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 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.

The invention relates to a method for jacketing strandlike elements (10), comprising the method steps of: a) producing or providing a strandlike element (10), b) wrapping the strandlike element (10) with an adhesive tape (12) to give a wrapped strand (14), the adhesive tape (12) comprising as curable adhesive a radiation-curing and/or thermally curing adhesive, c) arranging the wrapped strand (14) in one or more holding elements (16) of a holding arrangement (18) to establish a predetermined shape and to give a shaped strand (20), and d) curing the curable adhesive in the shaped strand (20) by irradiating the adhesive tape (12) with electromagnetic radiation of a wavelength λ, to give a jacketed strand (22), wherein the one or the two or more holding elements (16) at least in sections are at least partly transmissive for electromagnetic radiation of wavelength λ, wherein the irradiation of the adhesive tape (12) with the electromagnetic radiation of wavelength λ takes place at least partly through the one or the two or more holding elements (16).

[Problem] To obtain a composite electric wire with high electrical conductivity and high plasticity.

[Means for Resolution] A conductive layer 3 is disposed around a central core wire 2 and an insulating coating layer 4 is provided around the conductive layer 3 in a composite electric wire having an outer diameter of approximately 500 μm. The core wire 2 is made of four middle wires 2a to 2d twisted together. Each of the middle wires 2a to 2d is made by twisting a strand made of 48 aramid fibers. As for the conductive layer 3, 12 copper wires 3a with a diameter of 80 μm are closely and spirally wound around the core wire 2 and the circumference of the copper wires 3a is shaped into a circle by tightening.

An electric wire conductor includes a wire strand having a plurality of elemental wires twisted together. The wire strand includes a deformed part in which a cross-section of the wire strand intersecting an axial direction of the wire strand is formed into a flat shape in which a width of the cross section is larger than a height of the cross section, and an entire outer periphery of the cross section is formed as an outward curve. In the cross-section of the deformed part, the elemental wires have deformation ratios from a circle of 70% or lower at an outer peripheral part facing the outer periphery of the deformed part than at a center part located inside the outer peripheral part.

A twisted wire producing apparatus includes an electric wire twisting unit that twists two electric wires, a controller that controls the electric wire twisting unit, and a tension adding part that adds tension to the two electric wires. The electric wire twisting unit includes a one end chuck part, the other end chuck part, and chuck rotating parts for rotating the one end chuck part and/or the other end chuck part under control of the controller. The other end chuck part includes a base, a chuck main body, twist prevention parts, and a wire length difference absorbing part. The wire length difference absorbing part includes an inter-electric wire inserting part which is movable in a direction perpendicular to the electric wires extending direction.

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. The inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes deflecting central portions of the first and second wires orthogonally from the longitudinal axis and rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.

An electric wire conductor is excellent in space saving and flexibility and is less likely to concentrate a load on specific elemental wires, and a covered electric wire and a wire harness contain the electric wire conductor. The electric wire conductor contains a wire strand containing a plurality of elemental wires twisted together. The wire strand has a sector-shaped part in which a cross-section intersecting an axial direction of the wire strand contains either a single edge or two edges touching each other at an apex, and an outward curve connecting the ends of the single edge or the two edges. In the sector-shaped part, the elemental wires having deformation ratios from a circle lower at an outer peripheral part facing an outer periphery of the sector-shaped part than at a center part of the sector-shaped part located inside the outer peripheral part in the cross-section intersecting the axial direction.

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. The inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes deflecting central portions of the first and second wires orthogonally from the longitudinal axis and rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.

The device and the method are used for the automatic assembly of an in particular twisted pair of wires, wherein the pair of wires has two wire elements each with a contact element arranged at one end of a wire end. The respective contact elements are brought into a predetermined rotary position by gripping the wire pair with a main gripper which has an axis of rotation about which it can rotate, and wherein the wire ends are each gripped by a gripping element. The respective contact element is brought into the predetermined rotary position by rotating the pair of wires by way of the main gripper.