Systematized bundling method for high-voltage waste cables

Abstract

The invention discloses a systematized bundling method for high-voltage waste cables, and belongs to the field of warehouse logistics automation. A working platform capable of fixing and compressing cable bundles is arranged, and a plurality of cable seats are arranged on the working platform; carrying out transverse and vertical extrusion treatment on the placed cable bundle; binding operation is completed through an arrow penetrating type binding machine; measuring the weight of the cable bundle by using a weight sensor arranged at the bottom of each cable seat; data support is provided for calculating the gravity center position of the bundled cable bundle; printing information labels including cable specifications, binding dates and total weight, pasting the information labels on any binding tape, and meanwhile, archiving data to a warehouse database; the horizontal gravity center position of the cable bundle is calculated according to data of all the weight sensors, indicator lamps of cable bases located on the two sides of the gravity center position are lightened, a forklift operator is guided to hoist the cable bundle at the cable base position between the two lamps, and it is ensured that the cable bundle is safely transferred to a storage area. And the method is especially suitable for classified management of cables with different lengths and bending after construction.

Description

Technical Field

[0001] This invention belongs to the field of packaging and logistics automation, and in particular relates to a systematic processing method for compressing, bundling and center of gravity positioning of waste high-voltage cable bundles. Background Technology

[0002] The recycling of waste cables plays a crucial role in the circular utilization of copper resources. Given my country's relatively scarce copper resources, domestic copper supply mainly relies on the recycling of waste cables, with high-voltage cables accounting for a significant proportion; therefore, improving waste cable recycling technology is of great importance.

[0003] Currently, scrap cables are typically unearthed at construction sites, collected, and transported to warehouses. Before being stored, each truckload of scrap cables is weighed and then hoisted into the warehouse as a whole using a lifting cable pre-placed at the bottom of the cables. This lifting cable remains at the bottom of the cables throughout the storage process for subsequent relocation.

[0004] The specifications of each bundle of cables vary, with diameters typically ranging from 50 mm to 137 mm and lengths from approximately 5 to 6 meters. A single cable can weigh up to 120 kg. Due to the flexibility of the cables, they are often slightly bent and prone to tangling (the degree of bending can be defined by the length and width dimensions of the smallest circumscribed rectangle; in this case, the maximum bending degree is approximately 1 meter of lateral offset per 6 meters of length).

[0005] Currently, the cables in the warehouse are stored in a rather disorganized manner, with cables of different specifications stacked haphazardly. As more cables are brought in, the stacks eventually form a pyramid-shaped structure. This stacking method not only affects the overall appearance but also poses problems such as low space utilization and significant safety hazards.

[0006] A utility model patent, authorized on July 25, 2025, with authorization announcement number CN 223148803 U, discloses a "bundling device for cable and wire processing." The device includes a base, a fixed frame fixed on the base, a circular groove on the fixed frame, a circular ring slidingly disposed within the groove, a toothed ring fixed on the circular ring, a gear rotatably mounted on the fixed frame, the gear meshing with the toothed ring, a motor fixed on the fixed frame, and a motor output shaft fixedly connected to the gear. A rotating wheel is movably disposed on one side of the toothed ring, a transmission assembly is located above the base, and a pre-tightening mechanism is also located above the base. The motor drives the gear to rotate, the gear drives the toothed ring to rotate, and the toothed ring drives the rotating wheel to rotate around the cable / wire. The binding tape binds the cable / wire layer circle by circle, preventing damage to the outer insulation layer of the cable / wire during transportation. Two pairs of threaded grooves are pre-drilled on the toothed ring; when the cable / wire needs to be bound more securely, multiple rotating wheels can be added using screws for further binding as required. The technical solution employed involves pre-clamping the cables and wires, then bundling them up layer by layer (also known in the industry as "arrow-piercing bundling"), and finally transporting the cables and wires away. However, this method only focuses on the bundling and securing of the cable bundles, neglecting the issue of the horizontal center of gravity of the bundled cables. Without knowing the balance point (center of gravity or center of mass) of the cable bundles, it is detrimental to the stability and safety of the forklift during the lifting of bundled cables.

[0007] The invention patent application with publication date of September 24, 2024, and publication number CN 118684060 A discloses "a cable bundling machine with adjustable bundling width". It includes a support mechanism, which includes a bundling shaft. An adjustment mechanism is located at the front end of the bundling shaft, and a winding mechanism is located inside the bundling shaft. A dust removal mechanism is located on the side of the adjustment mechanism near the bundling shaft. The adjustment mechanism includes a guide shaft that adjusts the width of the cable winding to make it more uniform. The guide shaft is located at the front end of the bundling shaft. The adjustment mechanism is used to uniformly adjust the width of the cable bundling. This device can adjust the winding width of the cable during bundling, preventing situations where some coils are more than others, avoiding uneven coil widths, ensuring relatively even pressure on the internal cable, protecting the cable insulation layer, and preventing short circuits. It also prevents insecure bundling due to inconsistent cable width. Similarly, this technical solution only focuses on bundling multi-turn cables wound on a rotating shaft. The machinery used in this technical solution cannot handle the bundling of multiple cable bundles in segments, and it does not address the issue of the center of gravity of the bundled cable bundle (also known as cable bundle) in the horizontal direction.

[0008] The current technical challenge lies in how to effectively bundle and smoothly load waste cables into storage racks. Although the cables in a bundle have the same diameter, their lengths vary and they are often bent, making them prone to tangling. The cables are heavy and flexible, so pushing one end often causes bending rather than movement of the whole cable. Furthermore, unlike rigid materials such as steel pipes, the cable sheath is soft and has high frictional resistance; moving a single cable often pulls on surrounding cables, increasing the difficulty of the operation.

[0009] To achieve effective binding, a standardized binding process needs to be defined. Summary of the Invention

[0010] The purpose of this invention is to provide a systematic bundling method for high-voltage waste cables. It employs a mobile, arrow-type bundling machine for dynamic, interval bundling without moving the cable itself. By applying bidirectional compression, automatic bundling, and center-of-gravity positioning to the cable bundles, and then securely placing the bundled cables on shelves in the storage area, space utilization is improved. It enables the classified management of waste cables of different specifications, significantly simplifying the identification and retrieval process. Due to its high structural stability, it significantly reduces the risk of injury from cable slippage. It fills the gap in existing bundling technologies for handling non-coiled waste cables, and is particularly suitable for post-construction cables of varying lengths and with bends.

[0011] The technical solution of this invention is: to provide a systematic bundling method for high-voltage waste cables, characterized in that:

[0012] 1) Set up a working platform that can fix and compress cable bundles, wherein the working platform is equipped with several horizontally arranged cable seats;

[0013] 2) Perform horizontal and vertical compression on the cable bundles placed on the work platform;

[0014] 3) Use an arrow-type strapping machine to complete the strapping operation;

[0015] 4) Measure the weight of the cable bundle using weight sensors installed at the bottom of each cable holder; this provides data support for calculating the center of gravity of the cable bundle after bundling.

[0016] 5) Print information labels containing cable specifications, bundling date, and total weight, and affix them to any of the bundling straps. At the same time, archive the data to the warehouse database.

[0017] 6) Calculate the horizontal center of gravity of the cable bundle based on the data from each weight sensor, and illuminate the indicator lights on the cable holders located on both sides of the center of gravity to guide the forklift operator to lift the cable bundle at the cable holder position between the two lights, ensuring safe transfer to the storage area.

[0018] Specifically, the working platform that can fix and compress cable bundles allows the arrow-type strapping machine to move along the length of the waste cable and fix the strapping at different positions.

[0019] Specifically, a fixed lateral compression device is provided at the rear of each cable holder, and a sliding lateral compression device is provided at the front of each cable holder. The two work together to laterally compress the cable.

[0020] Furthermore, the sliding transverse extrusion device is connected to a transverse pneumatic cylinder, and the cylinder piston rod pushes the pressure plate to move backward, forming a clamping structure with the fixed transverse extrusion device.

[0021] Furthermore, the top of the sliding lateral extrusion device is provided with a funnel-shaped guide structure for receiving cable bundles transported by forklifts and effectively guiding the cables into the central area of ​​the cable seat; a central cavity is provided between the sliding lateral extrusion device and the fixed lateral extrusion device; a rotary vertical extrusion device with a rotating arm is provided at the position corresponding to the fixed lateral extrusion device and the central cavity; the central cavity ensures that the rotary vertical extrusion device can smoothly rotate into / out of the extrusion area to cooperate with subsequent vertical extrusion operations.

[0022] Furthermore, the rotary vertical compression device is pivotally connected to the rear of the cable holder; driven by a stepper motor, it rotates into the central cavity, and then a vertical pneumatic cylinder presses down the pressure plate to complete the vertical compression, reducing the cross-sectional area of ​​the cable bundle and improving the bundling efficiency.

[0023] Specifically, the arrow-type strapping machine is installed on a horizontal guide rail assembly and performs positioning and strapping at the gaps between each cable seat; the arrow-type strapping machine has a retractable bottom guide mechanism that extends at the work station to form a closed loop and complete the strapping operation; the top guide mechanism of the arrow-type strapping machine can be adjusted up and down to adapt to the cable height; after the strapping tape of the arrow-type strapping machine is subjected to maximum tension, it is cut and the two ends are welded; the arrow-type strapping machine then moves laterally to the next work station and repeats the process until all strapping is completed.

[0024] Specifically, after the final strapping is completed, the weight sensor at the bottom of the cable holder transmits the measured weight data to the main controller in real time; the system calculates the horizontal center of gravity of the bundled cable based on this data to ensure stability during lifting and transportation.

[0025] Furthermore, the formula for calculating the horizontal center of gravity position is as follows:

[0026] Xcg =

[0027] Where wi is the subtotal weight of each cable holder; xi is the distance between the cable holder and the first cable holder; and Xcg is the position of the center of gravity.

[0028] The systematic bundling method for high-voltage waste cables described in this technical solution uses a mobile arrow-type bundling machine for dynamic interval bundling, eliminating the need to move the cable itself. By implementing bidirectional compression, automatic bundling, and center-of-gravity positioning of the cable bundles, the bundled cables are securely placed in the storage area's shelves, improving space utilization. It enables the classified management of waste cables of different specifications, significantly simplifying the identification and retrieval process. Its high structural stability significantly reduces the risk of personnel injury caused by cable slippage. It is particularly suitable for post-construction cables of varying lengths and with bends.

[0029] Compared with the prior art, the advantages of the present invention are:

[0030] 1. The technical solution of the present invention, by implementing bidirectional compression, automatic bundling and center of gravity positioning of the cable bundles, and stably placing the bundled cables in the storage area shelves, can improve the space utilization rate by about 31%; using shelf storage can also realize the classified management of waste cables of different specifications, significantly simplifying the identification and retrieval process.

[0031] 2. The technical solution of the present invention adopts an operation mode of fixing cable bundles and moving the bundling machine, which can significantly optimize the quality of cable pretreatment before bundling and avoid a significant increase in system structural complexity and control difficulty due to the movement of cable seats.

[0032] 3. The technical solution of the present invention adopts an independent cable seat design structure. The cable seat serves as a temporary support base and has an optimized spacing design to ensure that the arrow-type strapping machine can safely pass between adjacent cable seats and complete the strapping operation.

[0033] 4. The technical solution of the present invention adopts a bidirectional compression mode of horizontal and vertical before bundling; the sliding horizontal compression device is located at the front end of the cable seat, and the pressure plate is driven to move backward by the horizontal pneumatic cylinder, forming a clamping structure with the fixed horizontal compression device; a funnel-shaped guide structure is provided at the top of each cable seat to guide the bent cable to fall smoothly into the central area; a central cavity is provided between the sliding device and the fixed device for the rotating vertical compression device to enter the compression area; the rotating vertical compression device is connected to the rear of the cable seat through a pivot, and is driven to rotate into the central cavity by a stepper motor, and then the vertical pneumatic cylinder presses down the pressure plate to complete the vertical compression; this dual-axis compression structure can significantly reduce the cross-sectional area of ​​the cable bundle and improve the bundling efficiency.

[0034] 5. The technical solution of the present invention integrates multiple functions such as pressing, bundling, center of gravity positioning and light guidance. All key actions are uniformly controlled by the main controller through the PLC module. Operators only need to start the process through remote control equipment to complete the automated processing of the entire batch of cables, significantly reducing the need for manual intervention. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the arrow-piercing strapping machine used in this invention and its guide rail structure.

[0036] Figure 2 This is a schematic diagram showing the positional relationship between the cable holder and the waste cable of the present invention.

[0037] Figure 3 This is a schematic diagram of the cable holder of the present invention performing a lateral compression mode on a bundle of waste cables.

[0038] Figure 4 This is a schematic diagram of the cable base of the present invention, as well as the funnel-shaped guide structure and the central cavity structure thereon.

[0039] Figure 5 This is a schematic diagram of the cable holder and its rotating vertical extrusion device according to the present invention.

[0040] Figure 6 This is a schematic diagram of the cable holder and the four weight sensors at its bottom according to the present invention.

[0041] Figure 7 This is a schematic diagram illustrating the operating principle of the entire equipment of the present invention.

[0042] Figure 8 The first step in bundling waste cables according to this invention is: the forklift moves toward the center of the cable base.

[0043] Figure 9 The first step in bundling waste cables according to this invention is: a forklift begins to place the waste cable bundles onto the cable holder.

[0044] Figure 10 The first step in bundling waste cables according to this invention is: the driver slowly reverses the forklift to place the waste cable bundles onto the cable holder.

[0045] Figure 11 The first step in bundling waste cables according to this invention is forklift driver to reverse away from the bundling operation area.

[0046] Figure 12 The third step of the present invention for bundling waste cables is: the sliding transverse compression device compresses the waste cable bundles on the cable seat.

[0047] Figure 13The third step of the present invention for bundling waste cables is to use a rotating vertical compression device to compress the waste cable bundles on the cable seat.

[0048] Figure 14 This is the fourth step in the process of bundling waste cables according to the present invention: bundling the compressed waste cable bundles.

[0049] Figure 15 This is the fourth step in the present invention for bundling waste cables: the arrow-type bundling machine is moved to the end of the guide rail.

[0050] Figure 16 This invention relates to the algorithm rules and code for calculating the center of gravity position.

[0051] Figure 17 This is a block diagram illustrating the overall working mode and process of the present invention.

[0052] In the diagram, 1 is an arrow-type strapping machine, 2 is the strapping machine guide rail, 3 is a telescopic arrow, 4 is a waste cable, 5 is a cable holder, 6 is a fixed transverse extrusion device, 7 is a sliding transverse extrusion device, 8 is a transverse pneumatic cylinder, 9 is a funnel-shaped guide structure, 10 is the central cavity of the transverse extrusion device, 11 is a rotating vertical extrusion device, 12 is a stepper motor, 14 is a vertical pneumatic cylinder, 15 is a weight sensor, 16 is a forklift, 17 is the funnel structure above the transverse extrusion device, 18 is the top strapping guide mechanism, and 19 is a strapping tape. Detailed Implementation

[0053] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0054] like Figure 1 As shown, the simplest bundling method is the arrow-type bundling machine (referred to as the bundling machine). The arrow-type bundling machine moves along the length of the cable while the cable remains stationary to complete the bundling of the cable bundle.

[0055] The guide rail located at the bottom of the arrow-type strapping machine is retractable and extends only during the strapping process to form a strapping path, providing obstacle avoidance capability.

[0056] The current technological challenge lies in building a facility that can integrate the aforementioned bundling processes to achieve efficient bundling of waste cables. This facility needs to have cable bundle pre-processing capabilities to ensure secure bundling while minimizing space requirements.

[0057] Unlike existing technologies that mainly target coiled cables and bundling or wrapping with strapping tape during the laying process, the technical solution of this invention focuses on the static bundling of long, flexible, and heavy waste cables.

[0058] In this technical solution, a mobile arrow-type strapping machine is used for dynamic interval strapping, which eliminates the need to move the cable itself. This fills the gap in existing strapping technology for handling non-coiled waste cables, and is especially suitable for cables of varying lengths and with bends after construction.

[0059] The technical problem this invention aims to solve is to provide a system for bundling waste cables to improve storage efficiency. The system includes a work platform capable of securing and compressing the cable bundles, which are of the same diameter but between 5 and 6 meters in length; simultaneously, the platform must allow a piercing-type strapping machine to move along the length of the waste cables and secure the strapping at different locations.

[0060] In addition, the design of this platform needs to take into account the following factors: First, the waste cables may be bent (the maximum bending degree is 1 meter offset for every 6 meters of length); second, the center of gravity of the bundled waste cables may not be located at the geometric center of its length.

[0061] This invention enables the compact bundling of flexible waste cables (typically with slight bends) with a length of 5 to 6 meters and a diameter of 50 to 137 millimeters, thereby increasing warehouse space utilization by 31%. The system achieves an efficient and safe automated processing flow through the coordinated operation of modules such as bidirectional compression, dynamic bundling, and center of gravity positioning.

[0062] The technical solution of the present invention will be described in detail below.

[0063] like Figure 2 As shown, the system includes four horizontally arranged cable holders, with optimized spacing between each holder to collectively support bundles of scrap cables 5 to 6 meters in length. This four-unit cable holder system completes the cable reception, compression, and fixation before the bundling operation.

[0064] like Figure 3 As shown, each cable holder has a fixed lateral compression device at the rear and a sliding lateral compression device at the front. These two devices work together to laterally compress the cable. The sliding lateral compression device is connected to a lateral pneumatic cylinder. The cylinder piston rod pushes the pressure plate backward, forming a clamping structure with the fixed lateral compression device. This movement is precisely controlled by the main controller via a PLC module.

[0065] like Figure 4 As shown, the top of the sliding lateral extrusion device features a funnel-shaped guide structure for receiving cable bundles transported by forklifts. Even with some bending in the cable, this structure effectively guides the cable into the central area of ​​the cable holder. To facilitate subsequent vertical extrusion operations, a central cavity is provided between the sliding and fixed devices, ensuring that the rotating vertical extrusion device can smoothly screw into / out of the extrusion area.

[0066] like Figure 5As shown, each cable holder is also equipped with a rotating vertical compression device, which is pivotally connected to the rear of the cable holder. The rotating arm of this device is driven by a stepper motor, rotating into the central cavity, where a vertical pneumatic cylinder presses down on the pressure plate to complete the vertical compression. This dual-axis compression structure significantly reduces the cross-sectional area of ​​the cable bundle and improves bundling efficiency. All actions are uniformly controlled by the main controller via a PLC module.

[0067] like Figure 6 As shown, each cable holder has four weight sensors at its bottom to measure the weight of the cable bundle. This configuration serves a dual purpose: firstly, to provide an overload warning for the system; and secondly, to provide data support for calculating the center of gravity of the bundled cables. Sensor data is transmitted to the main controller in real time.

[0068] like Figure 7 As shown, the arrow-type cable tie is mounted on a horizontal guide rail assembly and can perform positioning and tying at the gaps in the cable seats. The prototype of this equipment is the commercially available model XMXY-8000-XXX, manufactured by Shandong XX Intelligent Equipment Co., Ltd. It features a retractable bottom guide mechanism that extends at the workstation to form a closed loop and complete the tying operation. The top guide mechanism is adjustable up and down to accommodate the cable height. After applying a maximum tension of 4 kN to the tying tape, it is cut and the two ends are welded. The tying machine then moves laterally to the next workstation, repeating the process until six tyings are completed.

[0069] After bundling is completed, the system prints a label containing information such as cable specifications, bundling date, and total weight, and affixes it to any of the bundling straps. At the same time, the data is archived to the warehouse database.

[0070] Finally, the main controller calculates the horizontal center of gravity of the cable bundle based on the weight sensor data and illuminates the cable seat indicator lights on both sides of the center of gravity to guide the forklift operator to lift the cable bundle between the two lights, ensuring safe transfer to the storage area.

[0071] The technical solution of the present invention provides a method for bundling waste cables, comprising the following steps:

[0072] Step 1: Use a forklift to load the scrap cables into the cable trays;

[0073] Step 2: Input parameters and start the bundling process;

[0074] Step 3: Perform horizontal and vertical extrusion processing;

[0075] Step 4: Use an arrow-type strapping machine to complete the strapping operation;

[0076] Step 5: Print labels and complete location management;

[0077] Step 6: The system will calculate the horizontal center of gravity of the bundled cable bundles and safely transfer them to the storage area using a forklift.

[0078] Implementation of specific technical solutions:

[0079] Step 1: Use a forklift to load the scrap cables into the cable trays:

[0080] like Figure 8 As shown, a forklift loaded with a batch of scrap cables approaches the cable seat along the center line of the platform.

[0081] like Figure 9 In the middle, when the foremost cable approaches the funnel structure above the rear fixed transverse extrusion device, the driver tilts the forks forward, causing the cable to slide forward and be blocked and positioned by the funnel structure.

[0082] Subsequently, as Figure 10 and Figure 11 As shown, the driver slowly reverses the forklift, allowing the entire batch of cables to fall smoothly into the center area of ​​the cable holder, completing the loading.

[0083] Step 2: Input parameters and start the strapping process:

[0084] Operators input the specifications of the batch of scrap cables through the user interface and initiate the bundling process. The system will automatically perform the following operations: 1) Upload the processed cable bundle data to the warehouse database; 2) Automatically print information labels for affixing to the finally bundled cable bundles.

[0085] Step 3: Implement horizontal and vertical compression treatment:

[0086] like Figure 12 As shown, after the cable bundle is securely placed in the cable seat, the operator starts the clamping process via remote control equipment.

[0087] The sliding lateral extrusion device moves backward under the drive of the lateral pneumatic cylinder, forming a clamping structure with the fixed device to complete the lateral compression. The pneumatic cylinder then remains locked, awaiting vertical extrusion.

[0088] like Figure 13 As shown, the rotating vertical pressing device is activated. A stepper motor drives it to rotate from a stationary position to a vertical position, with the end pressure plate hovering above the cable. After the vertical pneumatic cylinder is activated, the lower pressure plate completes the vertical pressing. This concludes the entire pressing stage.

[0089] Step 4: Use an arrow-type strapping machine to complete the strapping operation.

[0090] like Figure 14 As shown, after the compression is completed, the arrow-type strapping machine moves from the end of the guide rail to the station between the first and second cable seats.

[0091] After coming to a complete stop, the bottom binding and guiding mechanism extends to form a loop to cover the cable. The top guiding mechanism is adjustable up and down, and tightens the binding straps simultaneously after descending and contacting the cable to compensate for displacement.

[0092] The strapping runs along the loop, and after completing the wrapping, a maximum tension of 4 kN is applied. The system automatically cuts off the excess and welds the two ends together. The top guide mechanism then rises back, completing the first layer of strapping.

[0093] The arrow-piercing guide mechanism remains extended, and the entire strapping machine moves 300 mm laterally to the next station, repeating the above process to complete the second strapping. Then, the arrow-piercing guide mechanism is retracted, and the strapping machine advances to between the second and third cable seats to perform two more strapping operations. Finally, the last two strapping operations are completed between the third and fourth cable seats, for a total of six strapping operations.

[0094] like Figure 15 As shown, after the strapping is completed, the arrow-type strapping machine retracts its guide mechanism and moves to the end of the guide rail, exiting the work area. All cable holders simultaneously perform reset actions: 1) the sliding horizontal pressing device is driven back to its original position by a pneumatic cylinder; 2) the rotating vertical pressing device is pushed up by a pneumatic cylinder and then rotated back to its original position by a stepper motor.

[0095] Step 5: Print labels and complete location management.

[0096] After bundling is completed, the operator can print a label through the user interface and affix it to any of the bundling straps. The label content includes: 1) cable specifications (corresponding to the input in step 2); 2) bundling date; 3) total weight of the cable bundle.

[0097] The above data is simultaneously uploaded to the warehouse database. Combined with the sensor system on the storage area shelves, precise positioning and traceability management of each batch of bundled cables can be achieved.

[0098] Step 6: The system will calculate the horizontal center of gravity of the bundled cable bundles and safely transfer them to the storage area using a forklift.

[0099] The entire process and system operation mode described above can be found in [reference needed]. Figure 17 As shown in the image.

[0100] After the final layer of strapping is applied, four weight sensors at the bottom of the cable tray transmit their measured weight data to the main controller in real time. The system then uses this data to calculate the horizontal center of gravity of the bundled cables, ensuring stability during lifting and transport.

[0101] The formula for calculating the horizontal center of gravity position of the bundled cable is as follows:

[0102] Xcg = ;

[0103] w i= Subtotal weight of each cable connector, x i = Distance between the cable socket and the first cable socket (i = 1 to 4), Xcg: Center of gravity position (relative to the position of the first cable socket).

[0104] Qualitative explanation: This formula is used to calculate the average mass position of the cable bundle in the horizontal direction, i.e., the center of gravity.

[0105] Each cable holder has a different degree of influence on the overall center of gravity position depending on the weight it bears and its relative position; the heavier the cable holder, the greater its contribution to the final center of gravity; the center of gravity position calculated by weighted average can accurately reflect the balance point of the cable bundle, which helps the forklift maintain stability and safety during lifting.

[0106] Finally, four weight sensors at the bottom of the cable holder transmit data to the main controller in real time, allowing the system to calculate the horizontal center of gravity of the bundled cables. To assist forklift operators in accurate lifting, the system is equipped with five indicator lights (frame1 {cable holder 1} to frame4 {cable holder 4}), each corresponding to a horizontal coordinate segment of the cable holder.

[0107] The system uses a rule-based algorithm to determine the location of the lights that should be lit. The specific logic is as follows:

[0108] The input is the center of gravity position (unit: millimeters), ranging from the starting point 0mm to the ending point 4000mm.

[0109] Distance of cable holder 1 = 0mm; Distance of cable holder 2 = 1300mm; Distance of cable holder 3 = 2700mm; Distance of cable holder 4 = 4000mm.

[0110] A buffer zone (400mm) is provided between each location to avoid misjudging the boundary.

[0111] If the center of gravity is located within a certain position segment, the system will illuminate the indicator light corresponding to that position.

[0112] For example:

[0113] If the center of gravity is 800mm, the system will illuminate cable holder 1 and cable holder 2.

[0114] If the center of gravity is 1400mm, the system will illuminate cable holder 1 and cable holder 3.

[0115] If the center of gravity is 2000mm, the system will illuminate cable holder 2 and cable holder 3.

[0116] If the center of gravity is 2900mm, the system will illuminate cable holder 2 and cable holder 4.

[0117] If the center of gravity is 3500mm, the system will illuminate cable holder 3 and cable holder 4.

[0118] This logic can be implemented using a PLC module or deployed in a controller using embedded code (such as Python). For details on the relevant algorithm rules and code implementation, please refer to [link to relevant documentation]. Figure 16 As shown in the image.

[0119] The system guides the forklift operator to lift the cable bundle between the two indicator lights on the two cable holders closest to the center of gravity, thereby ensuring that the cable bundle remains balanced and stable during transport.

[0120] For example: Assume the weights of the four cable connectors are as follows:

[0121] w1 = 500 kg, x1 = 0 mm.

[0122] w2 = 600 kg, x2 = 1300 mm.

[0123] w3 = 400 kg, x3 = 2700 mm.

[0124] w4 = 500 kg, x4 = 4000 mm.

[0125] but:

[0126] Xcg = = = 1930mm.

[0127] Calculation results show that the center of gravity of the cable bundle is located 1.93 meters to the right of the first cable seat.

[0128] The system will automatically illuminate the indicator lights (cable seat 2 and cable seat 3) on the two cable seats closest to the center of gravity based on the result, prompting the forklift operator to perform the lifting operation between the two lights, thereby ensuring that the cable bundle remains balanced and stable during the transfer.

[0129] The comparative advantages of the technical solution of this invention compared with the prior art are as follows:

[0130] Compared to the current practice of stacking multiple batches of waste cables into a pyramid shape, this technical solution improves space utilization by approximately 31% by implementing bidirectional compression, automatic bundling, and center-of-gravity positioning of the cable bundles, and then securely placing the bundled cables in the storage area's shelves. Shelf storage also enables the classified management of waste cables of different specifications, significantly simplifying the identification and retrieval process.

[0131] Even without using shelving, bundled cables are still safer than loosely stacked cables because of their high structural stability, which can significantly reduce the risk of injury caused by cables slipping.

[0132] The advantages of this technical solution compared to the current system are:

[0133] 1) Limitations of handheld cable bundling equipment: A single bundle of scrap cables weighs approximately 2 tons, with individual cables weighing up to 120 kg. Even after compression, the strength of the strapping used in a handheld bundling machine may still be insufficient to secure the compressed cable bundle. Handheld systems require operators to be in close contact with the cables, posing a risk of injury from strapping breakage.

[0134] 2) Shortcomings of the existing arrow-type cable ties system: Traditional systems typically keep the arrow-type cable tie stationary while moving the items to be tied in and out of the work area, suitable for lightweight items such as cartons, crates, or steel pipes. However, waste cable bundles are heavy, flexible, and easily tangled, requiring pre-secured clamping via four independent cable holders before tying. All cable holders are equipped with high-precision weight sensors and mounted on stable bases. Therefore, a solution that allows the arrow-type cable tie to move while keeping the cable frame stationary is more reasonable.

[0135] To achieve this mode, the technical solution of the present invention modifies the structure of the arrow-type strapping machine, for example, by removing the bottom fixing structure connecting the left and right legs. Although this slightly reduces the integrity of the machine body, the overall structural strength is still guaranteed because both legs are firmly fixed by guide rails.

[0136] In summary, the key innovative points of this invention are as follows:

[0137] A complete automated processing solution is proposed for waste cables that are long, heavy, highly flexible, have adhesive surfaces, and are easily tangled. Its core innovations are as follows:

[0138] 1) Static cable bundles and mobile arrow-type cable bundling machines: The operation mode of fixing the cable bundles and moving the cable bundling machine can significantly optimize the quality of cable pretreatment before bundling and avoid a significant increase in system structure complexity and control difficulty due to the movement of cable seats.

[0139] 2) Independent cable seat design: The cable seat serves as a temporary support base and features an optimized spacing design to ensure that the arrow-type cable tie can safely pass between adjacent cable seats and complete the tying operation.

[0140] 3) Bidirectional Compression Device Structure: Before bundling, the system employs a bidirectional compression device, combining horizontal and vertical compression. The sliding horizontal compression device is located at the front end of the cable seat, driven by a horizontal pneumatic cylinder to move the pressure plate backward, forming a clamping structure with the fixed horizontal compression device. A funnel-shaped guide structure is provided at the top to guide the bent cable smoothly into the central area. A central cavity is provided between the sliding device and the fixed device, allowing the rotating vertical compression device to enter the compression area.

[0141] The rotating vertical compression device is pivotally connected to the rear of the cable holder and is driven by a stepper motor to rotate into the central cavity. A vertical pneumatic cylinder then presses down on the pressure plate to complete the vertical compression. This dual-axis compression structure significantly reduces the cross-sectional area of ​​the cable bundle and improves bundling efficiency.

[0142] The technical advantages of the present invention are as follows:

[0143] 1) Increased Automation: This system integrates multiple functions such as clamping, bundling, center of gravity positioning, and lighting guidance. All key actions are uniformly controlled by the main controller through the PLC module. Operators only need to start the process remotely to complete the automated processing of the entire batch of cables, significantly reducing the need for manual intervention.

[0144] 2) Improved processing efficiency: Through the coordinated operation of the bidirectional clamping structure and the mobile arrow-type strapping machine, the system can complete the clamping and binding of heavy and flexible cable bundles in a short time. The optimized cable seat spacing design further improves the continuity of the binding path, and the overall processing efficiency is far higher than that of traditional manual or semi-automatic solutions.

[0145] 3) Advantages of Calculating Center of Gravity Position: The weight sensor at the bottom of the cable holder not only monitors the total weight in real time but also accurately calculates the horizontal center of gravity position of the bundled cables. Based on the sensor data, the system uses a rule-based algorithm to control the lighting system, dividing the platform into four lighting sections (cable holder 1 to cable holder 4), with a 400mm buffer zone between each section. When the center of gravity falls into a certain section, the system illuminates the corresponding light, guiding the forklift operator to lift the cable bundle between two lights, ensuring safe transport. For details on the relevant algorithm rules and code implementation, please refer to... Figure 16 As shown in the image.

[0146] This invention can be widely used in the systematic treatment of waste high-voltage cable bundles.

Claims

1. A systematic bundling method for high-voltage scrap cables, characterized by: 1) A working platform is set up to fix and compress cable bundles, and the working platform is equipped with several horizontally arranged cable seats; 2) Perform horizontal and vertical compression on the cable bundles placed on the work platform; 3) Use an arrow-type strapping machine to complete the strapping operation; 4) Measure the weight of the cable bundle using weight sensors installed at the bottom of each cable holder; this provides data support for calculating the center of gravity of the cable bundle after bundling. 5) Print information labels containing cable specifications, bundling date, and total weight, and affix them to any of the bundling straps. At the same time, archive the data to the warehouse database. 6) Calculate the horizontal center of gravity of the cable bundle based on the data from each weight sensor, and illuminate the indicator lights on the cable holders located on both sides of the center of gravity to guide the forklift operator to lift the cable bundle at the cable holder position between the two lights, ensuring safe transfer to the storage area.

2. The systematic bundling method for high-voltage waste cables according to claim 1, characterized in that: The working platform that can fix and compress cable bundles allows the arrow-type strapping machine to move along the length of the waste cable and fix the strapping at different positions.

3. The systematic bundling method for high-voltage waste cables according to claim 1, characterized in that... Each cable holder is provided with a fixed lateral compression device at the rear and a sliding lateral compression device at the front of each cable holder. The two work together to laterally compress the cable.

4. The systematic bundling method for high-voltage waste cables according to claim 3, characterized in that: The sliding transverse extrusion device is connected to a transverse pneumatic cylinder. The cylinder piston rod pushes the pressure plate to move backward, forming a clamping structure with the fixed transverse extrusion device.

5. The systematic bundling method for high-voltage waste cables according to claim 3, characterized in that: The sliding transverse extrusion device is provided with a funnel-shaped guide structure at the top, which is used to receive the cable bundles transported by the forklift and effectively guide the cables into the central area of ​​the cable seat. A central cavity is provided between the sliding transverse extrusion device and the fixed transverse extrusion device; A rotary vertical extrusion device with a rotating arm is installed at the position corresponding to the fixed horizontal extrusion device and the central cavity. The central cavity ensures that the rotary vertical extrusion device can be smoothly screwed into / out of the extrusion area, facilitating subsequent vertical extrusion operations.

6. The systematic bundling method for high-voltage waste cables according to claim 5, characterized in that: The rotary vertical extrusion device is pivotally connected to the rear of the cable seat; Driven by a stepper motor, the cable bundle rotates into the central cavity, and then a vertical pneumatic cylinder presses down on the pressure plate to complete the vertical compression, reducing the cross-sectional area of ​​the cable bundle and improving the bundling efficiency.

7. The systematic bundling method for high-voltage waste cables according to claim 1, characterized in that: The arrow-type cable tie is installed on a horizontal guide rail assembly and performs positioning and tying at the gaps between each cable seat; The arrow-type strapping machine has a retractable bottom guide mechanism that extends at the work station to form a closed loop and complete the strapping operation; The top guide mechanism of the arrow-type cable tie can be adjusted up and down to accommodate the cable height. The strapping tape of the arrow-type strapping machine is cut off and the two ends are welded together after the maximum tension is applied; The arrow-type strapping machine then moves laterally to the next station and repeats the process until all strapping is completed.

8. The systematic bundling method for high-voltage waste cables according to claim 1, characterized in that: After the final strapping is completed, the weight sensor at the bottom of the cable holder transmits the measured weight data to the main controller in real time. The system calculates the horizontal center of gravity of the bundled cable based on this data to ensure stability during lifting and transportation.

9. The systematic bundling method for high-voltage waste cables according to claim 8, characterized in that: The formula for calculating the horizontal center of gravity position is as follows: Xcg = ; Among them, w i Subtotal weight for each cable holder; x i Xcg is the distance between the cable socket and the first cable socket; Xcg is the position of the center of gravity.

10. The systematic bundling method for high-voltage waste cables according to claim 1, Its characteristic is the systematic bundling method of the high-voltage waste cable, which uses a mobile arrow-type bundling machine for dynamic interval bundling without moving the cable body. By implementing bidirectional compression, automatic bundling and center of gravity positioning on the cable bundle, the bundled cable is stably placed in the storage area shelf, improving space utilization. It enables the classified management of waste cables of different specifications, significantly simplifying the identification and retrieval process; Its structure has high stability and can significantly reduce the risk of personnel injury caused by cable slippage; it is especially suitable for cables of varying lengths and with bends after construction.

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