Automated cable processing method, system and method for automated conductive contact attachment

Abstract

The invention relates to an automatic cable processing method, system and method of automatic conductive contact attachment. The method includes receiving a set of two or more cables including at least a first cable positioned at a selected location and a second cable positioned remotely from the selected location. The cable selection tool is automatically moved to contact the set of two or more cables such that contact between the cable selection tool and the first cable causes a tip portion of the first cable to extend into the working area, and contact between the cable selection tool and the second cable moves the tip portion of the second cable out of the working area. One or more tip processing operations are applied to the tip portion of the first cable within the working area.

Description

Technical Field

[0001] The present invention generally relates to techniques for automated cable wire selection and processing. Background Art

[0002] Different types of connectors are often used to conductively couple one cable to another, and / or to couple a cable to an electronic device for transmitting data and / or power. The manufacture of electrical connectors typically requires that one or more processing steps be applied to the cable wires intended for use with the electronic connectors. As examples, such processing steps may include insulation jacket cracking, shield trimming, jacket stripping, inspection, and / or contact crimping. Summary of the invention

[0003] This summary is not an extensive overview of the specification. It is neither intended to identify key or important elements of the specification nor to delineate any scope that is unique to any scope of the embodiments of the specification or the claims. Its sole purpose is to present some concepts of the specification in a simplified form as a prelude to the more detailed description presented in this disclosure.

[0004] A method for automatic cable wire handling includes receiving a group of two or more cable wires, the group of cable wires including at least a first cable wire positioned at a selected location and a second cable wire positioned away from the selected location. A cable selection tool is automatically moved to contact the group of two or more cable wires such that contact between the cable selection tool and the first cable wire causes a tip portion of the first cable wire to extend into a work area, and contact between the cable selection tool and the second cable wire moves a tip portion of the second cable wire out of the work area. One or more tip handling operations are applied to a tip portion of the first cable wire within the work area.

[0005] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1A , Figure 1B and Figure 1C The tip treatment of a set of cable wires is schematically shown.

[0007] Figure 2 An exemplary method for automated cable wire handling is shown.

[0008] Figure 3A and Figure 3B An exemplary cable tip handling system is schematically illustrated wherein a cable selection tool is used to select a cable wire.

[0009] Figure 4A , Figure 4B and Figure 4C The routing of a set of cables to selected locations is schematically shown.

[0010] Figure 5 Aspects of an exemplary cable separation clamp are shown.

[0011] Fig. 6A An exemplary cable redirection comb is shown.

[0012] Figure 6B and Figure 6C Various views of an exemplary cable selection tool are shown.

[0013] Fig.6D Shown is the use of a cable selection tool and a cable redirection comb to select a cable wire in a group of cable wires.

[0014] Fig. 7A , Figure 7B and Figure 7C The application of a tip processing operation to a cable tip in a working area is schematically illustrated.

[0015] Figure 8 Attaching conductive contacts to electrical cables in a working area is schematically shown.

[0016] Fig. 9 An embodiment computing system is schematically illustrated. DETAILED DESCRIPTION

[0017] The present disclosure relates to automated techniques for selecting and processing cables. For example, the techniques described herein can be used to prepare a collection of cables before assembling a cable connector (e.g., a harness) by applying one or more processing operations to the tips of the cables. As an embodiment, such processing operations can include cutting the cables to length, scoring and removing sections of the insulating jacket near the cable tips, cable shield trimming, stripping the wires, contact crimping, and / or inserting the cables into a cable connector housing.

[0018] Any or all of these processing operations are applied to the tips of cable wires that have been automatically “selected” according to the techniques described herein. Specifically, a cable tip processing system receives a group of two or more cable wires (e.g., transported by a conveyor system along an automated assembly line) and then moves an electrical selection tool to contact the group of cable wires. Contact between the cable selection tool and at least one cable wire present at a “selection” position (e.g., due to movement of the conveyor system) causes the cable wire to extend into a work area where the tip processing operation is applied. Contact between the cable selection tool and any other cable wires positioned away from the selection position causes the other cable wires to move away from the work area—for example, the other cable wires are bent away.

[0019] In this way, when any unselected cable line is removed, the processing operation can be applied to one or more selected cable lines at a time. The process can be repeated any number of times to select and process any cable line currently in the selection position. For example, the conveyor system can be controlled to place a new cable line in the selection position while moving the previously selected cable line away from the selection position. In addition, in some embodiments, the selection and processing techniques described herein can be performed at one or more stations along the automated assembly line. For example, the sheath notch and removal can occur at the first station, while the contact crimping occurs at the second station, the visual inspection occurs at the third station, etc. In this way, the technology described herein contributes to automatic cable processing technology, which beneficially reduces the manual effort required in the assembly of cable connectors. This reduces costs, reduces the incidence of defects, and reduces the ergonomic burden on staff.

[0020] Cable Processing Figure 1A , Figure 1B and Figure 1C It is shown schematically. It should be understood that Figures 1A to 1C The specific components shown in the figure and other components described herein Figures 2 to 8 Highly simplified for explanation purposes. Figures 1A to 8 The sizes, shapes, and specific appearance of the components shown are non-limiting and are not drawn to scale.

[0021] Specifically, Figure 1A An embodiment electrical cable 100 is schematically shown including three different electrical cables 102A- 102C. Figures 1A to 1C It is intended to illustrate exemplary processing operations that may be applied to a cable after selection via a selection technique that will be described in more detail below. As used herein, a "cable" includes a length of material (e.g., copper wire, optical fiber) used to transmit data and / or power, typically coated with a protective material (e.g., plastic or rubber insulation, ground shield). In other words, the term "cable" is often used herein to refer to not only the conductive (e.g., copper) or non-conductive (e.g., optical fiber) core of the cable, but may additionally refer to any coating, insulation, and / or shielding applied to the core.

[0022] A "cable" includes one or more distinct cable strands. In the case where a cable includes only one cable strand, the terms "cable strand" and "cable" may be used interchangeably. However, in some embodiments, a cable includes two or more cable strands bundled together. For example, in Figure 1A-Figure 1CIn the embodiment of the present invention, the cable 100 is a multi-conductor cable including three different cable lines 102A-102C. In other words, the cable lines 102A-102C take the form of different conductive copper wires, each of which is coated in their own corresponding insulating cable jacket, and are also bundled together in additional insulation and / or shielding to form the multi-conductor cable 100. In some embodiments, the "cable" is a shielded twisted pair cable, in which the different cable lines include conductor pairs twisted together and protected by an insulating jacket. The twisted pairs themselves are bundled together and surrounded by nearby shields and / or insulation to form a shielded twisted pair cable. In any case, it will be understood that the selection and processing techniques described herein can be used with cables of a wide range of different suitable types.

[0023] As mentioned above, the tip processing operation applied to the selected cable may include notching and removing a portion of the insulating jacket of the cable. For example, relative to cable 102C, a portion of the insulating jacket is stripped to expose conductive core 104. As will be described in more detail below, this can be completed after cable 102C is selected for processing. For example, the cable selection tool applied to the group of cables can make cable 102C extend into the work area, where jacket notching and stripping occur, and other cables are bent away.

[0024] As another non-limiting example, the tip processing operation may include attaching conductive contacts to the cable wires. Figure 1B Schematically shown, where the conductive contacts 106A-106C have been attached to the cables 102A-102C. For example, as will be described in more detail below, this can be accomplished by a cable contact attachment system that crimps the conductive contacts to the conductive ends of the selected cables.

[0025] In some embodiments, the cable wire selection and processing techniques described herein are used to prepare cables for assembly into cable connectors, such as wire harnesses. Figure 1C Schematically shown, wherein the cable wires 102A to 102C including the conductive contacts 106A to 106C have been inserted into the cable insertion module 108. The cable wires, the cable insertion module and the conductive contacts together constitute a male cable connector. In some embodiments, Figure 1C The assembly shown in is a component of a larger modular cable connector in which other cables attached to other cable insert modules are held together by the module holder. It should be understood that Figure 1C The specific size, shape and appearance of the cable connector shown are non-limiting.For example, in some embodiments, instead of or in addition to the male conductive pins, the cable wires can be conductively coupled to the female recesses.

[0026] Figure 2An exemplary method 200 for cable wire selection and processing is shown. For example, before inserting a module of a cable connector assembly, the method 200 can be used to perform such as Figures 1A to 1C The method 200 is primarily described as being performed by a cable processing system, which takes the form of any suitable computing system of one or more computing devices. For example, the one or more computing devices may control the movement of a cable selection tool, control the operation of a conveyor system, control the operation of a machine used to directly perform cable processing (e.g., a contact crimping machine), etc. It will be understood that any computing device implementing the steps of the method 200 has any suitable capabilities, hardware configuration, and form factor. In some embodiments, the method 200 is performed by the following regarding Fig. 9 The described computing system 900 is implemented.

[0027] At 202, method 200 includes receiving a group of two or more cable lines for processing, including at least a first cable line located at a selected location and a second cable line located away from the selected location. In some embodiments, the group of two or more cable lines are transported by a conveyor system, and thus "receiving" the group of two or more cable lines may include stopping the conveyor system to position the first cable line at the selected location. This will refer to FIG. 4A to FIG. 4C In other embodiments, the set of cables may be received and the first cable may be positioned at the selected location in any other suitable manner. For example, the set of cables may be provided to the cable handling system via another suitable mechanism (e.g., via a robotic arm), or may be manually placed by an operator as an additional embodiment.

[0028] As will be described in more detail below, a "selected position" refers to the spatial region in which contact between a cable and a cable selection tool causes the tip portion of the cable to extend into the working area for processing. As will be described in more detail below, any cable positioned away from the selected position will bend outside the working area when contacted by the cable selection tool. Therefore, the specific area defined as the "selected position" depends on the specific size, shape, position, and range of motion of the cable selection tool. Similarly, the "working area" is defined as the spatial region in which a tip processing operation can be applied to the tip of a cable present in the working area. Therefore, the specific size, shape, and position of the working area depends on the specific implementation - for example, the capabilities and range of motion of any tool used to perform the tip processing operation.

[0029] Continuing with method 200, at 204, the method includes automatically moving the cable selection tool to contact the group of two or more cable lines. This contact causes the tip portion of the cable positioned at the selection position (e.g., the "first" cable line) to extend into the work area, while also causing the tip portion of any cable line positioned away from the selection position (e.g., including the "second" cable line) to bend out of the work area.

[0030] Relative to Figure 3A and Figure 3B This process is schematically shown. Specifically, Figure 3A An exemplary cable processing system 300 for processing a multi-conductor cable 302 is schematically illustrated. In this embodiment, the cable 302 includes three cable wires 304A, 304B, and 304C extending away from the cable 302. In other words, in this embodiment, the group of cable wires 304A-304C are bundled together in the same insulating jacket as the multi-conductor cable 302 so that individual cable wires can be individually selected and processed. It will be understood that in other embodiments, the group of two or more cable wires may include two or more different cables, each of which may include one or more cable wires.

[0031] In this embodiment, only the cable wires 304A-304C are shown extending from one end of the multi-conductor cable 302. However, it will be understood that the cable selection and processing described herein may be applied to cable wires extending from either or both ends of a multi-conductor cable.

[0032] As shown, the cable handling system 300 includes a cable selection tool 306, which in this embodiment is located above a group of cable lines 304A-304C. In this embodiment, the cable handling system 300 also includes a cable redirection comb 308. As shown below with respect to Figure 3B As shown, movement of the cable selection tool 306 toward the cable redirection comb 308 compresses the set of two or more cable wires 304A-304C between the cable selection tool 306 and the cable redirection comb 308, which results in selection of the cable wires positioned at the selected location.

[0033] In this embodiment, the cable selection tool 306 is positioned above the group of cable wires 304A-304C. It will be appreciated that in other embodiments, the cable selection tool may have another suitable position and / or orientation relative to the group of cable wires. For example, in one embodiment, the cable selection tool may be positioned below the group of cable wires, while the cable redirection comb is positioned above the group of cable wires.

[0034] As will be described in more detail below, the cable redirection comb 308 includes a plurality of separator protrusions (eg, the "teeth" of the comb) that define a plurality of cable channels. Figure 3AIn an embodiment of the present invention, each cable line 304A-304C extends through a different corresponding cable channel of the cable redirection comb 308. The cable lines 304A-304C can be moved into the channels of the cable redirection comb 308 in any suitable manner. In some embodiments, the position (e.g., height) of the cable redirection comb is dynamically adjustable relative to other components of the cable handling system. In this way, when the cable lines are automatically or by an operator placed in a predetermined position, the cable redirection comb can initially be placed below (or at another suitable height) relative to the cable lines. The cable redirection comb can then be moved manually or automatically so that the previously placed cable lines fall into the cable channel of the cable redirection comb.

[0035] exist Figure 3A In an embodiment of the present invention, the group of cables 304A-304C is transported by a conveyor system 310. For example, the cable selection tool 306 and the cable redirection comb 308 can be positioned at a predefined assembly station along an automated assembly line where one or more different processing operations are applied. By controlling the movement of the conveyor system, the cables can be moved from one processing station to another. Figure 3A In a specific embodiment, the set of two or more cables 304A-304C is attached to a tray 312 transported by a conveyor system 310. FIG. 4A to FIG. 4C As described in more detail, the cables may in some cases be attached to predetermined locations relative to the tray - for example, by being held in different channels of a cable separation fixture. It should be understood that this particular transport scheme is non-limiting, and a group of cables may be transported to and / or from the cable handling system in any suitable manner.

[0036] Figure 3A Camera 314 is also schematically shown. In some embodiments, a cable processing system as described herein includes one or more cameras for performing a visual inspection of the cable wire. This can be performed, for example, to confirm that a current or previous processing operation was successfully completed. For example, the visual inspection can be used to confirm that the cable wire is present, cut to the appropriate length, jacket scoring and removal are successfully performed, shield trimming is performed without leaving extra strands of shielding material, conductive contacts are successfully attached, etc. The images captured by the camera can be processed in any suitable manner - for example, by a previously trained computer vision system and / or manually by an operator.

[0037] In some embodiments, visual inspection occurs before, during, or after a tip handling operation is applied. In some embodiments, a "tip handling operation" as described herein includes visual inspection via one or more cameras. For example, in some embodiments, an automated assembly line may include one or more stations where the only tip handling operations applied are visually inspected via a camera system - for example, to confirm that one or more previous tip handling operations were successfully performed. As an embodiment, during visual inspection, each cable line in a group of cable lines can be selected so that a visual inspection can be performed on each cable line at once.

[0038] It will be appreciated that any suitable type and number of cameras may be used. For example, in one embodiment, an array of four cameras is used to capture images of one or more selected cables extending into the work area. Such cameras may include visible light cameras, infrared cameras, depth cameras, and / or any other suitable type of camera.

[0039] Figure 3A Also included is a representation of a controller 316. As used herein, a "controller" includes any suitable combination of computer logic and / or storage hardware that can be used to perform any or all of the computerized functions described herein. For example, in some embodiments, the controller 316 can control the cable selection tool 306, the cable redirection comb 308, the movement of the conveyor system 310, the behavior of the camera 314, the behavior of one or more machines for applying tip processing operations, etc. In some embodiments, the controller 316 is implemented as follows with reference to Fig. 9 A computing system 900 is described.

[0040] Once the cable handling system receives the group of two or more cable wires, the cable selection tool is moved to contact the group of cable wires. Figure 3B Schematically shown, a cable handling system 300 is also shown. In this embodiment, a cable selection tool 306 has been moved to contact a cable redirection comb 308 so that the group of cable lines 304A-304C are compressed between the cable selection tool 306 and the cable redirection comb 308. This will cause the first cable line 304A to extend forward into the working area where the cable tip treatment operation is applied, as will be described in more detail below. In contrast, cable lines 304B and 304C are bent away from the working area. Although in this embodiment, only one cable line is selected, it should be understood that this is non-limiting. In contrast, in other embodiments, two or more cable lines can be selected at a time. In some embodiments, each cable line in the group of two or more cable lines is selected.

[0041] The cable selection tool moves toward a group of cable lines at any suitable time and in response to any suitable conditions. As a non-limiting embodiment, the controller automatically moves the cable selection tool toward a group of cable lines in response to detecting that the cable lines are appropriately positioned - for example, based on input from one or more cameras. As an additional embodiment, the cable selection tool can be automatically moved in response to the elapse of a timer and / or input from an operator - for example, once the cable lines are in place, the operator can press a button or provide another suitable input to cause the cable selection tool to move.

[0042] about FIG. 4A to FIG. 4C The transmission of a group of cables using a conveyor system is schematically shown. Specifically, Figure 4A Aspects of another exemplary cable handling system 400 are schematically illustrated. As shown, in this embodiment, cables 402 are placed on top of a tray 404 and transported by a conveyor system 406. The cables include three different cable strands 408A-408C. In this embodiment, each of the cable strands is held within a separate channel of a cable separation fixture 410 attached to the tray. Figure 5 Additional non-limiting details related to suitable cable separation clamps are described. As described above, in some cases, cable handling and selection may be applied to cable wires extending from both ends of a cable. Thus, in some embodiments, two cable separation clamps may be attached to the same tray, each holding a cable wire extending from a different respective end of the cable.

[0043] In this embodiment, the cable handling system 400 also includes a cable redirection comb 412 toward which the group of cable wires 408A-408C are moved by the conveyor system 406. Figure 3A and Figure 3B As depicted, the cable handling system 400 may additionally include a cable selection tool that, when moved toward the cable redirecting comb 412, causes selection of cable wires at a selected location. Figure 4A An indication of a selection position 414 is shown. In this embodiment, the selection position is defined relative to a particular channel of the cable redirection comb 412. In other words, when a particular cable line is in the selection position, it will be aligned with the designated channel of the cable redirection comb 412. Any cable lines positioned away from the selection position will occupy other cable channels of the cable redirection comb, causing the unselected cable lines to move away from the work area once contacted by the cable selection tool.

[0044] It should be understood that Figure 4AThe specific size and position of the selection position shown are non-limiting. In general, the selection position can be defined relative to any suitable cable channel of the cable redirection comb, any single feature of the cable selection tool, and / or any other suitable component of the cable handling system, so that once contacted by the cable selection tool, the cable line located in the selection position extends into the work area. In some embodiments, the selection position is large enough so that multiple cable lines can occupy the selection position at one time so that each cable line is selected. Additionally or alternatively, a plurality of different selection positions can be defined.

[0045] Now turn to Figure 4B , again schematically illustrating the cable handling system 400. In this embodiment, the movement of the conveyor system 406 has caused the group of cable strands 408A-408C to move relative to the cable redirection comb 412, as indicated by the movement indicator 416. As shown, the movement of the group of cable strands 408A-408C has caused the first cable strand 408A to enter the selected position 414. Thus, as shown in FIG. Figure 3B As shown, contact with the cable selection tool will cause the first cable line 408A to extend into the work area, while the other cable lines 408B and 408C located away from the selection location bend away from the work area.

[0046] It will be appreciated that the movement of the conveyor system may be controlled in any suitable manner. As one embodiment, the conveyor system may be automatically stopped to position the first cable line at the selected location. For example, once the presence of the first cable line at the selected location is detected, for example, via a computer vision system and / or via input from an operator, the movement of the conveyor system may be stopped. As another non-limiting embodiment, a human may manually stop and / or start the movement of the conveyor system.

[0047] Now turn to Figure 4C , again schematically illustrating the cable processing system 400. Specifically, Figure 4C The cable treatment system 400 is shown later after a tip treatment has been applied to the first cable wire 408A. In this embodiment, the conductive contact 418 has been attached to the tip portion of the first cable wire 408A.

[0048] In addition, in this embodiment, the conveyor system has been controlled to move the group of cables again. In other words, after the tip processing operation (e.g., conductive contact crimping) is applied to the tip portion of the first cable 408A, the conveyor system 406 is controlled to move the first cable away from the selection position 414 and move the second cable 408B toward the selection position 414. From then on, when the second cable 408B is positioned at the selection position 414, the cable selection tool can be moved again to contact a group of two or more cable lines so that the tip portion of the second cable extends into the working area where the tip processing operation can be applied. Because the first cable has been moved away from the selection position, the contact with the cable selection tool causes the first cable to bend outside the working area.

[0049] As described above, in some cases the set of two or more cable wires is attached to a tray for transport via a conveyor system using a cable separation clamp. Figure 5 Aspects of an exemplary cable separation clamp 500 are shown. As shown, the clamp includes several different channels, two of which are labeled as channels 502A and 502B. The cable strands of the cable are held within the different channels of the cable separation clamp, which forces the cable strands to have a relatively fixed position relative to each other and relative to the tray. Figure 5 Also shown is a spring retention mechanism 504 disposed within the cable separation clamp which advantageously compresses the cables held within the various channels and serves to reduce movement and slippage of the cables.

[0050] Now refer to FIG. 6A to FIG. 6D Describes exemplary components for use with a cable processing system. Specifically, Fig. 6A A non-limiting embodiment of a suitable cable redirection comb 600 is shown. As described above, the cable redirection comb 600 can be used to influence the direction in which the cable runs when the cable is compressed between the cable redirection comb and the cable selection tool.

[0051] In this embodiment, the cable redirection comb 600 includes a plurality of separator protrusions, two of which are labeled as protrusions 601A and 601B. Each pair of separator protrusions defines a cable channel, such that the cable redirection comb includes a plurality of different cable channels, two of which are labeled as channels 602 and 604. In general, the cable redirection comb includes a selection channel and at least one redirection channel. Fig. 6A , channel 602 is a cable selection channel, and channel 604 is a cable redirection channel. It will be appreciated that a cable redirection comb may include any suitable number of total cable channels, any of which may be a selection channel and / or a redirection channel.

[0052] As described above, the presence of a cable line at a selected position causes the cable line to occupy the selected channel of the cable redirection comb. Similarly, the presence of other cable lines away from the selected position causes the other cable lines to occupy the redirection channel of the cable redirection comb. As described above, in some embodiments, this can be achieved by moving the cable redirection comb toward a group of cable lines after the group of cable lines have been placed in the predetermined position, so that the cable lines fall into the appropriate position in the cable channel when the cable redirection comb moves. In other embodiments, the cable lines can be fed through or otherwise placed in their corresponding cable channels in another suitable manner (e.g., via a suitable automated mechanism or by manual movement of an operator).

[0053] The selection and redirection channels have different geometries, affecting the direction in which the cable wires extend after contact with the Cable Selection Tool. Fig. 6A As shown, the cable selection channel 602 includes a face 606, which guides the tip portion of the cable occupying the channel 602 toward the work area. In this embodiment, the face of the cable selection channel has a flat geometry. On the contrary, the redirection channel 604 includes a curved surface 608, which guides the tip portion of the second cable occupying the channel 604 away from the work area. For example, the contact between the second cable and the cable selection tool can make the cable bend along the curved surface of the cable redirection channel and conform to the curved surface of the cable redirection channel, which in turn makes the tip of the second cable extend beyond the work area. It will be understood that in other embodiments, the face of the cable channel can have other suitable geometries. For example, in one embodiment, the face of the cable selection channel can have a cylindrical profile that matches the radius of the cable.

[0054] Figure 6B and Figure 6CTwo views of an exemplary cable selection tool 610 that can be used with the cable processing system described herein are provided. As shown, the cable selection tool 610 includes a notched leading surface 612 that contacts one or more of a group of cable lines when the cable selection tool 610 moves toward a group of cable lines. In this embodiment, the cable selection tool 610 additionally includes a notch 614 corresponding to a selected position in the notch leading surface 612. In other words, when the cable selection tool 610 moves toward a group of cable lines, the cable line at the selected position occupies the notch 614 in the notch guiding surface 612. This is consistent with the geometry of the cable redirection comb described above, so that the cable line at the selected position extends into the working area. The contact between the notch leading surface and any cable line positioned away from the selected position causes the tip portion of the unselected cable line to bend outside the working area, for example, as guided by the curved surface of the cable line redirection channel of the cable redirection comb. In embodiments intended to select two or more cable lines simultaneously, an alternative cable selection tool having more than one notch and / or a notch sized to accommodate two or more cable lines simultaneously can be used.

[0055] In addition, Figure 6C In the embodiment, the cable selection tool 610 includes a plurality of guide channels corresponding to the cable line positions away from the notch 614, wherein two channels are marked as guide channels 616A and 616B. The guide channels are additionally used to guide the unselected cable channels away from the working area.

[0056] Fig.6D The cable redirection comb 600 and the cable selection tool 610 are again shown. However, in this embodiment, the cable selection tool 610 has been moved toward the cable redirection comb 600, and a group of cable lines 618A-618C are compressed between the cable selection tool 610 and the cable redirection comb 600. As shown, the first cable line 618A occupies the notch 614. The geometry of the cable selection tool and the cable redirection comb together is such that the first cable line extends into the working area, while the unselected cable lines 618B and 618C are bent out of the working area.

[0057] Return briefly Figure 2 At 206, method 200 includes applying one or more tip processing operations to a tip portion of the cable line extending into the work area. 7A to 7C Specifically, Fig. 7ASchematically illustrates aspects of an exemplary cable selection tool 700 contacting a cable redirection comb 702 such that two cable lines 704A and 704B are compressed between the cable selection tool and the cable redirection comb. A tip portion 706A of the first cable line 704A extends into a working area 708. A tip portion 706B of a second, unselected cable line is bent outside of the working area 708.

[0058] In this embodiment, the working area 708 is represented as a spatial area extending perpendicular to the direction of movement of the cable selection tool 700. It should be understood that Fig. 7A The specific size, shape, and location of the working area 708 shown in are non-limiting. As described above, the working area is defined as a predetermined area of ​​space in which one or more tip processing operations can be applied to the cable tip portion present in the working area. Therefore, the specific characteristics of the working area will vary depending on the implementation, for example, depending on the specific tip processing operation applied, and depending on the specific capabilities and range of motion of any tool or system used to perform the tip processing operation.

[0059] exist Figure 7B In the embodiment, the tip portion 706A of the first cable 704A is inserted into a processing tool 710, which is configured to apply a processing operation to the cable tip. It should be understood that the processing tool 710 takes any suitable form, depending on the implementation and on the specific type of tip processing operation to be applied. In this embodiment, one or more tip processing operations include scoring and removing a portion of the insulating jacket of the cable. This is relative to Figure 7C It is schematically shown where a processing tool has been used to remove a portion of the insulating jacket of the cable 704A, thereby exposing the conductive core 712 of the cable.

[0060] The processing tool is controlled in any suitable manner. In some embodiments, the processing tool is automatically moved toward and / or away from the cable tip (e.g., by a controller of the cable processing system). For example, upon detecting (e.g., via a computer vision system) that the cable line is present in the work area, the controller can move the processing tool toward the cable tip, automatically apply a tip processing operation to the cable tip, and then move away from the cable tip. Additionally or alternatively, an operator can move the processing tool, and / or otherwise control the operation of the processing tool.

[0061] Figure 8 Another non-limiting tip processing operation is schematically shown. Specifically, Figure 8Aspects of another exemplary cable selection tool 800 and cable redirection comb 802 are schematically illustrated compressing a first cable line 804A and a second cable line 804B. A tip portion 806A of the first cable line 804A extends into a working area 808, while a tip portion 806B of the second cable line extends away from the working area 808.

[0062] In this embodiment, another exemplary processing tool 810 has been used to attach a conductive contact 812 to the tip of the first cable line 804A. This can include, for example, crimping the conductive contact to the conductive end of the first cable line via an automated cable contact attachment system. It should be understood that any suitable automated crimping system can be used to attach the conductive contact to the cable tip as described herein.

[0063] As described above, in some cases, the tip treatment operation can be applied to the tip portions of different cable lines simultaneously and / or sequentially. For example, in some embodiments, two or more cable lines can be selected and extended into the work area simultaneously so that the two cable tips are processed simultaneously. Additionally or alternatively, after the tip treatment is applied to the first cable line, the group of two or more cable lines can be moved so that the first cable line moves away from the selected position and the second cable line moves toward the selected position. Depending on how many cables need to be processed, this can be repeated any suitable number of times.

[0064] To this end, briefly return to Figure 2 At 208, method 200 includes determining whether the treatment should be applied to additional cable lines. This can be determined in any suitable manner. For example, in some embodiments, the cable tip treatment can be sequentially applied to different cable lines until a predetermined number of cable lines have been treated, a predetermined amount of time has passed, a predetermined stop time has been reached, the system detects that no more cable lines are present (e.g., via a computer vision system), the system is deactivated by an operator, and / or in response to any other suitable condition.

[0065] If it is determined that there are more cables for processing (e.g., yes at 208), the method 200 proceeds to step 210, which includes moving the group of cables so that the last processed cable moves away from the selection location and the next cable moves to the selection location. From there, the method 200 returns to step 204, in which the cable selection tool is moved to contact the group of cables so that any cable present at the selection location extends into the work area. If it is determined that no more cable processing should be performed, the method 200 ends at 212.

[0066] The methods and processes described herein may be bound to a computing system of one or more computing devices. Specifically, such methods and processes may be implemented as an executable computer application, a network accessible computing service, an application programming interface (API), a library, or a combination of the above and / or other computing resources.

[0067] Fig. 9 Schematically illustrates a simplified representation of a computing system 900 that is configured to provide any of the computing functions described herein. The computing system 900 may take the form of one or more network accessible devices, personal computers, server computers, mobile computing devices, embedded computing devices, and / or other computing devices.

[0068] The computing system 900 includes a logic subsystem 902 and a storage subsystem 904. The computing system 900 may optionally include a display subsystem 906, an input subsystem 908, a communication subsystem 910, and / or Fig. 9 Other subsystems not shown.

[0069] The logic subsystem 902 includes one or more physical devices configured to execute instructions. For example, the logic subsystem may be configured to execute instructions as part of one or more applications, services, or other logical structures. The logic subsystem may include one or more hardware processors configured to execute software instructions. Additionally or alternatively, the logic subsystem may include one or more hardware or firmware devices configured to execute hardware or firmware instructions. The processor of the logic subsystem may be single-core or multi-core, and the instructions executed thereon may be configured for sequential, parallel, and / or distributed processing. The individual components of the logic subsystem may optionally be distributed in two or more separate devices, which may be remotely located and / or configured for collaborative processing. Aspects of the logic subsystem may be virtualized and executed by a remotely accessible networked computing device configured in a cloud computing configuration.

[0070] The storage subsystem 904 includes one or more physical devices configured to temporarily and / or permanently hold computer information such as instructions and data that can be executed by the logic subsystem. When the storage subsystem includes two or more devices, the devices can be collocated and / or remotely located. The storage subsystem 904 can include volatile, non-volatile, dynamic, static, read / write, read-only, random access, sequential access, location addressable, file addressable, and / or content addressable devices. The storage subsystem 904 can include removable and / or built-in devices. As the logic subsystem executes instructions, the state of the storage subsystem 904 can be transformed - for example, to hold different data.

[0071] Aspects of the logic subsystem 902 and the storage subsystem 904 may be integrated together into one or more hardware logic components. Such hardware logic components may include, for example, program and application specific integrated circuits (PASIC / ASIC), program and application specific standard products (PSSP / ASSP), systems on chips (SOC), and complex programmable logic devices (CPLD).

[0072] The logic subsystem and the storage subsystem can collaborate to embody one or more logic machines. As used herein, the term "machine" is used to collectively refer to a combination of hardware, firmware, software, instructions, and / or any other components that collaborate to provide computer functions. In other words, a "machine" is never an abstract concept and always has a tangible form. A machine may be embodied by a single computing device, or a machine may include two or more subcomponents embodied by two or more different computing devices. In some implementations, a machine includes a local component (e.g., a software application executed by a computer processor) that collaborates with a remote component (e.g., a cloud computing service provided by a network of server computers). The software and / or other instructions that give a particular machine its functionality can optionally be saved as one or more unexecuted modules on one or more suitable storage devices.

[0073] When a display subsystem 906 is included, the display subsystem 906 can be used to present a visual representation of the data maintained by the storage subsystem 904. The visual representation can take the form of a graphical user interface (GUI). The display subsystem 906 can include one or more display devices utilizing nearly any type of technology. In some implementations, the display subsystem can include one or more virtual, augmented, or mixed reality displays.

[0074] When an input subsystem 908 is included, the input subsystem 908 may include one or more input devices or interface with one or more input devices. The input device may include a sensor device or a user input device. Examples of user input devices include a keyboard, a mouse, a touch screen, or a game controller. In some embodiments, the input subsystem may include selected natural user input (NUI) components or interface with selected natural user input (NUI) components. Such components may be integrated or peripheral devices, and the conversion and / or processing of input actions may be processed on-board or off-board. Exemplary NUI components may include microphones for speech and / or voice recognition; infrared, color, stereo and / or depth cameras for machine vision and / or gesture recognition; head trackers, eye trackers, accelerometers and / or gyroscopes for motion detection and / or intent recognition.

[0075] When included, the communication subsystem 910 can be configured to communicatively couple the computing system 900 to one or more other computing devices. The communication subsystem 910 can include wired and / or wireless communication devices compatible with one or more different communication protocols. The communication subsystem can be configured to communicate via personal, local, and / or wide area networks.

[0076] The present disclosure is presented by way of example and with reference to the associated drawings. Parts, processing steps and other elements that may be substantially the same in one or more of the drawings are coordinately identified and described with minimal repetition. However, it will be noted that the co-identified elements may also be different to some extent. It should be further noted that some of the figures may be schematic and not drawn to scale. The various drawing scales, aspect ratios and numbers of parts shown in the drawings may be purposefully deformed to make it easier to see certain features or relationships.

[0077] In an embodiment, a method for automatic cable wire handling includes: receiving a group of two or more cable wires, including at least a first cable wire positioned at a selection location; and a second cable wire, the second cable wire positioned away from the selection location, automatically moving a cable selection tool to contact the group of two or more cable wires, such that contact between the cable selection tool and the first cable wire causes a tip portion of the first cable wire to extend into a working area, and contact between the cable selection tool and the second cable wire moves the tip portion of the second cable wire outside the working area; and applying one or more tip handling operations to the tip portion of the first cable wire within the working area. In this embodiment or any other embodiment, the moving the cable selection tool causes the cable selection tool to move toward a cable redirection comb and compress the group of two or more cable wires between the cable selection tool and the cable redirection comb. In this embodiment or any other embodiment, the cable redirection comb includes a plurality of separator protrusions defining a plurality of cable channels, the plurality of cable channels including a selection channel and a redirection channel, and wherein the presence of the first cable wire at the selection location causes the first cable wire to occupy the selection channel, and wherein the presence of the second cable wire away from the selection location causes the second cable wire to occupy the redirection channel. In this or any other embodiment, the selection channel includes a surface that guides the tip portion of the first cable line toward the work area, and wherein the redirection channel includes a curved surface that guides the tip portion of the second cable line outside the work area. In this or any other embodiment, the cable selection tool includes a notched leading surface, wherein contact between the notched leading surface and the second cable line moves the tip portion of the second cable line outside the work area, and wherein the first cable line occupies a notch in the notched leading surface. In this or any other embodiment, the group of two or more cable lines is transported by a conveyor system, and wherein receiving the group of two or more cable lines includes stopping movement of the conveyor system to position the first cable line at the selected position. In this or any other embodiment, the method further includes, after applying one or more tip processing operations to the tip portion of the first cable line, controlling the conveyor system to move the first cable line away from the selected position and to move the second cable line to the selected position. In this or any other embodiment, the method also includes, when the second cable line is positioned in the selection position: automatically moving the cable selection tool to contact a group of two or more cable lines, so that the contact between the cable selection tool and the second cable line causes the tip portion of the second cable line to extend into the working area, and the contact between the cable selection tool and the first cable line moves the tip portion of the first cable line outside the working area; and applying the one or more tip processing operations to the tip portion of the second cable line within the working area.In this or any other embodiment, the group of two or more cable lines is attached to a tray transported by the conveyor system. In this or any other embodiment, each of the group of two or more cable lines is held in a separate channel of a cable separation fixture attached to the tray. In this or any other embodiment, one or more tip processing operations include scoring and removing a portion of an insulating jacket of a first cable line. In this or any other embodiment, one or more tip processing operations include attaching a conductive contact to the first cable line. In this or any other embodiment, the attachment of the conductive contact includes crimping the conductive contact to the conductive end of the first cable line at a cable contact attachment system. In this or any other embodiment, the group of two or more cable lines are bundled together as a single multi-conductor cable in a common insulating jacket.

[0078] In an embodiment, a cable tip handling system includes: a controller configured to: control movement of a conveyor system to position a first cable line from a group of two or more cable lines at a selected position and position a second cable line from the group of two or more cable lines away from the selected position; move a cable selection tool to contact the group of two or more cable lines so that contact between the cable selection tool and the first cable line causes a tip portion of the first cable line to extend into a working area and contact between the cable selection tool and the second cable line moves the tip portion of the second cable line out of the working area; and apply one or more tip handling operations to the tip portion of the first cable line within the working area. In this or any other embodiment, moving the cable selection tool causes the cable selection tool to move toward a cable redirection comb and compress the group of two or more cable lines between the cable selection tool and the cable redirection comb. In this or any other embodiment, the controller is further configured to control the conveyor system to move the first cable line away from the selected position and move the second cable line to the selected position after the one or more tip handling operations are applied to the tip portion of the first cable line. In this or any other embodiment, the one or more tip processing operations include scoring and removing a portion of an insulating jacket of the first electrical cable wire. In this or any other embodiment, the one or more tip processing operations include attaching a conductive contact to the first electrical cable wire.

[0079] In an embodiment, a method for automatic conductive contact attachment includes: receiving a group of two or more cable lines, including at least a first cable line positioned at a selection position and a second cable line positioned away from the selection position; automatically moving a cable selection tool to contact the group of two or more cable lines, so that contact between the cable selection tool and the first cable line causes a tip portion of the first cable line to extend into a working area, and contact between the cable selection tool and the second cable line moves the tip portion of the second cable line out of the working area; and automatically attaching a conductive contact to the tip portion of the first cable line via a cable contact attachment system.

Claims

1. A method (200) for automatic cable line processing, the method (200) comprising: Receiving a set of two or more electrical cables (304A-304C), the set of two or more electrical cables (304A-304C) comprising at least a first electrical cable (304A) positioned at a selected location (414) and a second electrical cable (304B) positioned away from the selected location (414); automatically moving a cable selection tool (306) to contact the set of two or more cable wires (304A-304C) such that contact between the cable selection tool (306) and the first cable wire (304A) causes a tip portion (706A) of the first cable wire (304A) to extend into a working area (708), and contact between the cable selection tool (306) and the second cable wire (304B) moves a tip portion (706B) of the second cable wire (304B) out of the working area (708); as well as One or more tip processing operations are applied to a tip portion (706A) of the first cable wire (304A) within the working area (708).

2. The method (200) according to claim 1, wherein: Moving the cable selection tool (306) causes the cable selection tool (306) to move toward a cable redirection comb (308) and compress the set of two or more cable wires (304A-304C) between the cable selection tool (306) and the cable redirection comb (308).

3. The method (200) according to claim 2, wherein: The cable redirection comb (308) includes a plurality of separator protrusions (601A, 601B) defining a plurality of cable channels (602, 604), the plurality of cable channels including a selection channel (602) and a redirection channel (604), and wherein the presence of the first cable line (304A) at the selection position (414) causes the first cable line (304A) to occupy the selection channel (602), and wherein the presence of the second cable line (304B) away from the selection position (414) causes the second cable line (304B) to occupy the redirection channel (604).

4. The method (200) according to claim 3, wherein: The selection channel (602) includes a surface (606) that guides the tip portion (706A) of the first cable line (304A) toward the working area (708), and wherein the redirection channel (604) includes a curved surface (708) that guides the tip portion (706B) of the second cable line (304B) outside the working area (708).

5. The method (200) according to claim 2, wherein: The cable selection tool (306) includes a notched leading surface (612), wherein contact between the notched leading surface (612) and the second cable wire (304B) moves the tip portion (706B) of the second cable wire (304B) outside the working area (708), and wherein the first cable wire (304A) occupies a notch (614) in the notched leading surface (612).

6. The method (200) of claim 1, wherein: The set of two or more cable lines (304A-304C) is transported by a conveyor system (310), and wherein receiving the set of two or more cable lines (304A-304C) includes stopping movement of the conveyor system (310) to position the first cable line (304A) at the selected location (414).

7. The method (200) of claim 6 further comprises, after applying the one or more tip processing operations to the tip portion (706A) of the first cable line (304A), controlling the conveyor system (310) to move the first cable line (304A) away from the selected position (414) and to move the second cable line (304B) to the selected position (414).

8. The method (200) of claim 7, further comprising, when the second electrical cable (304B) is positioned at the selected position (414): automatically moving the cable selection tool (306) to contact the set of two or more cable wires (304A-304C) such that contact between the cable selection tool (306) and the second cable wire (304B) causes a tip portion (706B) of the second cable wire (304B) to extend into the working area (708), and contact between the cable selection tool (306) and the first cable wire (304A) moves the tip portion (706A) of the first cable wire (304A) out of the working area (708); and The one or more tip processing operations are applied to a tip portion (706B) of the second cable wire (304B) within a working area (708).

9. The method (200) according to claim 6, wherein: The set of two or more electrical cables (304A-304C) is attached to a pallet (312) transported by the conveyor system (310).

10. The method (200) according to claim 9, wherein: Each of the set of two or more cable wires (304A-304C) is held within a separate channel (502A, 502B) of a cable separation clamp (500) attached to the tray (312).

11. The method (200) of claim 1, wherein: The one or more tip processing operations include scoring and removing a portion of an insulating jacket (102C) of the first electrical cable (304A).

12. The method (200) of claim 1, wherein: The one or more tip processing operations include attaching a conductive contact (106A) to the first electrical cable (304A).

13. The method (200) according to claim 12, wherein: Attachment of the conductive contact (106A) includes crimping the conductive contact (106A) to the conductive end (104) of the first cable wire (304A) at a cable contact attachment system (810).

14. The method (200) of claim 1, wherein: The set of two or more cable wires (304A-304C) are bundled together in a common insulating sheath as a single multi-conductor cable (100).

15. A cable tip processing system (300), comprising: A controller (316), the controller being configured to: controlling movement of the conveyor system (310) to position a first cable line (304A) from a group of two or more cable lines (304A-304C) at a selected location (414) and to position a second cable line (304B) from the group of two or more cable lines (304A-304C) away from the selected location (414); moving a cable selection tool (306) to contact the set of two or more cable wires (304A-304C) such that contact between the cable selection tool (306) and the first cable wire (304A) causes a tip portion (706A) of the first cable wire (304A) to extend into a working area (708), and contact between the cable selection tool (306) and the second cable wire (304B) moves a tip portion (706B) of the second cable wire (304B) out of the working area (708); as well as One or more tip processing operations are applied to a tip portion (706A) of the first cable wire (304A) within the working area (708).

16. The cable tip processing system (300) of claim 15, wherein: Moving the cable selection tool (306) causes the cable selection tool (306) to move toward the cable redirection comb (308) and compress the set of two or more cable wires (304A-304C) between the cable selection tool (306) and the cable redirection comb (308).

17. The cable tip processing system (300) of claim 15, wherein: The controller (316) is also configured to control the conveyor system (310) to move the first cable line (304A) away from the selected position (414) and to move the second cable line (304B) to the selected position (414) after the one or more tip processing operations are applied to the tip portion (706A) of the first cable line (304A).

18. The cable tip processing system (300) of claim 15, wherein: The one or more tip processing operations include scoring and removing a portion of an insulating jacket (102C) of the first electrical cable (304A).

19. The cable tip processing system (300) of claim 15, wherein: The one or more tip processing operations include attaching a conductive contact (106A) to the first electrical cable (304A).

20. A method (200) for automated conductive contact attachment, the method (200) comprising: Receiving a set of two or more electrical cables (304A-304C), the set of two or more electrical cables (304A-304C) comprising at least a first electrical cable (304A) positioned at a selected location (414) and a second electrical cable (304B) positioned away from the selected location (414); automatically moving a cable selection tool (306) to contact the set of two or more cable wires (304A-304C) such that contact between the cable selection tool (306) and the first cable wire (304A) causes a tip portion (806A) of the first cable wire (304A) to extend into a working area (808), and contact between the cable selection tool (306) and the second cable wire (304B) moves a tip portion (806B) of the second cable wire (304B) out of the working area (808); as well as A conductive contact (106A) is automatically attached to a tip portion (806A) of the first cable wire (304A) by a cable contact attachment system (300).

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