Cable production using mold gradient unification management method

Abstract

The present application relates to cable mold management technical field, especially a kind of cable production using mold gradient unified management method, comprising the following steps: S1: unified mold outside diameter standard;S2: establish mold gradient use mechanism;S3: adopt unified material to make all molds;S4: the wear amount of inner hole of mold is detected in real time by mold wear detection device;S5: all molds are carried out full life cycle digital management by central control system.The present application realizes the general interchange of mold between different stations by unified mold outside diameter standard, substantially reduces the specification type of mold, simplifies field management;The present application establishes "diameter setting-line" gradient use mechanism, and the diameter setting mold after wear is reused for line passing link, so that the comprehensive service life of mold is extended by 2-3 times, and mold consumption cost is significantly reduced.

Description

Technical Field

[0001] This invention relates to the field of cable mold management technology, and in particular to a graded and unified management method for molds used in cable assembly production. Background Technology

[0002] In cable production, the cabling process is a crucial step in twisting multiple insulated cores into a circular cable core at a specific pitch. A cabling production line typically includes a mold set, multiple non-metallic wrapping bins, and a metal wrapping head, with each station requiring a corresponding mold. The mold set has two sizing molds to control the final outer diameter of the cable core; each non-metallic wrapping bin has two wire-passing molds to guide and position the insulated cores; and the metal wrapping head has two wire-passing molds for guiding the cores during metal tape wrapping. A total of at least eight molds are distributed across different stations on the same production line.

[0003] In traditional cable production, the molds at each station are designed and managed independently, resulting in inconsistent outer diameters and mixed sizes. This leads to the following long-standing problems: Nylon molds can only be used for both non-metallic and metallic wrapping chambers; the diverse materials of molds on-site make unified management difficult; even when the precision requirements for the inner hole of the mold are not high, the coexistence of multiple materials still exacerbates mold wear; nylon molds have short service lives and require frequent replacement; the final outer diameter of the entire line is determined by the sizing mold on the mold base, but there is a lack of systematic correlation between the sizing mold and other wire-passing molds, leading to frequent mold replacements and complex management; the degree of mold wear relies on manual experience for judgment, which easily results in overuse or premature scrapping, causing resource waste; the mold replacement process is cumbersome, with low positioning accuracy, leading to long downtime and affecting production efficiency.

[0004] Therefore, there is an urgent need to develop a method that can uniformly manage the molds of the cable production line, extend the service life of the molds, and improve the replacement efficiency. Summary of the Invention

[0005] The technical problem to be solved by this invention is that in traditional cable production, the molds at each station are designed and managed independently, with different outer diameters and mixed sizes, making it difficult to manage uniformly; the molds have short service life and are frequently replaced, resulting in resource waste; the mold replacement process is cumbersome and has low positioning accuracy, resulting in long downtime and affecting production efficiency.

[0006] The technical solution adopted by this invention to solve its technical problem is: a method for graded and unified management of molds used in cable cabling production, comprising the following steps: S1: Standardize the outer diameter of the mold. Based on the outer diameter of the sizing mold on the mold base, standardize the outer diameter of the wire-passing molds of all non-metallic wrapping chambers and metal wrapping heads in the entire cable production line. S2: Establish a mold gradient usage mechanism, using the sizing mold as a primary mold, and when its wear reaches the first threshold, it is downgraded to a line-passing mold for continued use. S3: All molds are made of the same material and the mold surface is hardened. S4: The wear of the inner hole of the mold is detected in real time by the mold wear detection device, and the wear is automatically classified and the workstation is allocated according to the wear amount; S5: Digital management of all molds throughout their entire lifecycle through a central control system.

[0007] Furthermore, the unified mold outer diameter tolerance is controlled within ±0.02mm to ensure the mold's universal interchangeability between different workstations.

[0008] Furthermore, the first threshold is when the wear of the inner diameter of the sizing die reaches 0.1 mm; when the wear of the inner diameter of the wire-passing die reaches 0.3 mm, it is scrapped.

[0009] Furthermore, all molds are made of 45# steel, and a nitrided hardening layer with a thickness of 0.05-0.1mm is formed on the surface of the inner hole of the mold.

[0010] Furthermore, the mold wear detection device includes a laser displacement sensor and an image acquisition module, which are used to detect the wear amount of the inner hole diameter and the wear degree of the flared end of the mold, respectively.

[0011] Furthermore, a unique RFID tag module is set on each mold to record the mold number, material, production date, number of uses, wear history, and current rating information.

[0012] Furthermore, the central control system automatically generates mold replacement and scheduling plans based on the production plan and the current status of the molds, and issues an early warning when the molds reach the scrap threshold.

[0013] Furthermore, all mold stations are equipped with quick-change fixtures, which employ an eccentric locking structure and can complete mold replacement and positioning within 30 seconds.

[0014] Furthermore, the quick-change fixture is equipped with positioning pins and a foolproof structure to ensure the accuracy of the mold installation direction and position.

[0015] Furthermore, it also includes establishing a shared mold inventory system to bring molds from multiple cable production lines under unified management, enabling the allocation and use of molds between different production lines.

[0016] The beneficial effects of this invention are: (1) By standardizing the outer diameter of the mold, the present invention realizes the universal interchangeability of molds in different work stations, greatly reduces the types of mold specifications, and simplifies on-site management.

[0017] (2) The present invention establishes a “sizing-line” gradient use mechanism, which reuses the worn sizing die in the line-line process, thereby extending the overall service life of the die by 2-3 times and significantly reducing the die consumption cost.

[0018] (3) The present invention uses a uniform 45# steel material and performs surface nitriding hardening treatment, which improves the wear resistance and service life of the mold and solves the problem of easy wear and short service life of traditional nylon molds.

[0019] (4) The present invention introduces an automatic mold wear detection and grading system, which can detect the degree of mold wear in real time and accurately, avoid the error of manual judgment, and realize the scientific grading and rational use of molds. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] Figure 1 This is a schematic diagram of the steps of the present invention.

[0022] Figure 2 This is a field structure diagram of the present invention.

[0023] Figure 3 This is a schematic diagram of the sizing die and the wire guide die in this invention.

[0024] The diagram shows: 1. Cable production line; 2. Mold base; 3. Sizing mold; 4. Non-metallic wrapping bin; 5. Metallic wrapping head; 6. Wire guide mold; 7. Mold wear detection device; 8. RFID tagging module; 9. Central control system; 10. Mold storage rack; 11. Quick change fixture. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0027] Figure 1, Figure 2 and Figure 3 The cable forming production line 1 of the present invention, as shown, includes a wire feeding frame, a stranding head, two non-metallic wrapping bins 4, a metal wrapping head 5, and a die base 2 arranged sequentially. Two sizing dies 3 are mounted on the die base 2, two wire guiding dies 6 are installed in each non-metallic wrapping bin 4, and two wire guiding dies 6 are mounted on the metal wrapping head 5. The outer diameter of all dies is standardized based on the outer diameter of the sizing die 3, with tolerances controlled within ±0.02mm, ensuring that the dies are interchangeable between different workstations.

[0028] Both the sizing die 3 and the wire guide die 6 are made of 45# steel, and a nitrided hardening layer with a thickness of 0.05-0.1mm is formed on the inner surface of the die to improve the wear resistance and service life of the die. Each die has a unique RFID identification module 8 embedded on its outer circular surface to record the die number, material, production date, number of uses, wear history and current grade information.

[0029] All mold stations are equipped with quick-change fixtures 11. The quick-change fixture 11 employs an eccentric locking structure, including a fixture body, an eccentric locking handle, and a locating pin. The fixture body has mounting holes that match the outer diameter of the mold. The locating pin ensures circumferential positioning of the mold, and the foolproof structure prevents the mold from being installed backwards. In use, simply place the mold into the mounting hole and turn the eccentric locking handle to secure the mold; the entire process can be completed within 30 seconds.

[0030] The mold lifecycle management system of the present invention includes a mold wear detection device 7, an RFID reader / writer, a central control system 9, and a mold storage rack 10. The mold wear detection device 7, installed at the mold replacement station, includes a laser displacement sensor and an image acquisition module, used to detect the wear amount of the mold's inner hole diameter and the wear degree of the flared end, respectively. The RFID reader / writer is used to read information from the RFID tag module 8 on the mold. The central control system 9 is used to receive and process the detection data, perform hierarchical management of the molds, generate mold replacement and scheduling plans, and issue an early warning when the mold reaches the scrap threshold.

[0031] The specific implementation process of this invention is as follows: Mold making: Sizing mold 3 and wire guide mold 6 are made according to a unified outer diameter standard, using 45# steel and subjected to nitriding hardening treatment. An RFID tag module 8 is installed on each mold to record the basic information of the mold.

[0032] Die grading: The new die is first installed on the die holder 2 as a sizing die 3. When the die wear detection device 7 detects that the wear of the inner diameter of the sizing die 3 reaches 0.1mm, the central control system 9 downgrades it to a secondary die, namely the wire passing die 6, and assigns it to the non-metallic wrapping chamber 4 or the metal wrapping head 5 for continued use.

[0033] Mold scrapping: When the wear of the inner diameter of the die 6 reaches 0.3mm, the central control system 9 issues a scrap warning, and the operator removes it from the production line and sends it to the scrap area.

[0034] Mold replacement: When a mold needs to be replaced, the central control system 9 automatically generates a replacement plan based on the production plan and mold inventory. The operator takes out the corresponding mold from the mold storage rack 10 according to the plan and uses the quick change fixture 11 to complete the mold replacement.

[0035] Mold sharing management: Molds from multiple cable production lines 1 are incorporated into a unified shared inventory system. The central control system 9 automatically allocates molds across production lines according to their production needs, thereby improving mold utilization.

[0036] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for graded and unified management of molds used in cable assembly production, characterized in that, Includes the following steps: S1: Standardize the outer diameter of the mold. Based on the outer diameter of the sizing mold (3) on the mold base (2), standardize the outer diameter of the wire passing mold (6) of all non-metallic wrapping chambers (4) and metal wrapping heads (5) in the entire cable production line (1). S2: Establish a mold gradient use mechanism, use the sizing mold (3) as a first-level mold, and when its wear reaches the first threshold, it is downgraded to a line-passing mold (6) for continued use; S3: All molds are made of the same material and the mold surface is hardened. S4: The wear amount of the inner hole of the mold is detected in real time by the mold wear detection device (7), and the wear amount is automatically classified and the work station is allocated according to the wear amount; S5: Digital management of all molds throughout their entire lifecycle is achieved through a central control system (9).

2. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, In step S1, the unified mold outer diameter tolerance is controlled within ±0.02mm to ensure the universal interchangeability of the mold between different workstations.

3. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, In step S2, the first threshold is when the wear of the inner diameter of the sizing die (3) reaches 0.1 mm; when the wear of the inner diameter of the wire die (6) reaches 0.3 mm, it is scrapped.

4. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, In step S3, all molds are made of 45# steel, and a nitriding hardening layer with a thickness of 0.05-0.1mm is formed on the surface of the inner hole of the mold.

5. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, In step S4, the mold wear detection device (7) includes a laser displacement sensor and an image acquisition module, which are used to detect the wear amount of the inner hole diameter and the wear degree of the flared mouth of the mold, respectively.

6. The method for graded and unified management of molds used in cable cabling production according to claim 5, characterized in that, Step S4 further includes setting a unique RFID identification module (8) on each mold to record the mold number, material, production date, number of uses, wear history and current grade information.

7. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, In step S5, the central control system (9) automatically generates a mold replacement and scheduling plan based on the production plan and the current status of the mold, and issues an early warning when the mold reaches the scrap threshold.

8. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, All mold stations are equipped with quick-change fixtures (11), which adopt an eccentric locking structure and can complete the mold replacement and positioning within 30 seconds.

9. The method for graded and unified management of molds used in cable cabling production according to claim 8, characterized in that, The quick-change fixture (11) is equipped with a positioning pin and a foolproof structure to ensure the accuracy of the mold installation direction and position.

10. The method for graded and unified management of molds used in cable cabling production according to claim 1, characterized in that, It also includes establishing a shared inventory system for molds, which incorporates the molds of multiple cable production lines (1) into a unified management system, enabling the allocation and use of molds between different production lines.

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