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Core-cover product

Reference — Calculation: two-layer product made of core and cover

Purpose

Calculates a two-layer braided product made of a braided core and a Cover braided over it. From the outer diameter, the percentage split between core and cover and the braiding parameters of both layers, the function determines geometry, strand fineness, bobbin lengths, production and weight – separately for core and cover and as a total value. This way you can fully calculate a core-cover product in one step.

Inputs

The inputs are divided into three areas: common Product data and two identically structured panels for Core and Cover.

Product

Field Unit Meaning
Outer diameter: mm Finished outer diameter of the complete core-cover product.
Filling grade: % How densely the cross-section is filled with material (material share compared with the theoretically available cross-section).

Core and cover (identical for each panel)

Field Unit Meaning
Machine type: – Selection of the braiding machine type (Round braider, Square braider, Horizontal braider, Carbon fiber braider, Wire braider, Packing braider).
Bobbin: – Selection of a bobbin from the master data (matching the selected machine type). Supplies the outer diameter, core diameter and winding length of the bobbin for the length calculation.
Material: – Optional selection of a material from the master data; the Density is taken over from it automatically.
Density: g/cm³ Material density (three decimal places). Filled when a material is selected, but can also be overwritten manually.
Core share: or Cover share: % Cross-sectional share of the respective layer in the overall product. Core share + Cover share must add up to 100 %. When you type one of the two values, Herzog CAB completes the other one to 100 %. Values from the history or an order stay unchanged when loaded.
Braiding angle: ° Braiding angle of the layer.
Number of carriers per head: pcs Number of carriers of the machine (core ≥ 1, cover ≥ 3).
Ply count / carrier: pcs Number of threads/strands running in parallel per carrier.
Horngear speed: rpm Speed of the machine's horngear.

Shares must add up to 100 %

If Core share and Cover share together deviate from 100 % by more than 0.01 %, for example with values from an older order, the calculation reports "The proportions of the core and cover do not add up to 100%" and marks both share fields.

Result

The headline values are Output (Total) and Weight (Total); below them, Core diameter and Cover thickness as well as all other values are shown in pairs for core and cover.

Value Unit Meaning
Output (Total) kg/h Total throughput of the product in mass per hour.
Weight (Total) kg/100m Weight of the finished core-cover product per 100 m.
Core diameter mm Diameter of the core.
Cover thickness mm Wall thickness of the cover (radial).
Output (Core) / Output (Cover) kg/h Throughput of the respective layer.
Weight (Core) / Weight (Cover) kg/100m Weight share of the respective layer per 100 m.
Strand (Core) / Strand (Cover) tex Fineness (titer) of the strand per layer.
Strand diameter (Core) / Strand diameter (Cover) mm Diameter of the single strand per layer.
Length per bobbin (Core) / Length per bobbin (Cover) m Material length that can be wound per bobbin.
Product length (Core) / Product length (Cover) m Braid length that can be produced per bobbin.
Reduction (Core) / Reduction (Cover) % Length reduction caused by braiding (bobbin length compared with braid length).
Braiding length (Core) / Braiding length (Cover) mm Length of travel of a thread per product revolution (pitch).
Production (Core) / Production (Cover) m/h Production speed of the respective layer.
Braiding time (Core) / Braiding time (Cover) h Braiding time until a bobbin runs empty.

Operation

The common structure of all calculation pages is described in How calculation pages are structured. For this computation-intensive product, the result card is located to the right of the input.

The function calculates purely forwards: all results are calculated from all inputs. It is not reversible – no empty input field is calculated back from the results. If inputs are missing or invalid (no bobbin selected, value ≤ 0), the results are cleared.

Maintain material once, take over density automatically

Select a material from the master data in both panels – the Density is then set automatically. This is faster and avoids typing errors with this computation-intensive product.

Calculation

The exact calculation formula is not part of this documentation.

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