Systems and methods for forming a cable

Abstract

Systems and methods are provided for forming a cable. In one embodiment, a system for forming a cable comprises a non-driven roll station having a plurality of rolls for forming a shape of one or more strands associated with a first layer of the cable. Movement of the plurality of rolls of the non-driven roll station occurs passively during travel of the one or more strands associated with the first layer of the cable. The system further comprises a driven roll station having a plurality of rolls for forming a shape of one or more strands associated with a second layer of the cable. The plurality of rolls of the driven roll station are actively driven to effect movement and speed of the one or more strands associated with the second layer of the cable.

We claim: 
     
         1 . A system for forming a cable, the system comprising:
 a non-driven roll station having a plurality of rolls for forming a shape of one or more strands associated with a first layer of the cable,   wherein movement of the plurality of rolls of the non-driven roll station occurs passively during travel of the one or more strands associated with the first layer of the cable; and   a driven roll station having a plurality of rolls for forming a shape of one or more strands associated with a second layer of the cable,   wherein the plurality of rolls of the driven roll station are actively driven to effect movement and speed of the one or more strands associated with the second layer of the cable.   
     
     
         2 . The system of  claim 1 , wherein the first layer of the cable is disposed radially inward relative to the second layer. 
     
     
         3 . The system of  claim 1 , wherein the driven roll station is disposed upstream relative to the non-driven roll station. 
     
     
         4 . The system of  claim 3 , wherein the driven roll station comprises a through hole for travel of the one or more strands associated with the first layer of the cable. 
     
     
         5 . The system of  claim 1 , wherein the one or more strands associated with the first layer exit the non-driven roll station at a different speed relative to which the one or more strands associated with the second layer exit the driven roll station. 
     
     
         6 . The system of  claim 1 , wherein the one or more strands associated with the first layer exit the non-driven roll station at a slower speed relative to which the one or more strands associated with the second layer exit the driven roll station, and
 wherein the first layer of the cable is disposed radially inward relative to the second layer.   
     
     
         7 . The system of  claim 1 , further comprising a lay plate having a plurality of recesses and a plurality of roller guides, wherein each of the plurality of recesses houses a corresponding roller guide, and wherein each of the strands of the second layer of the cable are guided around a respective roller guide. 
     
     
         8 . The system of  claim 7 , wherein the lay plate comprises a central aperture, disposed radially inwardly relative to the plurality of roller guides, and wherein the one or more strands of the first layer are guided through the central aperture. 
     
     
         9 . The system of  claim 7 , wherein the non-driven roll station comprises a housing that is coupled to the lay plate. 
     
     
         10 . The system of  claim 7 , further comprising a first closing die disposed downstream of the non-driven roll station, wherein the first closing die is coupled to the lay plate using a mounting bracket, wherein the one or more strands associated with the first layer are passed through the first closing die. 
     
     
         11 . The system of  claim 1 , further comprising a common closing die disposed downstream of the non-driven roll station, wherein the one or more strands associated with both the first and the second layers are passed through the common closing die. 
     
     
         12 . The system of  claim 1 , where the plurality of rolls of the non-driven roll station can be changed independently of the plurality of rolls of the driven roll station, such that the shapes of the one or more strands associated with the first layer of the cable may be modified without changing the plurality of rolls of the driven roll station. 
     
     
         13 . A system for forming a cable, the system comprising:
 a non-driven roll station having a plurality of rolls for forming a shape of one or more strands associated with a first layer of the cable; and   a driven roll station having a plurality of rolls for forming a shape of one or more strands associated with a second layer of the cable,   wherein the one or more strands associated with the first layer exit the non-driven roll station at a different speed relative to which the one or more strands associated with the second layer exit the driven roll station.   
     
     
         14 . The system of  claim 13 , wherein movement of the plurality of rolls of the non-driven roll station occurs passively during travel of the one or more strands associated with the first layer of the cable, and wherein the plurality of rolls of the driven roll station are actively driven to effect movement and speed of the one or more strands associated with the second layer of the cable. 
     
     
         15 . The system of  claim 13 , wherein the first layer of the cable is disposed radially inward relative to the second layer, and wherein the one or more strands associated with the first layer exit the non-driven roll station at a slower speed relative to which the one or more strands associated with the second layer exit the driven roll station. 
     
     
         16 . The system of  claim 13 , wherein the driven roll station is disposed upstream relative to the non-driven roll station. 
     
     
         17 . The system of  claim 13 , further comprising a lay plate having a plurality of recesses and a plurality of roller guides, wherein each of the plurality of recesses houses a corresponding roller guide, wherein each of the strands of the second layer of the cable are guided around a respective roller guide. 
     
     
         18 . The system of  claim 17 , wherein the non-driven roll station comprises a housing that is coupled to the lay plate. 
     
     
         19 . The system of  claim 18 , further comprising a common closing die disposed downstream of the non-driven roll station, wherein the one or more strands associated with both the first and the second layers are passed through the common closing die. 
     
     
         20 . A method for forming a cable, the method comprising:
 forming a shape of one or more strands associated with a first layer of the cable using a non-driven roll station having a plurality of rolls,   wherein movement of the plurality of rolls of the non-driven roll station occurs passively during travel of the one or more strands associated with the first layer of the cable; and   forming a shape of one or more strands associated with a second layer of the cable using a driven roll station having a plurality of rolls,   wherein the plurality of rolls of the driven roll station are actively driven to effect movement and speed of the one or more strands associated with a second layer of the cable.