Automatic cable mounting tool with inductive weld engagement mechanism

Abstract

Various embodiments of the present disclosure relate to an automated cable mounting tool with an inductive weld joint mechanism. A system includes a body having a pair of cable clips. The pair of cable clips also includes a dispensing track on the inner periphery of the pair of cable clips to hold a section of thermoplastic cable material. The system includes a piston. The piston is configured to secure an overlapping section of thermoplastic cable material at a weld region. The induction coil is configured to apply an electromagnetic field. The system includes a power source.

Description

[0001] This application is a divisional application of the invention patent application with application date of October 21, 2022, application number 202211299507.2, and invention name “Automatic cable installation tool with induction welding joint mechanism”. Technical Field

[0002] The present disclosure relates generally to cable bundling and, more particularly, to an apparatus for automatically dispensing, tensioning, and engaging cable binding material around a set of elongated members (eg, wires, cables, etc.). Background Art

[0003] Automated cable installation has become increasingly relevant in the industry for high-volume cable installation customers, particularly in the automotive, aerospace, aviation, and data center sectors. Some automated cable installation tools utilize cable stock with ratchet heads, which create sharp edge hazards and generate significant amounts of waste. Other automated cable installation tools utilize ultrasonic welding, where weld quality is difficult to control due to the required rapid vibrations and high clamping forces. Therefore, there is a need for improved automated cable installation tools. Summary of the Invention

[0004] In some embodiments, a system includes a body having: a pair of cable clamps, wherein the pair of cable clamps further include a dispensing track on an inner periphery of the pair of cable clamps to retain a section of thermoplastic cable material; a piston configured to secure overlapping sections of thermoplastic cable material at a weld area; an induction coil for applying an electromagnetic field; and a power source.

[0005] In some embodiments, the system further comprises a tensioning motor and a tensioning track configured to tension a section of thermoplastic cable material around at least one elongated member being bundled, and wherein a section of thermoplastic cable material is fed through the distribution track of the pair of cable clamps, around the at least one elongated member, until an end of the thermoplastic cable material overlaps with a middle section of the thermoplastic cable material at a weld area, the tensioning motor tensioning the thermoplastic cable material around the at least one elongated member being bundled, and the overlapping sections of the thermoplastic cable material are coupled by the electromagnetic field of the induction coil.

[0006] In some embodiments, the body further includes a metallic or ferromagnetic insert that is sensitive to electromagnetic fields and is positioned at the weld area.

[0007] In some embodiments, the insert is a fixture configured to position the overlapping sections of thermoplastic cable material and to be heated by the induction coil to bond the overlapping sections of thermoplastic cable material.

[0008] In some embodiments, the insert is a staple, and wherein the staple is accelerated through the overlapping sections of thermoplastic cable material and heated by the induction coil to join the overlapping sections of thermoplastic cable material.

[0009] In some embodiments, the insert is positioned at the overlapping section at the weld area of the thermoplastic cable material, between the first section and the second section of the thermoplastic cable material.

[0010] In some embodiments, the insert is a mesh, and wherein the mesh is disposed between the first and second sections of thermoplastic cable material and heated by the induction coil to couple the first section of thermoplastic cable material to the second section of thermoplastic cable material.

[0011] In some embodiments, the insert is a foil that is disposed between the first and second sections of thermoplastic cable material and heated by the induction coil to join the first section of thermoplastic cable material to the second section of thermoplastic cable material.

[0012] In some embodiments, the thermoplastic cable material further comprises a metallic or ferromagnetic layer disposed between adjacent layers of the thermoplastic cable material, and wherein the overlapping sections of the thermoplastic cable material are configured to join when a magnetic field frequency is applied from the induction coil to the weld region.

[0013] In some embodiments, the main body further comprises: a holding member for holding a length of the cable material, the holding member being configured to release a length of the cable material based on a pulling force; a container for holding the holding member; a dispensing mechanism disposed at the container and configured to dispense a determined length of cable material around the bundled group of elongated members; and wherein the dispensing system is removably connected to the main body of the cable material induction welding system.

[0014] In some embodiments, the retaining member is rotatably connected to the receptacle of the body.

[0015] In some embodiments, the power supply operates at a frequency of 10 kHz to 10 MHz.

[0016] In some embodiments, the induction coil is a hairpin induction coil, a stacked spiral coil, or a spiral slice coil.

[0017] In some embodiments, the body further comprises an electromagnetically non-conductive shield for insulating the bound elongated members from the induction coil.

[0018] In some embodiments, a method of using a system includes the steps of dispensing a section of thermoplastic cable material through a pair of cable clamps along a dispensing track of the pair of cable clamps until a first section of thermoplastic cable material overlaps with a second section of thermoplastic cable material at an area formed by a piston, the piston being formed by an induction coil; tensioning the thermoplastic cable material to draw the thermoplastic cable material taut around the at least one elongated member being bundled; applying the piston to the overlapping first and second sections of the thermoplastic cable material to apply pressure to the first and second sections of the thermoplastic cable material; generating an electromagnetic field with a power source; and applying the electromagnetic field through the induction coil to couple the first section of the thermoplastic cable material to the second section of the thermoplastic cable material.

[0019] In some embodiments, dispensing a section of thermoplastic cable material further comprises positioning an insert between the first section and the second section of thermoplastic cable material.

[0020] In some embodiments, dispensing a length of thermoplastic cable material further comprises positioning an insert around the overlapping first and second lengths of thermoplastic cable material.

[0021] In some embodiments, a cable material welding tool includes: a pair of cable clamps; an induction coil; a length of cable material; and a power supply operating between 10 kHz and 10 MHz.

[0022] In some embodiments, the cable material welding tool further comprises: a piston; a tensioning motor and a tensioning track; and a non-conductive shield.

[0023] In some embodiments, the cable material further comprises a metallic or ferromagnetic layer disposed between adjacent thermoplastic layers, and wherein the overlapping sections of the cable material are configured to bond together when heat is applied from the induction coil.

[0024] In some embodiments, the induction coil is a hairpin coil, a helical coil, a stacked helical coil, or a helical slice coil.

[0025] In some embodiments, the cable material welding tool further comprises a shield to insulate the at least one elongated member being bundled from the electromagnetic field generated by the induction coil.

[0026] In some embodiments, the cable material tool further includes an insert comprised of a material sensitive to electromagnetic fields and positioned at the weld area to join overlapping sections of the cable material.

[0027] In some embodiments, the insert is a staple, mesh, clamp, or foil. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Reference is made to the accompanying drawings which form a part of this disclosure and which illustrate embodiments in which the systems and methods described in this specification may be practiced.

[0029] Figure 1 is a schematic diagram of a system including an automated cable material installation tool, according to some embodiments.

[0030] Figure 2 is a perspective view of a system including an automated cable material installation tool, according to some embodiments.

[0031] Figure 3 is a perspective view of a cable material laminated with a metal tape during production, according to some embodiments.

[0032] Figure 4 is a perspective view of a flat induction coil within a piston, according to some embodiments.

[0033] Figure 5 is a perspective view of a flat induction coil applied to a cable material, according to some embodiments.

[0034] Figure 6 is a perspective view of a hairpin induction coil applied to a cable material, according to some embodiments.

[0035] The same reference numbers will be used throughout to refer to the same or like parts. DETAILED DESCRIPTION

[0036] Embodiments of the present invention relate to an automated cable material installation tool. More specifically, the automated cable material installation tool described herein is a device for joining segments of thermoplastic cable material. The device includes a pair of cable clamps with a distribution track, a tensioning motor and tensioning track, a piston and anvil for applying pressure to the weld, an induction coil, and a power supply. In some embodiments, the device includes an insert that is heated by the induction coil to weld the cable material together.

[0037] As used herein, an "automated cable material installation system" includes a system or tool capable of wrapping at least one elongated member with thermoplastic cable material, tensioning the thermoplastic cable material around the at least one elongated member being bundled, and welding overlapping sections of the thermoplastic cable material together using an induction coil. In some embodiments, the automated cable material installation system may include an insert positioned adjacent to the overlapping sections of the thermoplastic cable material at a weld region for joining the overlapping sections of the thermoplastic cable material. In some embodiments, the automated cable material installation system includes a cable material dispensing system that holds a length of thermoplastic cable material and provides the thermoplastic cable material that is bundled around the elongated member and welded together.

[0038] As used herein, "cable material" includes a length of thermoplastic material suitable for being bundled around a group of elongated members. In some embodiments, the cable material can be a continuous length of thermoplastic material. In some embodiments, the cable material can be a predetermined length distributed by an automatic cable material installation system.

[0039] Figure 1 is a schematic diagram of a system 100 including an automated cable material installation tool, according to some embodiments. Figure 2 is a perspective view of a system 100 including an automated cable material installation tool according to some embodiments. Figure 1-Figure 2 The automated cable stock installation system 100 is generally configured for bundling a group of elongated members 170 using cable stock 115 .

[0040] In some embodiments, the automated cable material installation system 100 includes a tool 105. The tool 105 includes a control unit 110. According to some embodiments, the control unit 110 can control one or more settings related to the operation of the automated cable material installation system 100. The tool 105 can include a body having a pair of cable clamps 120, an induction coil 125, a tensioning motor 135 and a tensioning track 140, a piston 145, and an input port 155. The automated cable material installation system 100 can also include a power source 160 connected to the tool 105 at the input port 155.

[0041] In some embodiments, the pair of cable clamps 120 may have a dispensing track on the inner periphery of the pair of cable clamps 120. The dispensing track may hold a length of cable material 115 that is fed through the automated cable material installation system 100 around the elongated members 170 to be bundled. The tensioning motor 135 and the tensioning track 140 apply tension to the cable material 115 after the cable material 115 is fed around the group of elongated members 170 to be bundled, thereby securing the cable material 115 around the group of elongated members 170. A piston 145 may be positioned adjacent to the weld area. The piston 145 may be configured to apply pressure to the weld area at the overlapping section of the cable material 115.

[0042] In some embodiments, the induction coil 125 can generate an electromagnetic field capable of heating a metal or ferromagnetic material. The electromagnetic field generated by the induction coil 125 can be applied to the metal or ferromagnetic material, and the field frequency can be supplied to the induction coil 125 from a power supply. In some embodiments, the induction coil 125 can be made of copper wire capable of carrying the current required for induction. In other embodiments, the induction coil 125 can be made of other suitable materials capable of carrying the current required for induction.

[0043] In some embodiments, the current carried by the induction coil 125 may be less than 10 amps. In some embodiments, the current carried by the induction coil 125 may be less than 9 amps. In some embodiments, the current carried by the induction coil 125 may be less than 8 amps. In some embodiments, the current carried by the induction coil 125 may be less than 7 amps. In some embodiments, the current carried by the induction coil 125 may be less than 6 amps. In some embodiments, the current carried by the induction coil 125 may be less than 5 amps. In some embodiments, the current carried by the induction coil 125 may be less than 4 amps. In some embodiments, the current carried by the induction coil 125 may be less than 3 amps. In some embodiments, the current carried by the induction coil 125 may be less than 2 amps.

[0044] In some embodiments, the current carried by the induction coil 125 may be greater than 1 amp. In some embodiments, the current carried by the induction coil 125 may be greater than 2 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 3 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 4 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 5 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 6 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 7 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 8 amps. In some embodiments, the current carried by the induction coil 125 may be greater than 9 amps.

[0045] In some embodiments, power supply 160 generates a frequency for induction coil 125 of automated cabling material installation system 100. In some embodiments, power supply 160 may be a high frequency power supply that generates a frequency between 10 kHz and 10 MHz.

[0046] In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 100 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 200 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 300 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 400 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 500 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 600 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 700 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 800 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 900 kHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 1 MHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 2 MHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 3 MHz and 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 4 MHz to 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 5 MHz to 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 6 MHz to 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 7 MHz to 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 8 MHz to 10 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 9 MHz to 10 MHz.

[0047] In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 9 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 8 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 7 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 6 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 5 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 4 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 3 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 2 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 1 MHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 900 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 800 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency between 10 kHz and 700 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 10 kHz to 600 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 10 kHz to 500 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 10 kHz to 400 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 10 kHz to 300 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 10 kHz to 200 kHz. In some embodiments, the power supply 160 may be a high-frequency power supply that generates a frequency of 10 kHz to 100 kHz.

[0048] In some embodiments, power supply 160 is capable of generating a suitable drive signal for the inductive circuit. Examples of suitable drive signals include, but are not limited to, sawtooth, square, and half-wave signals. These relatively simple drive signals are advantageous compared to other high-frequency technologies, such as ultrasonic welders, which require well-controlled drive signals and intensive feedback control features.

[0049] In some embodiments, the coil design of the induction coil 125 can have a geometry that is suitable for the size of the cable material 115. Typically, the width of the cable material 115 is in the range of 0.09 inches to 0.32 inches. In some embodiments, the automated cable material installation system 100 can be adapted to operate with cable material 115 having a width greater than 0.32 inches. In some embodiments, the corresponding diameter of the induction coil 125 can be in the range of 0.09 inches to 0.32 inches. In some embodiments, the coil diameter or width can be smaller than the size of the cable material 115 to be welded.

[0050] In some embodiments, the diameter of the induction coil 125 may be in the range of 0.09 inches to 0.3 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.09 inches to 0.25 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.09 inches to 0.2 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.09 inches to 0.15 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.09 inches to 0.1 inches.

[0051] In some embodiments, the diameter of the induction coil 125 may be in the range of 0.1 inches to 0.32 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.15 inches to 0.32 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.2 inches to 0.32 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.25 inches to 0.32 inches. In some embodiments, the diameter of the induction coil 125 may be in the range of 0.1 inches to 0.32 inches.

[0052] In some embodiments, the automated cable material installation system 100 includes an insert 165 positioned at the welding area. In some embodiments, the insert 165 is constructed of metal or ferromagnetic material, including but not limited to iron, copper, aluminum, nickel, cobalt, carbon steel, stainless steel, graphite / graphene / carbon fiber / carbon nanotubes / other conductive carbon substances, combinations thereof, and the like.

[0053] In some embodiments, insert 165 may comprise a staple that is accelerated through the overlapping sections of cable material 115. The staple is designed with prongs that can be accelerated through the overlapping sections of cable material 115 to hold them in place under tension. Heating the staple melts the adjacent overlapping sections of cable material 115, forming a bond. In some embodiments, when heated by induction coil 125, the prongs of the staple heat faster than the flat areas of the staple. In some embodiments, insert 165 may comprise a wire mesh. The mesh may be sized to suit the frequency of the applied magnetic field so as to be non-reflective. When heated by induction coil 125, the mesh heats the cable material 115, and the molten cable material 115 flows between and fills the gaps in the mesh, encapsulating insert 165 and forming a uniform weld. In some embodiments, insert 165 may comprise a clamp. The clamp may be configured to hold the overlapping sections of cable material 115 together. Heating of the fixture by the induction coil 125 causes the overlapping sections of the layers of cable material 115 to melt to form a bond. In some embodiments, the insert 165 may be a foil positioned between the overlapping sections of the cable material 115. Heating of the foil by the induction coil 125 causes the overlapping sections of the cable material 115 to melt to form a bond.

[0054] In some embodiments, the insert 165 may be pressed into the cable material 115 just prior to induction welding by the induction coil 125. During tensioning of the cable material 115 by the tensioning motor 135 and the tensioning track 140, the clamping force applied to the leading end of the cable material 115 may also be used to mechanically press the insert 165 into the cable material 115.

[0055] In some embodiments, the automated cable material installation system 100 includes a dispensing system for the cable material 115. The cable material 115 can be constructed from a variety of thermoplastics, including but not limited to Nylon 4,6; Nylon 6,6; Nylon 11; Nylon 12; thermoplastic polyurethane; Acetal; Polypropylene; Polyethylene and High-Density Polyethylene; Fluoropolymers (e.g., polytetrafluoroethylene (PTFE), tetrafluoroethylene (ETFE)); and polyetheretherketone (PEEK), combinations thereof, and the like. In some embodiments, these thermoplastic materials can be combined with metal compounds during the production of the lacing, or combined with the insert 165 during the welding and tensioning process as described above, to connect the cable material 115 when tying the elongated member 170.

[0056] In some embodiments, the automated cable material installation system 100 includes a shield 180. The shield 180 may be constructed of an electromagnetically non-conductive material that resists the electromagnetic field of the induction coil 125, and the heat generated by the induction coil 125 is applied to the cable material 115 or the insert 165. The shield insulates the bundled elongated member 170 from the electromagnetic field of the induction coil 125, and the heat generated by the induction coil 125 is applied to the elongated member 170.

[0057] In some embodiments, the welding region may be disposed at piston 145. At the welding region, cable material 115 may be fed through automated cable material installation system 100 until first section 185 of cable material 115 may be positioned adjacent to and above second section 190 of cable material 115.

[0058] In some embodiments, the automated cable material installation system 100 further includes a cable dispenser 175 for holding a length of cable material 115 configured to be inserted into the tool 105 of the automated cable material installation system 100. In some embodiments, the tool 105 may include a cable dispenser 175 for receiving a length of cable material, for example, on a spool. The spool may be rotatably connected to the tool 105 so that a determined or predetermined length of cable material 115 can be dispensed based on a pulling force generated by the automated cable material installation system 100 or a user of the automated cable material installation system 100.

[0059] In some embodiments, a method of using the automated cable material installation system 100 includes dispensing a section of the cable material 115 through the dispensing track of the pair of cable clamps 120 until a first section 185 of the cable material 115 overlaps a second section 190 of the cable material 115 at the area of the piston 145. The automated cable material installation system 100 applies tension to the cable material 115 to tighten the cable material 115 around at least one elongated member 170 to be bundled. The piston 145 can be positioned at the weld area to apply pressure to the overlapping sections of the cable material 115 at the weld area. An electromagnetic field frequency can be generated by the power supply 160, and the generated electromagnetic field can be applied to the weld area via the induction coil 125 to couple the first section 185 of the cable material 115 to the second section 190 of the cable material 115.

[0060] In some embodiments of the method of using the automated cable material installation system 100, dispensing a section of the cable material 115 further comprises positioning the insert 165 between the cable material 115 and the elongated member 170. In some embodiments of the method of using the automated cable material installation system 100, dispensing a section of the cable material 115 further comprises positioning the insert 165 around the overlapping first and second sections 185, 190 of the cable material 115.

[0061] Figure 3 1 is a perspective view of a cable material laminated with a metal tape during production, according to some embodiments. In some embodiments, the cable material 115 can be laminated with a metal or ferromagnetic tape during production of the cable material 115. The insert 165 and the cable material 115 are bonded together during production using an extrusion process coupled with a lamination process. When heat is applied by the induction coil 125, the resulting laminated structure of the cable material 115 allows welds to form in the contact areas of the cable material 115. This structure can be achieved by multiple parallel thin strips, perforated films, or winding paths of metal or ferromagnetic material disposed between adjacent thermoplastic layers. The laminate can include discontinuous films rather than continuous tape, or continuous tape with periodic electrical insulation.

[0062] In some embodiments, the cable material 115 can be laminated or coextruded with a metal or magnetic particle-filled thermoplastic composite. Examples include iron particles / fillers in a thermoplastic matrix. The particle size in the thermoplastic composite can be large enough to respond to the applied magnetic field of the frequency, but can be limited by the geometry of the ribbon. An example of such a constraint could be a particle size of less than 1 mm in diameter for spheres, fibers, and needles, and less than 1 mm in thickness for irregularly shaped flakes or particles.

[0063] In some embodiments, the cable material 115 may be laminated or co-extruded with metal or magnetic materials such as graphite, graphene, carbon fiber, carbon nanotubes, other conductive carbon materials including iron, copper, aluminum, nickel, cobalt, and compounds thereof.

[0064] In some embodiments, the cable material 115 may also include a deposited layer of aluminum or other metal coatings, including copper, ferrite, nickel, cobalt, their compounds, or other suitable materials. The cable material 115 is extruded and then coated with a metal or magnetic material. The coating may be selectively applied to the cable material 115 by stencil printing or stenciling using one of the following techniques, or other suitable techniques: chemical vapor deposition, physical vapor deposition, sputtering, electroplating, electroless plating, arc spraying, powder coating, and flame spraying.

[0065] Figure 4-Figure 6 Shown Figure 1 Different embodiments of the induction coil 125. Figure 4 is a perspective view of a flat induction coil within a piston, according to some embodiments. Figure 5 is a perspective view of a flat induction coil applied to a cable material, according to some embodiments. Figure 6 is a perspective view of a hairpin induction coil applied to a cable material, according to some embodiments.

[0066] In some embodiments, the induction coil 125 can be a flat coil 305, a stacked spiral coil, a spiral slice coil, a hairpin coil 505, a single-turn coil, or a solenoid coil surrounding the weld area. In some embodiments, the induction coil 125 or a portion thereof can be embedded in the piston 145, wherein the piston 145 is constructed of a field-shaping material that controls the focus of the magnetic field on the weld area. In some embodiments, the leads of the coil pass through the piston and are minimally inducted. In other embodiments, the induction coil 125 is configured into a complex coil pattern to surround the cable material 115 at the weld area.

[0067] The terms used herein are intended to describe embodiments and are not intended to be limiting. The terms "a," "an," and "the" also include plural forms unless expressly stated otherwise. When used in this specification, the terms "include" and / or "comprise" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or components.

[0068] It should be understood that changes may be made in detail, particularly in the materials of construction employed and the shapes, sizes, and arrangements of parts without departing from the scope of the present disclosure. The specification and described embodiments are examples, with the true scope and spirit of the disclosure being indicated by the following claims.

Claims

1. A system comprising: A main body, the main body having: Pair of cable clips, including: a distribution track on the inner periphery of the pair of cable clamps for holding a length of thermoplastic cable material, wherein a length of the thermoplastic cable material is fed through the distribution track on the inner periphery of the pair of cable clamps, around at least one elongated member for bundling, until an end of the thermoplastic cable material overlaps a middle section of the thermoplastic cable material at a weld area; a tensioning motor configured to apply tension to secure the thermoplastic cable material around the at least one elongated member; a piston configured to secure an overlapping section of the thermoplastic cable material disposed about the at least one elongated member at the weld region, the piston comprising: an induction coil configured to apply an electromagnetic field to the welding area, the induction coil being embedded in the piston for controlling the electromagnetic field to focus on the welding area; and a power source coupled to the induction coil; The power supply is configured to apply a field frequency to the induction coil so that the induction coil generates an electromagnetic field and heats the metal or ferromagnetic material at the welding region to join the overlapping sections of the thermoplastic cable material disposed around the at least one elongated member.

2. The system of claim 1 , further comprising a tensioning track configured to tension a length of the thermoplastic cable material around at least one elongated member to be bundled, and the piston configured to secure the overlapping section of the thermoplastic cable material, the overlapping section being secured around the at least one elongated member to be bundled, and wherein the tensioning motor tensions the thermoplastic cable material around the at least one elongated member to be bundled, and the overlapping sections of the thermoplastic cable material are coupled by the electromagnetic field of the induction coil.

3. The system of claim 2, wherein the body further comprises: a holding member for holding a section of the thermoplastic cable material, wherein the holding member is configured to yield a section of the thermoplastic cable material based on a pulling force; a container for holding the holding member; as well as a dispensing mechanism disposed at the container and configured to dispense a determined length of thermoplastic cable material around the at least one elongated member to be bundled; wherein the dispensing mechanism is removably connected to the body. The system of claim 3 , wherein the retaining member is rotatably connected to the container of the body.

5. The system of claim 2 , wherein the body further comprises a non-conductive electromagnetic shield for insulating the at least one elongated member to be bound from heat generated from the induction coil applying the electromagnetic field to the metal or ferromagnetic material when joining the overlapping sections of the thermoplastic cable material.

6. The system of claim 1 , wherein the body further comprises a metallic or ferromagnetic insert positioned at the weld area that is sensitive to electromagnetic fields, Wherein the metallic or ferromagnetic insert is configured to join the overlapping sections of the thermoplastic cable material in response to being heated by the induction coil.

7. The system of claim 6, wherein the metallic or ferromagnetic insert is a clamp configured to hold the overlapping sections of the thermoplastic cable material in place and the clamp is heated by the electromagnetic field from the induction coil to join the overlapping sections of the thermoplastic cable material.

8. The system of claim 6, wherein the metallic or ferromagnetic insert is a staple, and wherein the staple has a prong that is accelerated through the overlapping sections of the thermoplastic cable material and heated by the electromagnetic field from the induction coil to join the overlapping sections of the thermoplastic cable material.

9. The system of claim 6, wherein the metallic or ferromagnetic insert is positioned at the overlapping section of the thermoplastic cable material at the weld area, between the first section and the second section of the thermoplastic cable material.

10. The system of claim 9, wherein the metallic or ferromagnetic insert is a mesh, and wherein the mesh is disposed between the first and second sections of the thermoplastic cable material and is heated by the electromagnetic field from the induction coil to couple the first section of the thermoplastic cable material to the second section of the thermoplastic cable material.

11. The system of claim 9, wherein the metallic or ferromagnetic insert is a foil that is disposed between the first and second sections of thermoplastic cable material and is heated by the electromagnetic field from the induction coil to couple the first section of thermoplastic cable material to the second section of thermoplastic cable material.

12. The system of claim 9, wherein the thermoplastic cable material further comprises a metallic or ferromagnetic layer disposed between adjacent layers of thermoplastic cable material, and wherein the overlapping sections of thermoplastic cable material are configured to join based on heat generated when the electromagnetic field is applied from the induction coil to the weld region.

13. The system of claim 1, wherein the power supply operates at a frequency of 10 kHz to 10 MHz.

14. The system of claim 1, wherein the induction coil is a hairpin induction coil, a stacked spiral coil, or a spiral slice coil.

15. A method comprising: dispensing a section of thermoplastic cable material through a pair of cable clamps along a dispensing track around at least one elongated member until the first section of thermoplastic cable material overlaps a second section of the thermoplastic cable material at a weld region through a piston, the piston including an induction coil embedded therein for controlling an electromagnetic field focused to the weld region; tensioning the thermoplastic cable material to draw the thermoplastic cable material taut around the at least one elongated member to be bundled, wherein a tensioning motor is configured to apply tension to the thermoplastic cable material around the at least one elongated member; applying the piston to the overlapping first and second sections of the thermoplastic cable material to apply pressure to the first and second sections of the thermoplastic cable material; generating the electromagnetic field at the induction coil using a power supply; as well as The electromagnetic field generated by the induction coil is applied to generate heat in the metallic or ferromagnetic material disposed at the welding region and to join the first section of the thermoplastic cable material to the second section of the thermoplastic cable material.

16. The method of claim 15, wherein dispensing a section of the thermoplastic cable material further comprises: An electromagnetically non-conductive shield is positioned between the first and second sections of thermoplastic cable material to isolate the at least one elongated member from heat generated by the metallic or ferromagnetic material during joining of the first and second sections of thermoplastic cable material.

17. The method of claim 15, wherein dispensing a section of the thermoplastic cable material further comprises: An insert comprising the metallic or ferromagnetic material is positioned at the weld area to join the first and second sections of the thermoplastic cable material.

18. A cable material welding tool, comprising: Pair of cable clips, including: a dispensing track on the inner periphery of the pair of cable clamps for holding a length of cable material, wherein a length of the cable material is fed through the dispensing track on the inner periphery of the pair of cable clamps, around at least one elongated member for bundling, until an end of the cable material overlaps a middle section of the cable material at a weld area; a tensioning motor configured to apply tension to secure the cable material about the at least one elongated member; piston; an induction coil configured to be positioned proximate to an overlapping section of the cable material at the weld area, wherein the induction coil is embedded in the piston for controlling the electromagnetic field to focus on the welding area, and wherein the induction coil is a hairpin coil, a spiral coil, a stacked spiral coil or a spiral slice coil; a shield configured to insulate the at least one elongated member to be bound from heat generated from the electromagnetic field generated by the induction coil; and A power supply is coupled to the induction coil and configured to operate between 10 kHz and 10 MHz to generate a field frequency so that the induction coil generates the electromagnetic field to join the overlapping sections of the cable material at the weld region.

19. The wire material welding tool according to claim 18, wherein the wire material welding tool further comprises: A tensioning track wherein the shield comprises a non-conductive shield to isolate the at least one elongated member to be bound from the heat generated by the induction coil when joining the overlapping sections of cable material.

20. The cable material welding tool of claim 18, wherein the cable material further comprises a metallic or ferromagnetic layer disposed between adjacent layers of thermoplastic cable material, and wherein the induction coil is configured to apply the electromagnetic field to the metallic or ferromagnetic layer to heat the metallic or ferromagnetic layer and join the overlapping sections of the cable material at the weld area.

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