the respective slide ways 40 in an radially inwards direction to bring the engagement surface 38 of the respective centering elements 37 into engagement with the outer surface 18 of the core 15, i.e. into an engagement position, and thereby centre the elongated object 16 on the central rotational axis R of the cutting device. Correspondently, a rotation of the guide plate 41 in a second direction opposite to the first direction entails that the slides 39 and thereby the centering elements 37 are moved radially outwards on the respective slide ways 40 to bring the engagement surfaces 38 out of engagement with the outer surface 18 of the core 15 of the elongated object 16. The centering element slides 39 and thereby the centering elements 37 can be moved into an outer inactive position in which the elongated element 16 can feely pass through the centering device 13. As seen in
When stripping a given elongated object 16, the cutting tools 31 can be preset or adjusted to a preselected cutting depth in the cladding corresponding to the outer diameter D of the core 15 of the elongated object whereby the cladding is removed up to a diameter corresponding to the preselected cutting depth. Additionally, the centering device 12 can be configured to continuously monitor the diameter D of the core 12 and the cutting device can be configured to adjust or control the cutting depth of the cutting tools 31 into the cladding, i.e. the radial position of the cutting tools, in dependency of the diameter of the core monitored by the centering device 13, e.g. by means of a control means or control system. Further, the diameter D of the core 12 can be monitored by means on sensors connected to the centering elements 37 of the centering device 13 or by means of sensors separated from the centering device, i.e. be parts of a separate diameter monitoring device configured to continuously monitoring the diameter of the core and communicating the monitored diameter to the cutting device 12, whereby the cutting device continuously removes the cladding 14 up to the outer surface of the core 15.
Reference is now made to
The shown system comprises a conductor pay-off reel 50 with a coil 51 of the conductor 15. From the pay-off reel 50, the conductor is moved through a conductor accumulator 59, around a wheel 52, also named a capstan, and into a preheater 53 preheating the conductor 15 before it enters a triple head extrusion machine 49 extruding a polymeric cladding 14 around the conductor 15. The triple head extrusion machine 49 comprises a triple extension head 54, a first extruder 55 extruding through the head 54 a first semiconductor layer 60 around the conductor, a second extruder 56 extruding through the head 54 an insulation layer 61 around the first semiconductor layer 60 and a third extruder 57 extruding through the head 54 a second semiconductor layer 62 around the insulation layer 61. From the triple head extrusion machine 49, the conductor provided with the insulation layer and the semiconductor layers is moved into a processing and conditioning device 58 in which the XLPE layer is vulcanized and cooled to form the high voltage cable 16. From the processing and conditioning device 58, the cable 15 is moved into the stripping apparatus 1 according to the invention to remove from the conductor the initial length or start-up length of the cladding 14 that is of insufficient quality. The conductor 15 freed from the cladding 14 leaves the apparatus 1 via a draw device 63, such as a caterpillar or draw rollers, and passes around a conductor return wheel 64.
From the wheel 64, the conductor freed from cladding 14 can be moved to and winded up on a conductor take-up reel 65. The conductor 15 freed from cladding 14 can, at a later point in time, be connected to the front end of a coil of conductor and thereby form the initial or start-up length of said conductor during a extrusion process where a cladding is extruded around the conductor. Thereby, the length of the conductor, from which the cladding from a previous extrusion process has been removed, forms the start-up length on which cladding of insufficient quality is formed during the extrusion process. The above procedure can be repeated a number of times, such as 4-10 times, using the same length of the conductor freed from cladding each time.
The removal of cladding of insufficient quality from the conductor is stopped when the cladding is of the desired quality and the conductor-length freed from the cladding is severed from the conductor provided with cladding of the desired quality adjacent the outlet end of the apparatus 1. After the conductor length freed from cladding 14 has been removed from the cable, the cable with cladding of the desired quality is moved via return wheels 66 and 67 to and winded up on a cable take-up reel 68. As described above, the same length of conductor freed from cladding can be reused several times and serve as the start length of a conductor on which the extruded cladding is of insufficient quality and is removed by the apparatus according to the present disclosure and the corresponding conductor start length reused.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16153830.1 | Feb 2016 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/052107 | 2/1/2017 | WO | 00 |
