Note: Descriptions are shown in the official language in which they were submitted.
CA 02382385 2002-05-10
r
Blowing Head
This invention relates to a blowing head for use in blown cable installations
and to
a buckle detector suitable for integration with such a blowing head.
Ei It is well known from European Patent EP-B-108590 and subsequent
publications that optical fibre transmission fines can be installed into ducts
using.
the fluid drag provided by ~ high-speed flow of a gaseous medium. This method
is
practised with optical fibre and copper cables ranging in size from about 1 mm
to .
20 mm or more, depending upon the application and the route into which
1 CI installation is to take place.
As described in EP-B-108590 a blowing head comprises a pair of motor
driven wheels which provide a propulsive force which serves to advance the
cable
until a sufficient length has been installed in the duct for viscous drag
forces to be
effective in further installing the cable (typically the first third to half
of the overall
15 length of the installation duct). The drive wheels also enable the
hydrostatic back
pressure, which acts to urge the cable back out of the duct, to be overcome.
The rate of the advance of the cable depends inter alia upon the
magnitude of the pushing force applied by the drive wheels, friction and the
amount of viscous drag available (which depends upon the applied gas pressure,
20 cable diameter, duct size and length and installed cable length). Typically
the rate
of installation in any given situation is controlled by the operator simply
controlling
the amount of pushing force applied by the motor. Because any given blowing
head can typically be used with a range of cable diameters, it is common for
the
blowing head motor to be able to provide more pushing force than a relatively
25 small cable can withstand without buckling. Normally the desire is to use
the
fastest possible installation rate whilst avoiding buckling and the motor
control is
adjusted to provide this. As the skilled person will understand, in practice a
given
cable will start to buckle under different conditions depending upon its free
length,
the pulling force provided by viscous drag, friction, duct diameter, duct
geometry,
30 etc. Thus, in practice the machine operator needs to stay with the blowing
head
in order to monitor the blowing process and to ensure that buckling is
avoided, at
least if a reasonable installation rate is to be achieved.
CA 02382385 2002-05-10
2
Cable buckling is avoided in order to prevent damage to both the cable and
blowing. head, especially the drive wheels. Buckling cari cause the cable. to
jam in
the duct and tends to .cause delays in the installation process. Blowing heads
may
include .motor stall sensors, clutches or frangible links operative to prevent
damage
to the .motor or drive wheels (or tyres). Even with heads having such
features, the
operator in practice still needs to monitor the blowing operation at the
blowing
head. A device, known as a buckle detector, for monitoring the onset of
buckling
and for controlling the blowing head drive to avoid buckling is described in
EP-B-
253636. It is known' from GB-A-2 294 131 to integrate a buckle detector with a
blowing head.
The .present applicants, who are the proprietors of the above-mentioned .
European Patents, have now devised a new buckle detector which can be
iritegrated with a blowing head to 'form a simple and compact device which
improves overall blowing.performance - even compared to the combined use of
the
blowing head of EP-B-108590 and the buckle detector of EP-A-345968. The new
head design resulting from the integration of the new buckle detector is
particularly
suitable for use with the very compact optical fibre cables described in EP-A-
521710 and EP-A-345968.
According to a first aspect of the invention there is provided a blowing
head for a blown cable installation process,, the blowing head comprising:
a cable inlet to receive a cable, a cai'le outlet for connection~to a duct
into
which the cable will be installed, the cable inlet being connected to the
cable outlet
by a co~necting~channel; . ~ .
one or more drive wheels coupled to drive means, the drive means, in use,
driving the one or more drive wheels to apply. a longitudinal drive force to
the
cable,
a ~ cavity contiguous with the connecting channel, deflecting means;
sensing means, control means; a gas inlet port and a gas .injection point, the
gas
injection point being coupled to the gas inlet port and opening into the
connecting
channel at a point intermediate the.cavity and the cable Outlet; .
said longitudinal drive force in use causing the cable to be advanced along
the connecting channel, through the cavity, past the .deflecxing means and the
gas
injection point, and through the cable outlet into a duct connected thereto;
CA 02382385 2002-05-10
l 3
There is also provided a blown cable installation apparatus, comprising a
blowing head as described a4ove and control means responsive to the 'output of
a
sensor in the buckle detector and operative to control the motor in response
to the
output of the sensor.
According to a second aspect of the invention there is provided a blowing
head for a cable installation process, the blowing head comprising: a cable
inlet
to receive a cable, a cable outlet for connection to a duct into which the
cable will
be installed , the cable inlet being connected to the cable outlet by a
connecting
channel, one or more drive wheels coupled to drive means, the drive means, in
1 () use, driving the one or more drive wheels to apply a longitudinal drive
force to the
cable, a cavity contiguous with the connecting channel, deflecting means,
sensing means, control means, a gas inlet port and a gas injection point, the
gas
injection point being coupled to the gas inlet port and opening into the
connecting
channel at a point intermediate the cavity and the cable outlet; said
longitudinal
1 a drive force causing the cable to be advanced along the connecting channel,
through the cavity, the deflecting means and the gas injection point, and
through
the cable outlet into a duct connected thereto; the sensing means being
configured to sense lateral. deviation of the cable, said lateral deviation
occurring
when excessive longitudinal drive force causes the cable to buckle at the
2n deflecting means; the control means being responsive to the sensing means
to
control the drive means to vary the driving force applied by the one or more
drive
wheels in accordance with the output of the sensing means.
Preferably means are provided to detect the direction of movement of the 7
transmission line such that if the transmission line moves in a reverse
direction t
25 from the usual installation direction) the control means direct the drive
means to
increase the driving force applied by the one or mare drive wheels until the
transmission line is held in equilibrium. Preferably only one of the drive
wheels is
coupled to the drive means. Preferably the sensing means comprise an optical
source and an optical detector.
30 Preferably the source of high pressure gas is chosen to be compatible with
the environment in which the installation will take place, although routinely
aw
CA 02382385 2002-05-10
4 c,. .
inert gas such as air or nitrogen will be used. A compressor or bottled gas
may be
used.
According to a further aspect of the invention there is provided a method .
of installing a cable into a duct, the method comprising the steps of:
I) coupling a blowing head according to the first or second aspects of .
the invention to the duct;
ii) introducing a cable into the blowing head and engaging the cable
with the rotatable driving element or wheel of the head;
iii) applying pressurized gas to the duct;
iv) advancing the cable through the head and along the duct; and
v) controlling the tractive force applied through the rotatable driving
element or wheel in accordancEl with the output of a sensor or sensors of the
blowing head.
According to a further aspect, the present invention provides a blowing
1 !5 head for a blown cable installation process, comprising: a motor and a
rotatable driving element operatively connected to the motor; a cable inlet to
receive a cable to be installed; a cable outlet for connection to an
installation duct
into which the cable is to be installed, the cable outlet being connected to
the
cable inlet by a through bore, the through bore defining a cable path along
which
the cable passes in use; a rotation sensor to sense the direction of movement
of the rotatable driving element; and control means, operatively connected to
the rotation sensor and to the motor; in use the control means causing, in
response to the detection of rotation of the driving means in the sense
opposite to
that which applies when the cable is being inserted into the duct, the motor
to
2.5 apply a holding torque to the driving element to counteract the opposite
rotation.
In a yet further aspect, the present invention provides a buckle detector
for a blown cable installation process for use downstream of the tractor
element
of a blowing head, the detector comprising: a cable inlet to receive a cable
to
:30 be installed; a cable outlet for connection to an installation duct into
which the
cable is to be installed, the cable outlet being connected to the cable inlet
by a
through bore, the through bore defining a cable path along which the cable
passes
CA 02382385 2002-05-10
in use; a cavity, through which the cable path passes, a sensor or sensors
being
provided to monitor, in use, the position of the cable within the cavity; the
buckle detector also including a deflector on which the cable impinges on its
passage along the cable path, the deflector being arranged to introduce a bend
5 into the path followed by the cable, the arrangement being such that, if the
cable
is propelled into the buckle detector with an excess of force the cable will
preferentially buckle within the cavity at the site of the deflector.
The invention will now be described, by way of example only, with reference to
the following drawings in which:
Figure 1 is a schematic depiction of a blowing head according to the prior
art;
Figure 2 is a schematic depiction of the control apparatus according to the
prior
art;
Figure 3 is a schematic depiction of a blowing head according to a first
embodiment of the present invention;
Figure 4 is a schematic depiction of the cross-section of the interior of a
blowing
head according to the first embodiment of the present invention;
Figure 5 is a block diagram showing the main elements of the electronic
subsystems that control a blowing head according to the present invention;
Figure 6 is a schematic depiction showing the arrangement of the encoder, the
motor and the drive wheels in a blowing head according to the present
invention;
Figure 7 is a schematic depiction of a blowing head according to a second
embodiment of the present invention;
Figure 8 is a schematic depiction of the cross-section of the interior of a
blowing
2~i head according to the second embodiment of the present invention; and
Figure 9 is a schematic perspective view of a blowing head according to the
second embodiment of the present invention;
Figure 10 is a schematic depiction of an experimental method for determining
the
resistance of a transmission line to compressive forces;
3() Figure 11 is a schematic partial cross-section through the blowing head
according
to the second embodiment of the present invention;
CA 02382385 2002-05-10
6
Figure 12 is a representation of a blowing head according to the present
invention;
and
Figure 13 is a representation of a blowing head according to the present
invention,
with the blowing head opened to show interior details.
'
Figure 1 shows a. schematic depiction of the prior art installation
apparatus 10 used to install transmission fines into pre-installed ducts. The
transmission Fine 1 is driven by a pair of drive wheels 2 and 3. The
installation
apparatus, or blowing head 7 0, also comprises an inlet 4 for the connection
of a
supply of a high-pressure (typically 3 to 10 bar) gaseous medium. The high-
pressure gaseous medium enters the passageway 7 at an injection point 5,
developing a high-pressure region within the blowing head 10. The drive force
applied by the drive wheels advances the transmission line through a seal 6
and
into the passageway 7, overcoming the hydrostatic potential due to the
difference
in pressure between the high-pressure region within the blowing head and duct
and the pressure (typically atmospheric) outside the blowing head. The drive
force
further propels the transmission line along the passageway, through tube 8 and
into the pre-installed duct 9. The injection of the gaseous medium causes a
high
speed airflow along duct 9 and the combination' of the drag force caused by
the
high speed airflow and the drive force applied by the wheels -propels the
transmission .line along the length of the pre-installed duct.
Figure 2 shows a schematic depiction of the prior art control apparatus 12
and 13 being in used in conjunction with a blowing head 10. The control
apparatus, or buckle detectors, 12 and 13 are both connected to ~a control
unit 14;
which is in turn connected to control means associated with the blowing head
10
(not shown). A continuous length of duct 9, which is the beginning of the
installation duct passes through buckle detector 12, which imparts a curve
onto
the trajectory of duct 9. Similarly the length of duct. 11, which carries the
transmission line 2 into the blowing head 10, passes through buckle detector
13.
Buckle detector 12 is configured to detect excessive .longitudinal compressive
'
forces in the transmission line whilst buckle detector 13 is configured to
detect '
excessive longitudinal tensile forces in the transmission line. When either of
the
CA 02382385 2002-05-10
7
buckle detectors detects excessive forces in the transmission line the
relevant
detector outputs a signal to the control unit 14, which in turn sends a signal
to the
control means within the blowing head to vary accordingly the drive force
applied
to the transmission line.
Figure 3 shows a schematic depiction of a first embodiment of the present
invention. Blowing head 7 5 has many features common to the blowing head of
the prior art such as the drive wheels 2 and 3, which drive the transmission
line
through the seal 6 and along the passageway 7. The passageway 7 is, in use, at
a pressure greater than the external pressure due to the supply of a high-
pressure
1 C1 gaseous medium to the inlet 4, the high-pressure gas being introduced
into the
passageway 7 at the injection point 5. The outlet of the blowing head is
connected, via tube 8, to pre-installed duct 9 along which the transmission
line 1
is propelled by the combination of the drive forces applied by the drive
wheels 2
and 3 and the drag forces caused by the high-speed flow of the gaseous medium.
1 ~i Additionally there is a cavity wf~tich adjoins the passageway
intermediate the seal
6 and the gas injection point 5. The cavity extends the cross-section of the
passageway throughout the length of the cavity. Optical sensors, here two in
number, 17 and 18 are situated in the walls of the cavity. The body of the
blowing head can be made from any material which can be suitably forrried to
20 manufacture the blowing head and resist the increased pressure that occurs
within
the blowing head. Preferably the material used to make the blowing head is a
metal such as an aluminium alloy or stainless steel, although an engineering
plastic
such as glass-reinforced nylon or an epoxy resin can be used. The seal 6 is
preferably annular with the aperture dimensioned so as to accept a
transmission
25 line whilst minimising the leakage of gas through the seal from the blowing
head
and minimising the friction between the seal and the transmission line. The
seal
can be made from a polymeric or metallic material, but metallic seals are
preferred
as they have a longer operating lifetime. Figure 3 shows the control circuit
and
the drive means as being located within the body of the blowing head. It will
be
30 understood that eithef, or both" of the control circuit or the drive means
may be
located in a separate unit which can be sited remotely from the blowing head
CA 02382385 2002-05-10
8
when the head is in operation. It is possible, and generally preferable, to
connect
the blowing head directly to the duct without an intermediate tube.
Figure 4 shows a schematic depiction of the cross-section of the interior
of the blowing head 15, with each sensor 17 and 18 comprising an optical
source,
respectively 17a and 18a, and an optical receiver, respectively 17b and 18b,
which are in direct alignment and sited on opposite sides of the cavity, on an
axis
which is perpendicular .to the axis of the cavity. The term "optical" includes
light
from the visible spectrum as well as infra-red radiation in the wavelength
bands
commonly associated with optical fibre communications systems:
ft will be readily understood that optical sensors are not the only type of
sensors that could be used. Mechanical contact switches could be used to give
either an indication of the position of the transmission line or the buckling
force
that was acting on the transmission line. If the transmission line contains
metallic
members then it would be possible to use non-optical electrical sensors which
could measure variations in inductance or capacitance:
The optical receivers of sensors 17 and 18 are connected to a control
circuit 19, which is in turn connected to the drive means 20 which is coupled
to
one of the drive wheels 2 and 3. The uppermost sensor 17, that is the sensor
closest to the axis of the passageway, is sited such that when in a normal
state of
2Cn operation the transmission Vine 'triggers the upper sensor 17 by
interrupting the
beam of light transmitted from optical source 17a to optical receiver 17b. It
is
generally unimportant whether the interruption is complete, i.e. the
transmission
line completely obscures the source or detector, or partial as long as there
is a
measurable change in the output of the detector between the presence and the
2=i absence of the transmission line.
If a transmission line were to be introduced into the blowing head and the
interior of the blowing head was already pressurised, then the pressure
differential
between the inside and the outside of the blowing head would cause a piston
force to be applied to the 'transmission line, tending to expel the
transmission line
317 from the blowing head. To prevent this from occurring, when sensor 17
initially
detects the presence of a transmission line it causes a holding torque to be
applied
to the transmission line, of a sufficient magnitude to overcome the piston
force
CA 02382385 2002-05-10
9
and maintain the position of the transmission line. This feature of the head,
which
does not appear to have been used before, clearly has application to blowing
heads of all types, whether of not they also include a buckle detector. Whew
the
installation is to begin the torque applied to the transmission line is
increased so
that the drive wheels drive the transmission line into the duct. The maximum
installation speed is governed by a potentiometer which is located on the
blowing
head, in such a position so as to allow the operator to manually adjust the
maximum installation speed of the transmission line. When an installation is
started, the control circuit 1.9 instructs the drive means 20 to increase
linearly the
installation speed from zero to the maximum installation speed in six seconds.
Under normal operating conditions the cable occupies the central position of
the
passageway, at least partially obscuring the sensor 17 and this gives rise to
a
green indicator (e.g. an LED) being illuminated to inform the operator that
the
installation is proceeding in a proper manner. -w
When the drive force applied by the drive wheels is greater than the force
due to the drag of the high-speed airstream which is "seen" at the blowing
head,
compressive forces occur in the cable at the blowing head. The cable is a
slender
column and will begin to buckle when sufficient compressive force acts upon
it.
The passageway constrains the lateral movement of the cable, but the portion
'of
the cable that is within the region of the passageway that adjoins the cavity
is
free to move laterally into or further into the cavity. However, when
sufficient
longitudinal compressive forces act on the cable, the cable in the region of
the
cavity will buckle. If the buckle in the cable causes the cable to move
laterally
such that it ceases to trigger the upper sensor 17, then the optical receiver
17b
2Fi will detect the radiation emitted by optical source 17a unimpeded by the
cable.
The control circuit receives the change in signal from sensor 17 and sends a
signal
to the drive means to reduce the driving force applied by the drive wheels.
This
situation causes an amber indicator LED to be illuminated to inform the
operator
that a minor problem has occurred.
3t) This decrease in drive force will reduce the compressive forces in the
cable and hence reduce the slight buckle in the cable, causing the cable to
tend to
return to its typical position and to re-trigger the upper sensor. The control
circuit
CA 02382385 2002-05-10
will then try to increase the installation speed from its reduced level back
to the
maximum level; increasing the speed linearly over a period of 6 seconds.
Situations may arise where the cable "hunts" in between the "green" and
"amber"
states and in this case the blowing head operator should use the potentiometer
on
the blowing head to reduce the set maximum installation speed of the cable:
The
feedback loop that minimises the amount of buckle in the cable is sufficiently
responsive so that the amouht of time that the cable is in the "amber" state
is
minimised. Circumstances which might cause the cable to enter the "amber"
state are the cable traversing a bend in the route of the duct or when the
cable is
1 C~ near to the end of the duct route.
if the transmission fine were to come to a stop, for some reason such as,
for example, a duct blockage or a bend of very small radii in the duct, then
there is
a significant possibility that the drive force would cause the transmission
line to
buckle so much that mechanical damage would occur, with the possibility of
1 Ei snapping the transmission line. In order to prevent this possible
failure, if the
buckled transmission line triggers lower sensor 18, the control circuit causes
the
drive means to stop the drive wheels instantly so that the problem with the
installation can be rectified. The position of the lower sensor is chosen such
that,
in general, the transmission line can buckle sufficiently to trigger the
sensor
2n . without experiencing significant mechanical damage. This situation causes
a red
indicator LED to be illuminated to inform the operator that a serious problem
has
occurred. If this "red" state is 'entered the blowing head can only be re-
started by
returning to the "green" state and increasing the installation speed from
zero. The
installation speed will then be increased linearly from zero to the maximum
value
25 over a period of six seconds.
Figure 5 shows a block diagram which indicates the main elements of the
electronic sub-systems that control the blowing head. The control logic 38
receives information from the buckle sensors 39 regarding the position of the
cable within the blowing head, i.e. whether the cable is in the "green",
"amber" or
30 "red" states. Depending upon the information received from the buckle
sensors '
the control logic instructs the motor drive circuit 35 to maintain, increase
or
decrease the speed of the motor 32, which in turn impels the drive wheels. The
CA 02382385 2002-05-10
11
motor drive circuit applies a drive voltage to the motor and the speed of the
motor
is proportional to the drive voltage applied by the motor drive circuit. The
maximum drive voltage is governed by a potentiometer, the setting of which can
be altered by the operator of the blowing head to control the installation
speed in
order to suit the characteristics of the route into which the cable is being
installed.
The encoder 33 is physically coupled to the motor (see Figure 6) to enable the
. speed and direction of the motor to be monitored. The encoder is a
conventional
two channel optical device, comprising two out-of-phase fine sets carried on a
disc
40 and an encoder detector 41 . From the relative position of the rising and
falling
edges generated by the two line sets, the direction of motion of the motor,
and
thus the drive wheels, can be ascertained. If the motor begins to move in a
reverse direction (relative to the direction of the cable when being
installed) then
the encoder logic 36 instructs the motor drive circuit to apply a holding
torque, in
order to hold the cable within the body of the blowing head and prevent it
from
being expelled out by the piston force caused by the pressure differential:
The encoder disc 40 generates 500 pulses per revolution for each of the
two channels. The disc is physically coupled to motor 32 (see Figure fi) which
is
connected to the drive wheels 2 and 3 via gearing 42. The gearing has a ratio
of
5:1 so that a single revolution of the drive wheels requires 5 revolutions of
the
2C! motor and thus generates 2500 pulses in each encoder channel. The tyres of
the
drive .wheels have a circumference of approximately 100 mm and thus 25,000
pulses are generated by installing the cable a distance of 1 metre. This
allows the
position of the cable to be accurately monitored as each encoder pulse
represents
a cable displacement of 40 ,um. As indicated above, this aspect of the new
head
2Ei has application to heads which are used without buckle detectors and it is
believed to be independently inventive.
Figure 6 shows the motor being coupled to both of drive wheels 2 and 3. It
should be understood that the motor could be coupled to only one of either
drive
wheels 2 or 3.
3~J The above discussion has referred to drive wheels but it will be apparent
to the
skilled person that the drive wheel for wheels) could be changed for an
equivalent
device such as, for example a drive belt or a caterpillar drive.
CA 02382385 2002-05-10
7._
12 E..,..
Referring to Figure 5, information regarding the installation distance and
speed are fed from the encoder logic 36 to the distance and speed calibration
circuit 37. The installed distance is displayed to the operator using display
34,
which preferably comprises an LCD display unit but may comprise any suitable
display unit ( e.g.an L.E.D. or electromechanical device). The display unit
also
displays the nominal installation speed of the cable, vvhich is derived from
the
position of the potentiometer that governs the motor drive current. If there
is a
difference between the installation speed as derived from the potentiometer
and
the installation speed as calculated by the encoder logic from the output of
the
encoder, then a calibration signal is sent to the encoder logic which causes a
further signal to be sent to the motor drive circuit, activating a
servomechanism
that causes the motor drive voltage to be suitably increased. This feedback
loop
ensures that the actual installation speed of the cable is the same as the
nominal
installation speed that is indicated by the display in accordance with the
1 ~~ positioning of the potentiometer by the operator of the blowing head.
Such a
discrepancy may arise due to temperature-dependent variations in the rolling
resistance of the tyres.
Figure 7 shows a schematic depiction of a second embodiment of the
present invention and Figure 8 shows a schematic depiction of the cross-
section
of the interior of the second embodiment of the present invention. Blowing
head
21 is structurally similar to blowing head 15 (as shown in Figure 3) except
for the
addition of deflector 22. The deflector is slightly curved and in this
particular
embodiment it is a plate. The deflector is positioned parallel to the axis of
and
slightly protruding into the bore of passageway 7. When the blowing head is
operating in its normal state, the transmission line passes over the
deflector,
triggering the upper sensor 17 which causes the drive force to be maintained
at its
maximum permissible level. When excess compressive forces act upon the
transmission line the blowing head operates in an identical manner to the
apparatus of the first embodiment, as described above and depicted in Figures
3
and 4. The addition of the deflector causes the transmission line to buckle in
a
more controlled manner and reduces the possibility of the transmission line
being
damaged by excessive compressive forces.
CA 02382385 2002-05-10
13
A blowing head as described above, sized appropriately, could be used in
the installation of cables with diameters ranging from 1 to 20 mm. In order to
maximise the utilisation of network infrastructure there is considerable
interest in
installing very small cables, i.e. 1 mrn diameter, into microducts with an
internal
bare of, say, 3.5 mm. Such , small cables are described in European Patent
Applications EP-A-345968 and EP-A-521710. Typically, such cables contain from
1 to 8 optical fibres, usually single mode, sometimes multimode, housed in a
common polymeric sheath. Because of their size and structure, these cables
have
little resistance to buckling and would benefit greatly from the use of a
blowing
head according to the present invention. The following discussion assumes the
use of such a cable with a nominal diameter of 1 mm. The underlying principles
hold true for cables with larger diameters, but the embodiments described in
the
following discussion would need to be scaled suitably to account for
differences in
cable diameter, stiffness, etc,.
Figure 10 shows a schematic perspective representation of a blowihg
head according to the second embodiment of the invention. The two halves of
the
blowing head are connected by hinge 29 and can be fastened shut using clamp
30. It is understood that any other method of effecting a seal by fastening
the
two halves of the blowing head together may be used, but the use of an
integral
20~ hinge has the advantage of reducing the numbers of fasteners needed for a
secure
fixing of the upper and lower parts of the head, reducing the time involved in
opening and closing the head. Also, the hinged arrangement lessens the
likelihood
of damage to seal 31 or the lower face of the upper half of the head. Seals 6
and
31 prevent the high-pressure gas escaping from the blowing head. Outlet 28
enables ducts of two different sizes to be seaiingiy clamped to the blowing
head.
Typically, circumferential grooves in the form of teeth are provided to
facilitate the
retention of the duct within the head are provided. The skilled person will
readily
understand that the head can be designed to receive only one tube size, or
more
than two tube sizes. It will be also understood that the tubes may be attached
to
the blowing head using a connector or any other means that effects an
efficient
seal.
CA 02382385 2002-05-10
14
Figure 9 shows a schematic depiction of an experimental method for
determining the resistance of a transmission line to compressive forces.
Samples
of transmission line 1 were piaced in experimental apparatus 26 and 27 which
recreate the dimensions and geometry of the interior of blowing heads 15 and
21,
Gi figures 7a and 7b respectively. Load cell 23 places an axial compressive
force,
which increases with time, on the end of the sample of transmission line and
transmits the magnitude of the compressive force to the data logger 25. As the
compressive force increases the transmission line will start to buckle subject
to
the constraints of the cavity and the passageway and will cease to trigger
sensor
17. Control unit 24 sends an output signal to data logger 25 and the
compressive
force at which buckling started is stored -in the memory of the data logger.
The
compressive force will continue to increase, further increasing the buckling
on the
transmission line. When the transmission line reaches the point of maximum
buckle it will trigger lower sensor 18, which causes the control unit to send
a
1 !5 signal to the data logger. The data logger will record the compressive
force at
which maximum buckling occurred.
Experimental apparatus 27 is similar to experimental apparatus 26, except
that it additionally comprises a deflector 22 which has the same size and
dimensions as the deflector used in blowing head 21. The deflector also has
the
same position relative to the cavity as the deflector in blowing head 21. The
compressive forces required t:o start buckling and for maximum buckle are
similarly recorder by the data logger 25.
Table 1 shows a number of experimental results obtained using the
experimental method described above with the apparatus shown in Figure 8a. The
2:5 t symbol denotes that the compressive forces were sufficient to break the
transmission line.
Force Required Force Required
Sample Number to for
Start Buckling Maximum Buckle
(grams force) (grams force)
1 38 58
2 88' 88t
3 1041 1041
CA 02382385 2002-05-10
4 88r 88r
5 48 58
6 35 64
7 42 64
8 41 64
_
g _35 56
10 g8r g8r
Table 1
Table 2 summarises a number of experimental results obtained using the
':~ experimental method described above with the apparatus shown in Figure 8b,
i.e.
including the deflector.
Force Required Force Required
Sample Number to for .
Start Buckling Maximum Buckle
(grams force) (grams force)
1 45 68
2 45 64
3 46 67
4 43 64
5 ' 46 65
6 38 60
7 ' 38 58
8 42 fi 5
9 44 67
10 43 68
Table 2
1 () A comparison of Table 1 and Table 2 shows that the inclusion of the
deflector significantly improves the repeatability of the experiment, making
both
CA 02382385 2002-05-10
the force at which buckling starts and the force that causes maximum buckling
more consistent. The deflector also prevents the build-up of higher forces
that
lead to very rapid buckling and fracture of the transmission fine. .
It will be recognised that the function of the deflector is to cause buckling
Ei to occur before the cable suffers physical damage and that this function is
more
significant than the structure of the deflector. Preferably the deflector is
curved.
If the deflector is not curved then any edges which may come into contact with
the cable should be chamfered, so that.the likelihood of the deflector
abrading the
cable is minimised. The deflector and its surroundings should be designed so
that
if the cable buckles within the head it does so into the cavity at the site of
the
deflector Conveniently, the deflector's curve may describe an 'arc of a
circle. The
deflector could alternatively have a parabolic curve or a non-curved
structure.
Any non-curved deflector would have to be designed such that the passage of
the
cable over the deflector does not lead to damage to the outer surface of the
cable.
1 Ei Figure 12 shows a representation of a blowing head according to the
invention with the two halves of the blowing head being sealed by clamp 30.
Housing 31 contains the motor and gearing and housing 32 contains the encoder.
Figure 13 shows a representation of a blowing head according to the invention
with the blowing head opened to show interior details.
21J The deflector is provided in order to provide the advantageous effects of
Ii) a more repeatable threshold for the onset of buckling and
tii) a reduced maximum buckle force which reduces the possibility of
damaging the transmission line. As indicated above, the exact shape of the
deflector is not critical and the deflector may have, for example, either a
circular
25 or a parabolic curve. It has been found that for a cable having a diameter
of 0.9
to 1.2 mm and for a deflector having a curve of part circular profile it is
preferable
that the deflector protrudes 0.5 mm to 1.5 mm into the passageway and has a
radius of 10 - 50 mm. More preferably, for this cable size, the deflector
protrudes
1 mm, or thereabouts, into the passageway and the radius of the deflector's
curve
30 may be 30 mm or thereabouts. In order to make allowance for the tolerances
attainable with mass production techniques it is preferred that the deflector
is
connected to adjusting means to allow for the protrusion of the deflector to
be
CA 02382385 2002-05-10
17
calibrated Ltypically before it is despatched to the field and periodically
thereafteri.
This will also enable the blowing head to be used with cables with a range of
diameters.
For a cable with a diameter of approximately 1 ~~nm it has been found that
the passageway 7 preferably has a diameter of 1.5 - 3 mm. More preferably the
passageway is 2 mm in diameter. The upper limit to the size of the passageway
is governed by the size of the duct into which the cable is to be installed.
In
__ general the diameter of the passageway should be less than the diameter of
the
duct. A typical duct diameter for a 1 mm cable is 3.5 mm. The relationship
between cable diameter and duct diameter for successful blowing installations
is
well known from EP-B-108590. It is preferred that the ratio of cable diameter
to
duct bore is within the range 1:3 to 1 :2. Installation of cables into ducts
which lie
outside of this range is not impossible but is much less efficient. The size
of the
cavity into which the cable will deviate also depends upon the diameter of the
cable. In general the depth of the cavity should be at least four times the
cable
diameter and the cavity length should be at least eight times the cable
diameter.
In order to prevent cables being subjected to too small a bend radius it is
preferred
that the cavity is at least twice as long as it is deep. For a cable with a 1
mm
diameter a preferred range of cavity depths is 6 - 10 mm and a preferred range
of
cavity. lengths is 20 - 30,mm. Highly satisfactory results have been achieved
with
a cavity depth of 8 mm and a cavity length of 25 mm. It is preferred that the
cavity has a convex curved shape in order to prevent cables being subjected to
too small a bend radius. An alternative cavity shape would be a substantially
rectangular shape but with chamfered corners to prevent damage occurring to
the
cable.
The drive means which are used to propel the transmission line along the
duct normally comprise an efectr'ic motor, typically low voltage 1<_ 50V) to
provide
the drive force, however it will be understood that other forms of motor e.g.
hydraulic or pneumatic motors may also be used. Pneumatic motors in particular
are preferred alternatives to electric motors although an appropriate control
transducer needs to be provided to enable the electrical output of the
controller 19
to control the motor's drive force. Additionally, rather than coupling both of
the
CA 02382385 2002-05-10
:r~ .,.
1s i
drive wheels to the drive means it is possible, and preferable, to provide the
drive
force through only one of the drive wheels. This avoids problems, which can
arise
with two drive wheels - if they are not sychronized, of different drive forces
being
provided by the different drive wheels - which can lead to serious cable
damage. It
'~ should also be understood that in the embodiments discussed above, the
speed of
the motor is governed by the do voltage fed to it. Alternatively the motor
could be
pulse width modulated, with the duty cycle of the pulses being varied in order
to
govern the speed of the motor.
Even though the rate of the installation process is automatically controlled
1 ~~ by the control means it is beneficial to supply information to the
operator of the
blowing head using some form of display, for example illuminating a green
tight to
indicate a normal operating state (referred to above as the "green" state), an
amber light to indicate that buckling is occurring and that the drive force is
being
reduced (referred to above as the "amber" state) and a red fight to indicate
that
15 maximum buckling has occurred and that the drive force has been removed
(referred to above as the "red" state). This display may be mounted on a
surface
of the blowing head and/or on a separate unit which can be sited remotely from
the unit when the head is in operation. Additionally or alternatively audible
signals
may be provided to indicate state changes or non- green states. Additionally a
20 manual override on the control circuit may be provided so that the
installation is
only re-started once the blockage that caused the "red" blockage to occur has
been removed.
Although in the above described embodiments the cavity has been shown
and described as extending "down" into the lower block, it could of course
extend
~!5 "horizontally" or laterally. An advantage of the "'vertical" arrangement
is that no
part of the optical sensor arrangement (which as either detector or source
needs
an electrical connection) needs to be in the upper position of the head. It
would
be possible to keep "all" the cavity and the sensors as part of the lower half
of the
head, even with a head which split generally along the axis of the bore along
',30 which the cable is guided and this would be preferable to arrangements in
which
an active part of the sensors were part of the upper half of the head.
CA 02382385 2002-05-10
19
Either in combination with a "horizontal" cavity as just proposed or with a
"vertical" cavity, the optical source and optical detector for a sensor could
be
mounted side-by-side with an appropriately positioned reflector serving to
guide
the light from the source to the detector. In a "horizontal" cavity
arrangement the
reflector (e.g. mirror or polished surface) would be best be provided on .the
upper
half of the head.
The drive wheels do not need to be mounted as an integral part of the
block which forms the rest of the head, but .too large a gap should be avoided
so
as to minimise the possibility of the cable buckling in the gap between the
wheel
housing and the rest of the head. (Obviously the size of gap that is
acceptable
will depend upon the ease with which the cable used will buckle and this will
in
general be related to the diameter of the cable.) The 'drive wheels are
typically
provided with rubber tyres, and these will typically need periodic
replacement. At
least for the small diameter Cables, the tyres are formed from a suitable
polymer
or rubber material. for example Welvic PVC, which has a density of 1170 kg m~3
and a softness of 115 (measured using British Standard BS 2782 Method 365A).
An alternative material is GA8718, which has a density of 1320 kg m'3, a
softness of 86 (measured using British Standard BS 2782 Method 365A) and a
Shore hardness of 57 (measured using British Standard 13S 2782 Method 3658).
The tyres have a diameter of approximately 30 mm and in use are compressed by
approximately 1 to 2 mm. Mounting the wheels outside the pressurised zone of
the head, as in the illustrated embodiments has the advantage that the seals
around this zone do not need to be disturbed when the tyres and/or wheels are
replaced. The wheels can, however, be mounted in the pressurised zone if this
is
preferred but it has been found to be non-optimum. The seats around the
pressurised zone are preferably formed of silicone rubber or the like.
