A system and method for manufacturing wire and cable products with a polymer cable component is provided. The systems and methods include increasing the hardness of a polymer cable component in order to reduce compression and deformation of the cable components during manufacturing. In some instances, the hardness is temporarily increased prior to or during the process of creating twisted pair or during the cabling process.

A dual cable alignment apparatus (10) for rotationally aligning assembled cable ends of two cables (3,4) of a twisted cable harness (2), the cable alignment apparatus (10) comprising two clamping jaws (7,8) and a central web (9) disposed between the clamping jaws (7,8). Each of the two clamping jaws (7,8), which can be moved towards one another in the closing direction (s), can clamp a cable (3,4) between the central web (9) and the clamping jaws (7,8). The clamping jaws (7,8) are further designed to be movable laterally past the central web (9) for changing the rotational position by rolling the cable (3,4) clamped between them. The clamping jaws (7,8) can be moved independently of one another in the lateral direction by means of their own lateral drives (16,17), ensuring that each cable (3,4) can be brought precisely and reliably into the desired rotational position.

A method and a device twist single cables about a twisting axis. The single cables each run along a cable axis and have wires, which are twisted in a strand twisting direction to form a strand, and also each have a first cable end and a second cable end. The first cable ends are held separately by a single rotating unit in each case. The second cable ends are held by a twisting unit. The second cable ends are rotated jointly about the twisting axis counter to the strand twisting direction to produce a twisted cable bundle. During the joint rotation, the first cable ends are rotated separately about a cable axis of the respective single cable, in the same rotation direction as the joint rotation. The single cables are each relieved of torsion thereby.

A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. Inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes the step of rotating the central portions of the first and second wires, thereby twisting the first and second wires about one another.

Embodiments of the disclosure relate to a method of preparing a bundled cable. In the method, a plurality of subunits is wound around a central member in one or more layers of subunits to form the bundled cable. For a section of the central member, each layer of subunits has a pitch over which a subunit of the layer of subunits makes one revolution around the section of the central member and a length of the subunit required to make the one revolution. The subunits are configured to have a nominal helical length equal to the ratio of a nominal length to a nominal pitch. Further, in the method, a measurement of the bundled cable is monitored, and a winding rate of the plurality of subunits is adjusted based on the measurement in order to account for deviations from the nominal helical length.

A device and a method twist single cables about a twisting axis to form a cable bundle along an extension axis. The device includes single rotating units, which are spaced from one another at a variable distance, for separately holding cable ends at one end of the single cables, wherein each single rotating unit is mounted rotatably about an associated pivot axis, wherein each pivot axis runs substantially perpendicular to the extension axis of the cable bundle; a twisting unit for holding and twisting cable ends at the other end of the single cables; and a distance-adjusting apparatus for adjusting the variable distance.

A device and a method twist single cables about a twisting axis to form a cable bundle along an extension axis. The device includes mutually spaced single rotating units for separately holding cable ends at one end of the single cables; a twisting unit for holding and twisting cable ends at the other end of the single cables; and a guiding apparatus, to which is fastened a guiding mandrel for separating the single cables, at least in some regions, during a twisting process by the twisting unit, in a region in which there is a transition from an untwisted region to a twisted region. The guiding mandrel includes a thickened portion on a side opposite its fastening to the guiding apparatus, the thickened portion having larger dimensions in a direction transverse to the running direction of the guiding mandrel than in most of the guiding mandrel.

A dielectric isolator for a twisted pair cable includes a body formed as an elongate strip with a top surface, bottom surface, a first side edge and a second side edge. A first slot is formed in the first side edge and extends at least half way toward the center of the isolator. A second slot is formed in the second side edge and extends at least half way toward the center of the isolator. During cable manufacturing, first and second wedges open the first and second slots. First and second twisted pairs are inserted into the first and second opened slots, respectively. Third and fourth twisted pairs reside at the top and bottom surface, respectively. The isolator has the cost and reel storage savings of a flat separator tape, while simultaneously providing the internal crosstalk performance of the isolator.

The present disclosure relates to a twisting system for twisting multiple conductors together. In one implementation, the twisting system may include a rotatable twisting head having multiple holders for individual conductors of a cable to be twisted, and a loading device for sequentially loading the holders with the individual conductors. The loading device may be configured to be displaced into a transfer position identical for all individual conductors for loading the twisting head, and the twisting head may be configured to rotate a free holder of the twisting head into a suitable receiving position for being loaded with an individual conductor. The present disclosure also relates to a method for loading a twisting head with individual conductors.

A wire (10) is disclosed. Said wire (10), when viewed in cross-section, has at least one first portion (12) and at least one second portion (14) that are interconnected by a third portion (16) in which the wire (10) has a reduced cross-section.