Claims:[0033] We claim:
1. A fusion and metal coating process for the flexible shafts, the process comprising the steps of:
a. swaging a circular flexible shaft end into a square flexible shaft end;
b. melting the swaged flexible shaft end (101)to the predetermined temperature at inert atmosphere, wherein the melting process fuses the wire strands (102) at the flexible shaft end (101) to form integral end bonds while the seeder cable (100) is so clamped;
c. dipping the fused wire strands (102) of the flexible shaft end in a liquid tin for a certain period of time; and
d. coating the dipped wire strands (102) of the flexible shaft end (101) with the liquid tin, wherein the liquid tin coating provides the chamfer and avoids the uneven surfaces in the wire strands at the flexible shaft end.
2. The process as claimed in claim 1, wherein the wire strands (102) of the square flexible shaft end (101) are dipped in the liquid tin for 5 seconds.
3. The process as claimed in claim 1, wherein the the flexible shaft end (101) is degreased before dipping in the liquid tin, wherein the flexible shaft end (101) is degreased through the ultrasonic cleaning with continues stirring using an organic solution.
, Description:[0001] Preamble to the Description
[0002] The following specification particularly describes the invention and the manner in which it is to be performed:
[0003] Description of the invention:
[0004] Technical field of the invention
[0005] The present invention relates to a fusion and metal coating process for the cable strands. More particularly, the present invention protects the cable strands from fraying during end cutting and swaging operations.
[0006] Background of the invention
[0007] Flexible shaft is a type of cable which consists of several strands of alloy steel wires. The strands of metal wires are twisted into a helix in the flexibleshaft. The flexible shaft having inner strands is strong and provides flexible operations and reliable connections between two substrates. The ends of inner strands are fused to protect against the fraying. The fused ends of inner strands provide efficient and stable insertion into a corresponding transition sleeve.
[0008] Various types of conventional fusion welding process for flexible shafts are known in the prior art. The United States Patent document 1339417A describes a bonded-wire-cable structure and method of making the same. In the cited patent document, the invention relates to the treatment of wire cables. The improved means for severing a piece of desired length from a cable of greater length and preventing the fraying of the strands at the end or ends and joining such a cable end to another part, or to the other end of the same piece to form for example an endless ring or hoop. The invention comprises certain steps constituting a novel method, and also includes an improved product or products.
[0009] The United States Patent document 2051900 A describes a method of making cable ends. In the cited document, an important object of the invention is to effect a separation of the cable in a manner which leaves the newly formed cable ends slightly tapered and fused into an integral mass, to obviate the flaring out or booming of the strands that would ensue should the cable be cut by ordinary methods.
[0010] The United States Patent document 3634649 A describes an apparatus for and method of joining stranded cable. In the cited document, the stranded cables are joined utilizing apparatus and method of this invention by coating individual strands of the end portions of the cables to be joined with a suitable cleaning liquid and then ejecting a fluid under pressure against such end portions to remove the liquid and any foreign particles from the end portions including forcing such particles along the length of the cable. The cleaned end portions are then fixed in an associated welding apparatus and welded together with a conventional welding device using an access port provided in the apparatus and the welding action provided assures that each cable strand is fused to the weld material. Any excess weld material is then removed from the welded end portions after removal from the welding apparatus and a tubular sleeve may be fixed in position over the welded junction to reinforce the high-strength weld.
[0011] The claimed methods use flexible shaft cables to provide flexible operations and reliable connections between two substrates. Typically, in conventional cables the ends of inner strand gets frayed and provides unstable operations at the flexible shaft end insertion into a corresponding transition sleeve. In conventional methods, the cable strands get frayed during the operations of end cutting, swaging and handling. Typically, the frayed cable end prevents smooth insertion into the mating sleeve and causes disruption in the assembly. Typically, the life span of the cable decreases due to fraying.
[0012] Hence, there is a need for a fusion and metal coating process for the cable strands to protect against fraying during end cutting and swaging operations and thereby increasing the lifespan of the cables.
[0013] Summary of the invention:
[0014] The present invention overcomes the drawbacks in the prior art and provides a fusion and metal coating process for the flexible shafts. In the preferred embodiment, the process includes the steps of swaging a circular flexible shaft end into a square flexible shaft end. After swaging, the swaged flexible shaft end ismeltedto the predetermined temperature at inert atmosphere, wherein the melting process fuses a plurality of wire strands at the flexible shaft end to form integral end bonds while the seeder cable is so clamped. After melting, the fused wire strands of the flexible shaft end are dippedin a liquid tin for a certain period of time. Finally, the dipped wire strands of the flexible shaft end are coatedwith the liquid tin. The liquid tin coating provides the chamfer and avoids the uneven surfaces in the wire strands at the flexible shaft end.
[0015] In a preferred embodiment of the invention, the wire strands of the square flexible shaft end are dipped in the liquid tin for 5 seconds.
[0016] In a preferred embodiment of the invention, the flexible shaft end is degreased before dipping in the liquid tin, wherein the flexible shaft end is degreased through the ultrasonic cleaning with continues stirring using an organic solution
[0017] The process is easy to use and simple and is more suitable for applications in agricultural industry, medical industry, aerospace industry, piping industry, automotive industry, etc.
[0018] It is to be understood that both the foregoing general description and the following details description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
[0019] Brief description of the drawings:
[0020] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.
[0021] Figure 1shows a perspective view of the seeder cable, according to one embodiment of the invention.
[0022] Figure 2 illustrates a process involved in fusion and metal coating for the flexible shafts, according to one embodiment of the invention.
[0023] Detailed description of the invention:
[0024] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in figures. Each example is provided to explain the subject matter and not a limitation. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope and contemplation of the invention.
[0025] The present invention provides a fusion and metal coating process for the cable strands to protect against fraying. The method (200) includes the steps of swaging a circular flexible shaft end into a square flexible shaft end. The swaged flexible shaft end is melted to the predetermined temperature at inert atmosphere.The melting process fuses the wire strands at the flexible shaft end to form integral end bonds while the seeder cable is so clamped. The fused wire strands at the flexible shaft end are dipped in a liquid tin for a certain period of time. The dipped wire strands of the flexible shaft end are coated with the liquid tin. The liquid tin coating provides the chamfer and avoids the uneven surfaces in the wire strands at the flexible shaft end.
[0026] The invented process providesa molded and coated flexible shaft which does not get fray during end cutting and swaging operations. The invented process increases the lifespan of the seeder cables by providing protection against fraying.
[0027] The process is easy to use and simple and is more suitable for applications in agricultural industry, medical industry, aerospace industry, piping industry, automotive industry, etc.
[0028] Figure 1shows a perspective view of the seeder cable, according to one embodiment of the invention. In the preferred embodiment, the seeder cable (100) includes a flexible shaft (101) having one or more inner wire strands (102). The wire strands (102) at the ends (101a and 101b) of the flexible shaft (101) are melted or welded to the predetermined temperature at inert atmosphere. The melted wire strands (102)getfusedto form integral end bonds while the seeder cable is so clamped. The fused wire strands (102) at the ends (101a and 101b) of the flexible shaft (101) are dipped and coated with a liquid tin. The liquid tin coating provides the chamfer and avoids the uneven surfaces in the wire strands (102) at the flexible shaft ends (101a and 101b).
[0029] Figure 2 illustrates a process involved in fusion and metal coating for the flexible shafts, according to one embodiment of the invention. In the preferred embodiment, the process includes the steps of swaging a circular flexible shaft end into a square flexible shaft end. The swaged flexible shaft end is meltedto the predetermined temperature at inert atmosphere at step (201). The melting process fuses a plurality of wire strands at the flexible shaft end to form integral end bonds while the seeder cable is so clamped at step (202). The fused wire strands of the flexible shaft end are dipped in a liquid tin for a certain period of time at step (203). Finally, at step (204), the dipped wire strands of the flexible shaft end are coated with the liquid tin. The liquid tin coating provides the chamfer and avoids the uneven surfaces in the wire strands at the flexible shaft end.
[0030] The invented process providesa molded and coated flexible shaft which does not get fray during end cutting and swaging operations. The invented process increases the lifespan of the seeder cables by providing protection against fraying.

[0031] The process is easy to use and simple and is more suitable for applications in agricultural industry, medical industry, aerospace industry, piping industry, automotive industry, etc.