Wire or cable drying system with water separator

An apparatus for drying cable, in accordance with the present invention includes a trench formed longitudinally on a plate for receiving a cable whereby a plurality of openings formed in the trench permit fluid communication therethrough such that water present on the cable is removed through the openings by evacuation. A water separator is coupled to the bottom portion for receiving the evacuated water and separating out the water by gravity.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to insulated wire fabrication, and more 
particularly to a wire drying system which employs a water separator to 
separate water from air to prevent water from entering a vacuum pump. 
2. Description of the Related Art 
Insulated wires may include one or more layers of insulation over a cable 
core, a stranded or solid conductor core or a fiber optic core. Insulated 
wires are manufactured by drawing the core through an extruder which 
includes a plastic melt at high pressure and temperature. The extruder 
provides an insulation coating on the core which adheres to the core and 
has a substantially uniform thickness around the core. Plastics such as 
polyvinyl chloride, polyethylene or equivalent plastics are employed as 
insulation. 
As the wire or cable is drawn from the extruder, the plastic insulation 
begins to cool. However, this plastic insulation is often still at the 
high temperature of the extruder plastic. Since plastic is a good thermal 
insulator, it takes a long time to cool to room temperature in air. The 
cable or wire is typically drawn through the extruder at a rate of about 
1100 feet per minute. It is preferable to spool the wire or cable as soon 
as possible to maintain the manufacture rate. Therefore, in-line cooling 
techniques are employed. 
The most commonly employed techniques includes passing the wire or cable 
through a cool water bath to increase heat transfer from the insulation 
material. One drawback of this technique is the need to dry off the wire 
or cable prior to spooling the wire or cable. This is typically performed 
by spraying high pressure air on the cable to blow the water off. Spraying 
the cable or wire with air jets is often noisy since the jets include 
spray nozzles which can cause noise levels as high as 90 decibels, and 
require hearing protection from operating personnel. 
Another technique includes vacuuming the wire or cable to suck the water 
away from the wire or cable. This technique causes the cable or wire to be 
sucked down into a trough where the vacuum suction causes wear due to 
friction on the cable as well as wear of the metallic surfaces of the 
trough. Further, since the vacuum is sucking away the water, the vacuum 
pumps of conventional system often take in water which seriously 
compromises the pump life. 
Therefore, a need exists for a water drying apparatus which avoids 
excessive wear on the cable and a vacuum trough employed to draw away 
water on the cable. A further need exists for a water separator which 
prevents water intake to the vacuum pump during operations. 
SUMMARY OF THE INVENTION 
An apparatus for drying cable, in accordance with the present invention 
includes a trench formed longitudinally on a plate for receiving a cable 
whereby a plurality of openings formed in the trench permit fluid 
communication therethrough such that water present on the cable is removed 
through the openings by evacuation. A water separator is coupled to the 
bottom portion for receiving the evacuated water and separating out the 
water by gravity. 
Another apparatus for drying cable, in accordance with the present 
invention, includes a trough disposed within a vacuum chamber for 
receiving a horizontally disposed portion of cable. The trough divides the 
chamber into a top portion and a bottom portion. A trench is formed 
longitudinally along the trough and facing into the top portion. The 
trench for receives the cable. The trough includes a liner in the trench 
to prevent wear of the trench and the cable as the cable moves relative to 
the trench. A plurality of openings are formed in the trench to permit 
fluid communication between the top portion and the bottom portion such 
that when the bottom portion is evacuated water present on the cable is 
removed through the openings. A water separator is coupled to the bottom 
portion for receiving the evacuated water and separating out the water by 
gravity. The water separator includes a vertical drain pipe for receiving 
the water and maintaining an amount of water therein having a weight at 
least equal to a vacuum pull force such that the water is prevented from 
entering a vacuum pump having an intake at a topmost vertically disposed 
location on the water separator. 
Another apparatus for drying cable, in accordance with the present 
invention, includes a cable guiding device adapted to transfer a cable 
along a straight horizontal path. A vacuum chamber is disposed about the 
straight horizontal path. A trough is disposed within the vacuum chamber 
for dividing the chamber into a top portion and a bottom portion. The 
trough includes a trench formed longitudinally thereon which faces into 
the top portion. The trench receives the cable, and the trough includes a 
liner in the trench to prevent wear of the trench and the cable. A 
plurality of openings are formed in the trench to permit fluid 
communication between the top portion and the bottom portion such that 
when the bottom portion is evacuated water present on the cable is removed 
through the openings. A water separator is coupled to the bottom portion 
for receiving the evacuated water and separating out the water by gravity. 
The water separator includes a vertical drain pipe for receiving the water 
and maintaining an amount of water thereon having a weight at least equal 
to a vacuum pull force such that the water is prevented from entering a 
vacuum pump having an intake at a topmost vertically disposed location on 
the water separator. 
An apparatus for removing water from a vacuum intake, in accordance with 
the invention includes a vacuum source for drawing in water from a vacuum 
chamber, and a water separator. The water separator includes a vacuum 
tight tube, and the tube includes a port for receiving the water drawn 
from the vacuum chamber. The port is oriented such that water received 
therein flows about an interior surface of the tube and is drawn 
downwardly by gravity. A drain pipe in the tube receives the water drawn 
downwardly. The drain pipe has a vertical length such that a column of 
water maintained in the drain pipe vacuum seals the tube and provides a 
weight capable of counter balancing a vacuum force supplied at a topmost 
vertical position on the tube by the vacuum source such that water in the 
tube is prevented from entering the vacuum source having an intake at a 
topmost vertically disposed location on the tube. 
In alternate embodiments, the liner may include a ceramic material, such as 
Alumina Titanium. The water separator may include a tube having an intake 
port therein for receiving the water such that water entering the tube is 
drawn downwardly in a helical flow into the drain pipe. The tube may be 
transitioned into the drain pipe by a funnel. The funnel may include 
baffles disposed therein to disturb the helical flow. The drain pipe may 
be connected to a tank having an output port to drain off the water. 
These and other objects, features and advantages of the present invention 
will become apparent from the following detailed description of 
illustrative embodiments thereof, which is to be read in connection with 
the accompanying drawings.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
The present invention relates to insulated wire fabrication, and more 
particularly to a wire drying system which employs a water separator to 
separate water from air to prevent water from entering a vacuum pump. The 
invention provides a ceramic lined vacuum trough insert which 
advantageously reduces friction when vacuuming water off of the cable. The 
vacuumed off air and water is then introduced to a water separator which 
prevents water from entering a vacuum pump which creates the vacuum to 
draw off the water. The water separator is connected between the vacuum 
pump and to the vacuum trough. 
Water and air drawn through the vacuum trough are introduced into a round 
cavity of the water separator. Water in the separator spins about the 
interior circumference of the cavity and is drawn down into a funnel by 
gravity. The funnel is in communication with a water line or pipe which 
begins to fill with water. The water line or pipe has a height sufficient 
to prevent the water therein from being drawn into the vacuum pump which 
has its intake at a high position on the water separator. Advantageously, 
the water separator is passive, that is, requires no power, and 
significantly increases vacuum pump life. 
Referring now to the drawings in which like numerals represent the same or 
similar elements and initially to FIG. 1, a cable/wire drying apparatus 10 
is shown in accordance with one embodiment of the present invention. The 
present invention will be described in terms of cable. For all intents and 
purposes of this disclosure cable means a core having an insulation 
coating, layer or cover formed thereon. The core may include a stranded or 
solid conductor, such as Aluminum or Copper, for example. The core may 
also include an optical fiber, strength members other wires of cables or 
any combinations thereof. A wet capstan 12 is employed to pull cable 14 
and provide sufficient tension in cable 14 for applying the present 
invention. Wet capstan 12 may wet cable 14 by employing sprayers or water 
nozzles and supplies cable 14 to a pulley 16. Cable 14 may be cooled by 
exposure to water prior to and/or during wet capstan 16 tensioning. 
From pulley 16, cable 14 may be tested for concentricity. A concentricity 
tester 20 is shown which, for example, ultrasonically scans cable 14 to 
determine insulation thickness thereon using ultra sonic transducers in 
assembly 18. Concentricity tester 20 is not necessary for the practice of 
the present invention; however, concentricity tester 20 is conveniently 
placed at this location since cable 14 is preferably submerged in water 
while ultrasonically testing cable 14. 
After concentricity tester 20, cable 14 enters a vacuum chamber 22. Vacuum 
chamber 22 includes a cable trough 24 which divides chamber 22 into a top 
portion 26 and a bottom portion 28. Bottom portion 28 includes a vacuum 
port 30 for connecting to a water separator 32 in accordance with the 
present invention. Water separator 32 will be described in greater detail 
with reference to FIG. 2. Water separator 32 is, in turn, connected to a 
vacuum pump 34 used for maintaining vacuum in bottom portion 28 of chamber 
22. Cable 14 is passed over trough 24 and water is drawn away from cable 
14 thereby drying cable 14. 
Trough 24 is surfaced with a friction-reducing material which reduces 
friction between cable 14 and trough 24. (See FIG. 4). Trough 24 
preferably includes a friction-reducing insert that may be replaced 
periodically without disturbing or replacing other components of the 
system. When cable 14 passes over trough 24, cable 14 is drawn toward 
trough 24. Suction through trough 24 causes contact between trough 24 and 
cable 14 and applies a normal force against cable 14. This increases 
friction and therefore wear in conventional systems. By surfacing trough 
24 with a reduced friction material, such as a polished ceramic, wear and 
friction are significantly reduced. In a preferred embodiment, trough 24 
is removable from chamber 22 and can be replaced easily. 
After vacuum drying cable 14, cable proceeds on to other testing or 
measurement equipment and then to a level winder (not shown) for spooling. 
A plurality of pulleys 40 are employed to direct cable 14 and maintain 
cable tension thereon for handling and winding procedures. 
Referring to FIG. 2, water separator 32 is illustratively shown in greater 
detail in accordance with the present invention. Water separator 32 
preferably includes a tube 102 preferably having a circular cross-section. 
Tube 102 includes a top portion 104 and a cover 106. Cover 106 provides a 
vacuum tight interface with top portion 104 of tube 102. A vacuum intake 
port 108 is installed through cover 106 for drawing air from an interior 
cavity 110 of tube 102 during operation. Another port 112 is formed 
through a sidewall of tube 102. Port 112 is oriented to tangentially 
introduce a water/air flow from bottom portion 28 of chamber 22 (FIG. 1) 
into cavity 110 of tube 102. In this way, an interior surface 114 of tube 
102 functions as a vane for directing water about its interior surface. 
Water is directed about the circular interior of tube 102 and begins 
spinning helically downward and in contact with interior surface 114 due 
to centrifugal force on the fluid. Baffles 116, which are attached to an 
interior surface of a funnel 118, disturb the flow of water. Baffles 116 
or other collecting device permit water flow into a tube or pipe 120. 
Water fills pipe 120 and provides a seal to prevent air from entering 
cavity 110 in top portion 104 of tube 102. The water column formed in pipe 
120 includes a height, H, sufficient to ensure that water is not drawn 
into vacuum intake port 108. This is achieved by providing a water column 
of sufficient weight to counter act the vacuum pull in the vertical 
direction (i.e., against gravity). In preferred embodiments, height H may 
be between about 50 to 70 inches high for a pump rated at about 15 to 
about 35 vacuum inches of water. 
Pipe 120 may exit to a tank 122 or be drained by a drain tube 124. 
Advantageously, the present invention provides separation between air and 
water such that water is prevented from entering vacuum pump 34. This 
significantly increases the useful life of the pump and ensures the 
reliability of the manufacturing line. A pump failure requires the 
manufacturing line to be stopped. Any stoppage of a continuous 
manufacturing line directly correlates to lost revenue. The present 
invention ensures proper suction for vacuum pump 34 in a vacuum dry cable 
process. 
Tube 102, interior surface 114, baffles 116, funnel 118 and pipe 120 are 
preferably fabricated from a corrosion resistant material. For example, 
these components may be made from plastics, glass, metals, such as 
stainless steel, etc. These components may further include combinations of 
corrosion resistant materials. 
It is to be understood that the water separator of the present invention 
may be employed in a plurality of different applications which employ 
vacuum drying and may benefit from the use of the water separator. It is 
further contemplated that the water separator of the present invention may 
be employed with other liquids to separate these liquids from a gas. The 
structure of the present invention is illustrative and may be varied 
depending on the application. 
Water separator 32 may include a stand 123 and supports 125 (which are 
exterior to tube 102), be suspended or mounted in its vertical position by 
a plurality of different methods. 
Referring to FIG. 3, a to view of funnel 118 is shown. Baffles 116 are 
installed in funnel 118 to disturb the flow of liquid through funnel 118. 
The disrupted flow advantageously increases flow rate through funnel 118. 
Other baffle configurations are contemplated as well. 
Referring to FIG. 4, trough 24 is shown in greater detail. Trough 24 
includes a plate 150 having a trench 152 formed along its length. Trench 
152 communicates with a plurality of slots 154 formed through plate 150. 
Trench 152 may include for example, a semicircular shape as shown in FIG. 
5A, or a triangular shape as shown in FIG. 5B, or other shapes such as a 
rectangular shape. Surface of trench 152 is treated or surfaced by forming 
a friction-reduced surface thereon using a material 155. In a preferred 
embodiment, the surface of trench 152 is lined with a ceramic material, 
such as Alumina Titanium; other ceramics may also be employed. Material 
155 preferably includes a thickness of between about 6 and 12 mils if 
ceramics are employed although other thicknesses may also be employed. 
Material 155 may preferably include a microfinish of between about 24 to 
about 32 micron inches (Arithmetic Average). Material 155 may be applied 
as a prefabricated insert which includes a preformed shape. The insert may 
be installed in trench 152, such that insert of material 155 includes 
slots 154 therethrough. If an insert is used, the insert may be adapted to 
fit trench 152 and provide for an appropriate shape and dimensions for a 
cable being processed. In this way, trough 24 achieves versatility as 
different cable sizes can be accommodated. Further, maintainability is 
achieved by permitting worn inserts of material 155 to be easily replaced. 
Plate 150 may include a material resistant to corrosion due to water such 
as, for example, stainless steel. 
Trough 24 may include a length sufficient to adequately dry cable 14 (FIG. 
1). In one embodiment, cable 14 travels at a rate of about 1110 feet per 
minute. Trough 24, in this instance, has an adequate length at about 36 
inches. One skilled in the art would understand that this length may be 
changed in accordance with system needs. 
Slots 154 are disposed at intervals along the bottom of trench 152. Slots 
154 are sized to provide sufficient suction from vacuum to remove water 
from cable 14 (FIG. 1). In one embodiment, slots 154 may include elongated 
holes which have a diameter of about 0.08 inches to about 0.1 inches 
(i.e., slot thickness), and the slots 154 may be between about 0.2 to 
about 0.4 inches in length. These dimensions may be altered based on the 
mount of water to be removed and the suction available from the vacuum 
pump. 
Having described preferred embodiments of wire or cable drying system with 
water separator (which are intended to be illustrative and not limiting), 
it is noted that modifications and variations can be made by persons 
skilled in the art in light of the above teachings. It is therefore to be 
understood that changes may be made in the particular embodiments of the 
invention disclosed which are within the scope and spirit of the invention 
as outlined by the appended claims. Having thus described the invention 
with the details and particularity required by the patent laws, what is 
claimed and desired protected by Letters Patent is set forth in the 
appended claims.