IM- PROVEMENTS IN COVERING, LAYING, AND UNITING WIRES AND ROPES . FOR TELEGRAPHIC PURPOSES, AND IN THE MACHINERY EMPLOYED THEREIN
Year: 1853

page_text: LETTERS PATENT to William Thomas Henley, of Saint John Street
Road, Loudon, Electrical Engineer, for the Invention of "IM-
PROVEMENTS IN COVERING, LAYING, AND UNITING WIRES AND ROPES
. FOR TELEGRAPHIC PURPOSES, AND IN THE MACHINERY EMPLOYED
THEREIN."
Sealed the 23rd July 1858, and dated the 25th January 1858.
PROVISIONAL SPECIFICATION left by the said William Thomas
Henley at the Office of the Commissioners of Patents, with his
..Petition, on the 25th January 1858.
I, WILLIAM THOMAS HENLEY, of St. John Street, London, Electrical
Engineer, do hereby declare the nature of the said Invention for
"IMPROVEMENTS IN COVERING, LAYING, AND UNITING WIRES AND ROPES
FOR TELEGRAPHIC PURPOSES, AND IN THE MACHINERY EMPLOYED THEREIN,"
to be as follows:-
:
The first part of my improvements relates to covering the wires,
before laying down, with some protecting medium to guard then from
violence. I take the copper wire when covered with gutta-percha, bitu-

page_text: men, or other insulating material, and by means of machinery hereafter
described cover it spirally with iron wire (either galvanized or not),
twisted round somewhat in the manner of a bell spring, or as harp
strings are covered. I sometimes use a single wire for lapping round
the insulated wire, and sometimes more; but I prefer using not more
than four, so that the spirals are of a very short pitch, or approaching
to a right angle with the axis of the insulated wire; as in that way the
latter is more closely covered with the protecting wire, the latter being
sufficiently fine so as not. to. injure the insulating covering.. It must be
borne in mind that, for wires intended to be laid in the earth, some
protection is required that shall resist violent blows or pressure, at the
same time they are not required to bear any lateral strain. In wire
ropes where great lateral strength is required the wires or strands are
very numerous, so as to form spirals of a very long pitch, or forming
very acute angles with-the--axis-of-the-rope;--but in my plan above
described I get a very close covering combined with great flexibility.
For submarine purposes I take the wires protected in the way before
mentioned, combining them into a number, and cover them with
coir or strands of coir or cocoa-nut fibre, forming a rope with the
covered wire inclosed; the latter giving the necessary weight for sink-
ing, and the former the requisite strength to resist a lateral strain, the
coir being well known to be almost indistructible in water, whereas
hemp or other fibrous material-soon-decays.....
i.
The machines for covering the wire consist of a frame with hori-
zontal. shafts or mandrils, hollow for the wire to pass through, and
carrying revolving tables or chucks, on which are fixed bobbins for
carrying the iron wire; the latter revolve on axles, fixed either at right
angles, or parallel with the face of the chuck. The hollow mandrils are
driven by bands from a drum on a central shaft, carrying also a 'cone
connected by a strap with another cone on a shaft with an endless
screw at the end, which drives a worm wheel on the axis of a large
drum for drawing and receiving the wires after they are covered.; "on
the same axis is placed a small pully with band leading to a larger
pulley, driving two toothed wheels and pinions; on the axis of the last is
placed a heart-shaped wheel. acting on a lever, the enil of the lattér

page_text: moving a slide parallel with the large drum, and laying the wire side
by side regularly along the drum. As the latter fills with wire, it would
draw the wire through too fast, by which it would be imperfectly
covered; but I obviate, this by having two slides carrying rollers placed
parallel with the before-mentioned cones; these slides are moved by a
screw carrying a wheel on one end, which is moved by a band passing
round a small pulley on the axis of the first toothed wheel before men-
tioned; this screw, makes about one turn. per hour, and causes the
slides with their rollers to move the band or the cones, so that the speed
of the receiving drum shall decrease as the diameter, gets larger, and by
that means the wire is always drawn through at the same, speed.
. In making submarine wire ropes, instead of making them of several
miles in length as now practised, and which causes great inconvenience
and delay in moving them to their destination, I propose to make them
in short lengths of about a mile or so, and then connect the several
lengths together by means of clamps of iron bolted together, the in-
terior insulated wires being previously joined and insulated, and the
outer wires turned up so as to form a ridge to prevent the iron, clamp
shifting: Another method is to cut a screw on the outer wires with
stock and dies, and connect the end with a screwed socket and lock
nuts; or instead of screwing the outside of the wire rope, I make a unt
or screwed socket of the same pitch as the spirals formed by the wires
of the rope, making the latter serve for the screw. I run this socket
or one of the rope some distance up; I then undo the outer wires, and
join the insulated ones, twist on the outer wires again, and turn the
socket back, until it firmly clamps both ends of the.rope, when I inake
all secure by a lock nut at each end-of the socket; it is. then stronger
than any other part of the rope. An easy way of making the nut or
socket is to take an iron casting from a piece of the rope, and then to
cast a brass socket on the iron casting; the rod on being hammered
easily unscrews froin the iron if the latter is smoothed a little in the
lathe previous to casting the brass, and from this iron casting any
number of sockets can be cast. The same method of joining sliould be
adopted when submarine ropes get broken by accidents.
.
In laying telegraph wires in the earth when pipes or troughs are

page_text: used, I propose to use a carriage or large truck, drawn by horses or other
means, carrying transverse spindles, on which the drums containing the
wires are suspended. According to the number of wires intended to be
laid down, there may be one or more drums on each spindle, and one
or more spindles; when more than one spindle is used, there should be
small spindles above the drums and carrying rollers, so that the wires
in reeling off should run clear of the other drunis.. This carriage or
truck should run in the road, by the side of the trench; and to carry
the wires into the trench I use another pair of wheels, one on each
side of the trench, and carrying a shaft on which is placed a large
grooved pulley. This is all moved forward by a coupling chain connected
with an arm or bracket standing out over the trench froni the before-
mentioned carriage or truck; the spindles in the latter rest on iron cast-
ings running along the sides, and which can be raised by three screws
on each side. By these means the drum, after being raised by three
screws on each side into the truck, can have the spindles passed through,
and then raised off the floor of the truck altogether to the desired
height to run free; at the same time, a slight break consisting of a
cord and weight must be attached to each drum to keep the wire from
running slack. The wires on leaving these drums pass over the
rollers, and are then led away over the large grooved pulley on the
shaft. Over the trench on this shaft is also hinged an arm which passes
into the trench, having a grooved roller with flanges at the lower end;
this runs on the wood troughs, and is kept in its place by the flanges of
the roller lapping over each side of the trough. The wires, after passing
over the large grooved pulley, are led down the depending arm by
means of rollers into the trough, and are there made to pass over the
groove in the bottom rollers, and thus deposited in the troughs, after
which the lids are placed on and secured. Wood troughs, being. well
known and in use, of course. form no part of my Invention. Wires
thus deposited entirely escape the usual handling and rough usage that
underground wires generally meet with in the ordinary process of lay-
ing, and by which the insulating coating is frequently injured, and the
efficiency of the wires thereby much impaired. Instead of several
drums, all the wires may be on one drum, either. laid side by side or

page_text: twisted together. In some cases I shall dispense with the truck or
carriage, and use one or more drums moveable on a shaft or spindle
mounted on wheels. The latter may run on each side of the trench or
on one side; in the former case there may be a depending arm as
before, or the wires may be conducted into the trench by hand. I
prefer in some cases to give the wires a coating of tarred yarn before
laying, which I do by means of the machines before mentioned for
covering with wire.
When the wires are protected by wire covering the troughs or pipes
are not necessary. In that case, or whenever pipes and troughs are dis-
pensed with, I propose to use a blade of metal sharp in frout and about
two inches thick at the back, although I don't confine myself to this
particular size. This is sunk into the earth to the depth of the required
trench, and is then drawn slowly through the ground by steam or other
power, forming a groove or trench the width of the thickness of the
blade. The telegraph wire or wires being carried down the back of
the blade by means of rollers attached thereto, and deposited in the
earth as the blade proceeds, the wires unreeling form a drum or drums
on a spindle mounted on wheels, and attached to a frame connected
with the blade, which prevents the latter being drawn out of the ground.
It may also for the same purpose have a frame and wheels in front.
A scraper should be find to the back frame to draw the remain-
ing earth into the trench; a roller might also be attached, to flatten it.
Where steam power is employed it should consist of a portable engine
on wheels, either drawn by horses, or it might propel itself. When
operating to draw the blade, the gearing should be disconnected from
the wheels, and made to move round a large drum by wheel and pinion,
which slowly winds up a chain attached to the blade near the ground
(the blade should stand above the ground some distance); the engine
should have a strut projecting so as to offer a resistance to the strain of
the chain, and so prevent the engine moving instead of the blade. When
the latter is drawn up to the engine the drum is disconnected, and the
engine moved to the length of the chain, and the operation renewed.
This apparatus is only applicable in the country; in town, where drains
and pipes would come in the way, the trench must be opened in the

page_text: usual way, and iron pipes should there be used. Instead of the blade
a revolving or reciprocating serracted cutter might be used, attached to
and worked by the engine; or several cutter might follow each other.
To facilitate testing the wires, I use a'square cast iron box open. at
the top, with lit fitting on witli screw bolts and vulcanised 'india-rubber
washer so as .to. make it air tight. The wires are brought through
holes. near the bottoin: The corresponding ends of the wires are con-
nected by a cylindrical piece of brass with holes drilled at the ends and
slit, and the wires clamped by nuts screwed on the brass, and wires are
-then covered with gutta-perchia joined to the covering of the wires
coming through the box so as to be entirely excluded from moisture.
The gutta-percha must be opened at the time of testing, & after-
wards closed. The bottom of the box is filled with marine glue
pitch above the holes in the side of the box. This--is buried in the
earth to the same depth as the line wires.
SPECIFICATION in pursuance. of the conditions of the Letters Patent
filed by the said William Thonias Henley, in the Great Seal
Patent Office, on the 25th July 1853.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I,
WILLIAM THOMAS HENLEY, of Saint John Street Road, London,
Electrical Engineer, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her
Letters Patent, bearing date the Twenty-fifth day of January, in' the
year of our Lord One thousand eight hundred and fifty-three, in the
sixteenth year of Her reign, did, for Herself, Her heirs and successors,
give and grant unto me, the said William Thomas Henley, Her
special licence that I, the said William Thomas Henley, his executors,
administrators, and assigns, or such others as he, the said William
Thomas Henley, his executors, administrators, and assigns, should at
any time agree with, and no others, from time to time and at all
times thereafter during the term therein expressed, should and lawfully
might make, use, exercise, and vend, within the United Kingdom of
Great Britain and Ireland, the Channel Islands, and Isle of Man, an

page_text: Invention for "IMPROVEMENTS IN COVERING, LAYING, AND. UNITING WIRES
AND ROPES FOR TELEGRAPHIC PURPOSES, AND IN THE MACHINERY EMPLOYED
THEREIN," upon the condition (amongst others) that I, the said William
Thomas Henley, hath, by an instrument in writing under my band and
seal, should particularly describe: and ascertain..the nature of the said
Invention, and in what manner the same was to be performed, and
cause the same to be filed.in the Great Seal Patent 'Office within six
calendar months next and immediately after the date of the said
Letters Patent..
NOW KNOW YE, that. I, the said William Thomas Henley, do
hereby declare the nature of my said. Invention, and in what manner
the same is to be performed, to be particularly described and ascer-
tained in and by the following statement :-
The first part of my improvements relates to covering the wires with
some protecting medium to guard them from violence. The .copper
wire, when covered with gutter' percha, bitumen, or other insulating
materials, and by means of machinery hereafter described, is to be
covered spirally with iron wire (either galvanised or not), twisted round
in the manner of a bell spring, or asharp strings are covered. I some-
times use a single wire for lapping round the insulated wire, and. some-
times more; but I prefer using not more than four, so that the spirals
are of a very short pitch, or approaching to a right angle witli the axis
of the insulated wire, as in that way the latter is more closely-covered
with the protecting wire; -the latter, being sufficiently fine not to injure
the insulating covering wires intended to be laid in the earth, must be
protected in a manner that shall resist violent blows or pressure,
although they are not required to bear any lateral strain. In wire ropes,
where great lateral strength is required; the wires or stands are very
numerous so as to form spirals of a very long pitch, or forming very
acute angles with the axis of the rope; but according to my Invention
a close covering combined with great flexibility may be obtained. For
submarine purposes I take the wires protected in the way before men-
tioned, combining many together, and cover them with coir or strands
of coir, or coca-nut fibre, forming a rope with the covered wire
enclosed; the latter giving the necessary weight for sinking, and the

page_text: former the requisite strength to resist a lateral strain, coir being almost
indestructible in water, whereas hemp or other fibrous material soon
decays.
The machines for covering the wire consist of a frame with horizon-
tal shafts or mandrils, hollow for the wire to pass through, and carrying
revolving tables or chucks on which are fixed bobbins for carrying the
iron wire; the latter revolve on axles fixed either at right angles or
parallel with the face of the chuck. The hollow mandrils are driven
by bands from a drum on a central shaft, carrying also a cone con-
nected by a strap with another cone on a shaft with an endless screw
at the end, which drives a worm wheel on the axis of a large drum for
drawing and receiving the wires after they are covered. On the same
axis is placed a small pulley with band leading to a larger pulley driving
two toothed wheels and pinions. On the axis of the last is placed a heart-
shaped wheel acting on a lever; the end of the latter moving a slide
parallel with the larger drum, and laying the wire side by side regularly
along the drum. As the latter fills with wire it would through too fast,
by which it would be imperfectly covered; but I obviate this by having
two slides carrying roller's placed parallel with the before-mentioned
cones. These slides are moved by a band passing round a small pulley
on the axis of the first toothed wheel before mentioned; this screw
makes about one turn per hour, and causes the slides with their rollers
to move the band on the cones, so that the speed of the receiving drum
shall decrease as the diameter gets larger; and by that means the wire
is always drawn thro' at the same speed.
I
vary
this arrangement, and I lay wires (coated with gutta percha
or other insulating material) parallel with each other, and cover them
with two coatings of tarred yarn or other similar material, laid on in
opposite directions by a machine represented in Sheets 1, and 2. A, and
B, are two vertical discs mounted on hollow horizontal shafts through
which the wires pass; these discs carry the bobbins containing the yarn,
and are made to revolve in opposite directions by the straps on the
drums a, and b, passing from the shaft beneath, one strap being crossed,
the other straight; the last-named shaft carries a cone pulley c, which
leads to a similar pulley on a second horizontal shaft, having an end-

page_text: less screw on the end working in the worm wheel C; on the same shaft
is placed the large pulley D, round which is passed the wires when
covered, and by which they are drawn through.
In the arrangement shewn by Sheet 2, the motion is conveyed to
the drawing pulley D, in a different manner; the hollow horizontal
shaft carrying the disc B, has a small bevil wheel D, working into
the larger one dl; the shaft on which this is fixed carries the cone
pulley C, driving another f, and moving the large pulley by tooth
wheel and pinion. The disc A, is moved by a small bevel wheel on its
hollow shaft, being driven by the large one dl, tlic two discs thus
moving in opposite directions and lays the two coatings of yarn or
other material crossing cach other. The rope thus formed is wound
on the large drum E, Sheet 4, by the winch, and when full is removed,
and an axle passed through the centre, on which are placed two wheels
and a pair of shafts for a horse, or a handle for men, represented in
Sheet 4, Fig. 3; this is for the convenience of laying the rope in the
trench. The end being made fast the drum is then drawn 'on; and the
wire deposited in the trench. The wires before they pass through
the machine are unwound from drums as represented in Figure 1,
Sheet 4, and are led through a thimble as shewn in Figure 3,
Sheet 1.
Sheet 3, represents an improved machine for making the ordinary
telegraph wire rope, twisting the insulated wire, covering it with yarn
and afterwards with wire, at one operation. When making it into a
wire rope, it is necessary to first twist the insulated wires, to give flexi-
bility and prevent their buckling when the rope is bent. F, shews a
large disc carrying several bobbins containing the insulated wire; this
receives a slow motion by the tooth wheel and pinion on the shafts G,
and H; this gives the wire a twist, and it then passes through the
hollow shaft, and, receiving a coating of yarn from the bobbins on the
disc I, and an external covering of wire from the bobbins on the disc K,
is drawn through by the drum L, by means of the wheel and pinion 1,
and m. The speed of the drum L, is altered by the cone pullies M,
and N, worked by bevil wheels and pinion on the horizontal shaft O.
On this shaft are three pulleys, a fast and loose for the strap from

page_text: the main shafting; and a third to give motion by the strap to the
upper -horizontal shaft P, on which is a cone pulley giving motion to
the shaft Q, the speed of which can be varied at pleasure. by means of
the cones R, and St The bobbins on these discs can be placed at right
angles to the face of the disc, or parallel, as shewn on the large lise F.
In either case a spring and adjusting screw is used for each bobbin to
make it work stiff, so as to keep a strain on the wire or yarn. These
springs are shown on the disc F, at 1, 2, 3, 4; on the other discs they
act under the bobbins. :
In making submarine wire ropes, instead of making them of several
miles in length as now practised (and which causes great inconvenience
and delay in moving them to their destination, I propose to make
them in short lengths of about a mile or so, and then connect the
several lengths together by means of clamps of iron. bolted together,
the interior insulated wires being previously joined and insulated, and
the outer wires turned up so as to form a ridge to prevent the iron
clamps shifting. Another method is to cut a screw on the outer wires
with stock and dies, and connect the ends with a screwed socket and
lock nuts; or instead of screwing the outside of the wire rope, I make
a nut or screwed socket of the same pitch as the spirals formed by
the wires of the rope, making the latter serve for the screw.
I run
this socket on one of the ends of the rope some distance up. I then
undo the outer wires and join the insulated ones, twist on the outer
wires again, and turn the socket back until it firmly clamps both ends
of the rope, when I make all secure by a lock nut at each end of the
socket; it is then stronger than any other part of the rope. An easy
way of making the nut or socket is to take an iron casting from a-piece
of the rope, and then to cast a brass socket on the iron casting. The
brass on being hammered easily unscrews from the iron if the latter is
smoothed a little in the lathe previous to casting the brass, and from this
iron casting any number of sockets can be cast. The same method of
joining should be adopted when submarine ropes get broken by accident.
In laying telegraph wires in the earth, when pipes or troughs are
-used I propose to use a carriage or large truck drawn by horses or
other means, carrying transverse spindles on which the drums contain-

page_text: ing the wires may be suspended. There may be one or more drums on
each spindle, and one or more spindles. When more than one spindle iš
used there should be small spindles above the druins and carrying
rollers, so that the wires in reeling off should run clear of the other
drums; this carriage or truck should run in the road by the side of the
trench. And to carry the wires into the trench I use another pair of
wheels, one on each side of the trench, and carrying a shaft on which
is placed a large grooved pulley. This is all moved forward by a coupling
chain connected with an arm or bracket standing out over the trench
from the before mentioned carriage or truck. The spindles in the latter
rest on iron castings running along the sides, and which can be raised
by three screws on each side; by these means the drums after being
raised into the truck can have the spindles passed thro', and then
raised off the floor of the truck altogether to the desired height to run
free; at the same time a slight break, consisting of a cord and break,
must be attached to each drum to keep the wire from running slack.
The wires on leaving these drums pass over the rollers, and are then
led away over the large grooved pulley on the shaft over the trench. On
this shaft is also hinged an arm which passes into the trench, having a
ground roller with flanges at the lower end; this runs on the word
troughs, and is kept in its place by the flanges of the roller lapping
over each side of the trough. The wires after passing over the large
grooved pulley, are led down the depending arm by means of rollers
into the trench, and are there to pass under the groove in the bottom
roller, and thus deposited in the troughs, after which the lids are placed
on and secured. Wires thus deposited entirely escape the usual hand-
ling and rough usage that underground wires usually meet with in
the ordinary process of laying, and by which the insulating coating is
frequently injured, and efficiency of the wire thereby much impaired.
Instead of several drums all the wires may be on one drum, either laid
"side by side or twisted together. In some cases I dispense with the
truck or carriage, and use onc or more drums moveable on a shaft or
spindle mounted on wheels; the latter may run on both sides of the
trench, or on one side. In the former case there may be a depending
arm as before, or the wires may be conducted into the trench by land.

page_text: I prefer in some cases to give the wire a coating of tarred yarn before
laying, which I do by means of the machines before mentioned for
covering with wire. In towns, where sewers and pipes are in the way,
the wires oftentimes have to be drawn a great way through the trench
under these obstructions; in that case I propose to use rollers or
sheems on frames for the wires to run over, and so prevent their
being injured by rubbing on the ground in the usual manner; besides
which they can be drawn a much greater distance without breaking
the wire.
When the insulated wires are protected by wire coverings, the
troughs or pipes are not necessary. In that case, or whenever troughs
and pipes are dispensed with, I propose to use a blade of metal sharp
in front and about two inches thick at the back, without restricting
myself to this particular size; this is sunk into the earth to the depth
of the required trench, and is then drawn slowly through the ground
by steam or other power, forming a groove or trench the width of the
thickness of the blade. The telegraph wire or wires being carried
down the back of the blade by means of rollers attached thereto, and
deposited in the earth, as the blade proceeds the wires unreel from a
drum or drums on a spindle mounted on wheels and attached to a
frame connected with the blade, which prevents the latter being drawn
out of the ground; it may also for the same purpose have a frame and
wheels in front; a scraper should be fixed to the back frame to draw
the remaining earth into the trench; a roller might also be attached, to
flatten it. Where steam power is employed, it should consist of a
portable engine on wheels. When operating to draw the blade, the
greaving should be disconnected from the wheels, and made to move
round a large drum by wheel and pinion, which slowly winds up a
chain attached to the blade near the ground, the blade standing above
the ground some distance. The engine should be moved by a chain
attached to something firm in the ground, or should have a strut pro-
jecting so as to offer a resistance to the strain of the chain, and so
prevent the engine moving instead of the blade. When the latter is
drawn up to the engine the drum is disconnected, and the engine
moved to the length of the chain, and the operation renewed. This

page_text: apparatus could only be used in the country; in towns, where there are
drains and pipes, the trench must be cut in the usual way, and iron
pipes used. Instead of the blade a revolving or reciprocating serrated
cutter might be used, attached to and worked by the engine, or several
cutters might follow each other.
To facilitate testing the wires I use a square cast iron box, open at
the top, with a lid fitting on with screw bolts and vulcanised india-
rubber waster, so as to be air-tight. The wires are brought through holes
near the bottom. The corresponding ends of the wires are connected by
a cylindrical piece of brass with holes drilled at the ends and slit, and
the wires clamped by nuts screwed on the brass; and wires are then
covered with gutta percha joined to the covering of the wires coming
through the box, so as to be entirely excluded from moisture. The
gutta percha must be opened at the time of testing, and afterwards
closed. The bottom of the box is filled with marine glue or pitch
above the holes in the side of the box; this is buried in the earth to the
same depth as the line wires.
I have described the nature of my said Invention, and how the same
is to be performed. I would wish it to be understood that I do not
confine myself to the precise details hercof. But what I claim is, tho
several modes of covering, uniting, and laying wires and ropes for
telegraphic purposes, and the machinery therefore, as herein-before
described and shewn by the Drawings annexed.
In witness whereof, I, the said William Thomas Henley, have
hereunto set my hand and scal, this 25th day of July, A.D.
WILLIAM THOMAS HENLEY. (L.S.)