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         ond conduit 32. The conduits 30, 32 may each be coupled
         to and extend from a housing 34 of the control system 10 to
         brackets 36 or other connectors mounted adjacent to the up-
         per corners of the tailgate. The bracket 36 or tailgate 16 may
         carry a pulley or other guide 38 around which the cable 12
         is routed to route the cable through an approximately ninety
         degree bend  as  the  cable  extends in  a lateral or  cross-car
         direction within the tailgate 16 and from the control system
         10, and is then routed from the tailgate 16 to the vehicle
         body in a manner that allows the pivoted motion of the tail-
         gate between its open and closed positions. The cable 12 may
         be a stranded wire, flat wire, rope, solid wire or of any other   Figure 14: Diagrammatic illustration of the production of a wire rope
         suitable construction.                               of which part of the length of the plastic core and of three of the wire
                                                              strands are respectively illustrated.
           As best shown in figures 11 - 13, the control system 10
         includes the housing 34, a spool 40 to take up and pay out   eter of the wire strands 15.
         the cable 12, the drive 14 which is coupled to the spool 40   The wire strands 15 are twisted around this plastic core
         to rotate the spool, and first and second clutches 18, 20 that   11 moved with a feed motion in the axial direction, said wire
         are coupled between the drive 14 and spool 40. The housing   strands being wound around the plastic core 11 with a spe-
         34 may include a base 42 and a cover 44 that when coupled   cific revolution speed and feed speed. The plastic core 11 is
         together define an interior in which the spool 40, clutches   provided with these helical grooves 20 by machining directly
         18, 20 and other components may be mounted. The cable 12   before the wire strands 15 are wound onto said core. This
         may extend out of the housing 34 through opposed openings   machining according to the invention of the plastic core 11
         46, 48 in the housing 34, and guides 50 (figure 13) may be   introduced as a cylindrical bar 11’ made of a flexible plastic
         carried by the housing 34, each adapted to engage one cable   is implemented by means of a machining device 25 in which
         segment 22, 24 between the openings 46, 48 and the spool   cutting tools 26 are rotated around the plastic core 11 with
         40, if desired. The guides 50 may reduce friction on the cable   the same revolution speed as the wire strands 15 in order to
         12 and help control cable movement into and out of the hous-  produce the helical grooves. The cutting tools 26 are directed
         ing 34. The drive 14 may include an electric motor carried   here with their blades opposing the direction of movement of
         by the housing 34 (e.g. the cover) to provide a self-contained   the plastic core.
         unit, if desired. The drive 14 may rotate an input shaft 52   There is assigned to each cutting tool 26 a tool holder 27
         that is coupled to the spool 40 through the first and second   which is respectively fastened with radial adjustment to a
         clutches 18, 20. The input shaft 52 may be directly driven by   rotatable  tool head  25 with a central opening for passing
         the motor 14, or it may be driven through one or more gears   through the bar 11’. The respective tool holder 27 consists
         driven by an output shaft of the motor.              of a clamping chuck 28 and an adjustment module (not de-
                                                              tailed) by means of which the cutting tool 26 can be set pre-
         Method of producing wire rope                        cisely to the diameter of the plastic core 11. The rotary drive
         Pat. 9,593,446 U.S. class D07B 5/00 Int. class D07B 1/06   of the tool head 25 and the reels with the wire strands 15
         Inventor: Christoph Nater, Kesswil, CH.              wound over them are not detailed.
         Assignee: Fatzer AG Drahtseilfabrik, Romanshorn, CH.  The wire  strands  15 and the plastic core  11 are drawn
           With a wire rope comprising at least one plastic core and   through an annular mandrel 22 in the axial direction with
         a number of wire strands twisted around the latter a heli-  the same feed speed. The wire strands 15 are advantageous-
         cal groove is respectively produced by machining around the   ly pre-formed in a helical shape when introduced for twist-
         periphery of the plastic core for each wire strand. The cross   ing and are drawn together with the plastic core, the wire
         section of these helical grooves is respectively matched to   strands being pressed against the plastic core by this man-
         the outside diameter of the wire strands. The plastic core   drel 22, these grooves 20 thereby serving as a guide for the
         is provided with the helical grooves for receiving the wire   wire strands 15.
         strands by this machining directly before the wire strands
         are wound onto said core. By thus forming the wire rope by
         means of this machining in order to produce helical grooves
         of the plastic core, optimal guiding of the wire strands in the
         twisted state is achieved, and so overall there are improve-
         ments to the properties of the wire rope.
           Figure 14 shows  the production of a wire rope  10 with
         a plastic core 11 and a number of wire strands 15 twisted
         around  the  latter,  for  better illustration  only  three  of  the
         total of six wire strands being shown. The plastic core 11
         is produced here from one or more flexible plastics, and it
         could, moreover, be provided with fibre reinforcement.
           Such wire ropes are suitable for all types of cable car, for
         example for use with railway vehicles which are pulled by
         wire cables which are guided  between the rails on rollers
         or the like. According to the invention a helical groove 20 is
         respectively produced by machining  around the periphery
         of the plastic core 11 for each wire strand 15, these helical
         grooves 20 respectively being matched to the outside diam-  Figure 15: Cross section of a wire rope.

         58     Wire Rope News & Sling Technology   June 2017
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