Cable alignment device and method for the rotationally correct alignment of assembled cable ends of two cables in a cable harness, as well as arrangement for fitting cable ends to connector housings using the cable alignment device

Description

[0001] The invention relates to a cable alignment device for aligning pre-assembled cable ends of two cables in a cable harness in the correct rotational position. Furthermore, the invention relates to an arrangement for handling cables and for fitting connector housings with cable ends aligned by means of such a cable alignment device, as well as to a method for aligning pre-assembled cable ends in the correct rotational position.

[0002] Cable harnesses, such as those used in automobiles or aircraft, consist of several cables which are fitted with connector housings at their pre-assembled cable ends. For this purpose, the previously pre-assembled cable ends, i.e. cut to length, stripped and provided with contact elements (e.g. crimp contacts), are inserted into chambers or receptacles in the connector housing. As a rule, the cables in a cable harness are available individually with the cable ends to be fitted and are therefore inserted individually into the chambers of the connector housings using appropriate mechanical devices. Cable harnesses consisting of two or more cables are increasingly being used in cable harnesses, primarily twisted cables, for which there is also a need to equip the free, in particular untwisted and possibly stretched, cable ends of the cable harness.Twisted cables, such as UTP cables (UTP: Unshielded Twisted Pair), offer greater protection against electrical and magnetic interference than untwisted pairs and are characterized by particularly good signal transmission quality. In addition to twisted cables, untwisted cables can also be used in cable harnesses or other multi-cable systems, in which the cables are simply arranged side by side and combined into a network.

[0003] For the automatic assembly of connector housings with cable harnesses consisting of two cables, corresponding mechanical devices, known to those skilled in the art as cable assembly stations, are used. The two contact elements must be in the correct rotational position (angular position around the longitudinal cable axis) so that they fit into the cells of a connector housing and can be inserted, which makes the automatic assembly of connector housings with cables challenging. To utilize the advantages of UTP cables, the untwisted sections of the cable ends should be as short as possible. Aligning such short cable ends of the twisted cable harness in the correct rotational position is particularly challenging.

[0004] A cable alignment device for aligning pre-assembled cable ends of two cables in a twisted cable harness in the correct rotational position is known from EP 3 301 768 A1. With this cable alignment device, the cable ends can be rotated by means of a rotary gripping device that acts on the cable harness at the twisted cable area. An optical detection device for determining the rotational position of the cables checks the alignment of the contact elements. Such an optical detection device was already described in EP 1 304 773 A1. The cable alignment device according to EP 3 301 768 A1 further comprises cable grippers arranged one behind the other in the longitudinal direction of the longitudinal axis at the section of the untwisted cable end. The cable grippers are configured to fix only one cable at a time at the cable end and to guide the cable end of the other cable.Once one cable end is correctly aligned by rotating the cable harness at the twisted cable section, it is secured by the corresponding cable gripper, while the other cable end is only guided by the cable gripper. Once both contact elements are correctly aligned, the actual assembly process can begin. The orientation process of this cable alignment device obviously takes place in several steps.

[0005] It is therefore an object of the present invention to avoid the disadvantages of the known and in particular to provide an improved cable alignment device for the rotationally correct alignment of prefabricated cable ends of two cables of a twisted cable harness, which can be operated in particular efficiently.

[0006] This object is achieved according to the invention with a cable alignment device for the rotationally correct alignment of pre-assembled cable ends of two cables of a particularly twisted cable harness, having the features of claim 1. For the sake of simplicity, this cable alignment device is also referred to below as a dual cable alignment device. The dual cable alignment device comprises two clamping jaws and a central web arranged between the clamping jaws, wherein a cable can be clamped between the central web and one of the clamping jaws. To create a closed position, the clamping jaws can be two clamping jaws that can be moved towards one another in the closing direction. In the closed position, the respective cable is clamped between the clamping jaws and the central web. In the closed position, the two cables preferably have an approximately axially parallel course with respect to their cable ends.To change the rotational position, at least one and preferably both of the clamping jaws are designed to be movable laterally past the central web, so that the respective rotational position of the cable can be changed by rolling as it moves past. In this case, lateral refers to a direction that runs, on the one hand, transversely and preferably at right angles to the longitudinal axis of the cable alignment device and, on the other hand, transversely and preferably at right angles to the closing direction. When the cable extends along a longitudinal axis, the cable clamped between the clamping jaws and the central web rotates about its longitudinal axis. In other words, the movement of the engagement means (clamping jaws, central web) past one another causes a rolling movement of the cable clamped between them. This type of rolling is particularly suitable for round cables, i.e. cables with a more or less circular outer contour.

[0007] With the dual cable alignment device, pre-assembled cable ends can be aligned efficiently and quickly. In particular, this dual cable alignment device allows both cables or cable ends to be aligned simultaneously, significantly reducing the process time for correct rotational alignment. The contact elements attached to the cable ends can thus be easily and precisely brought into the correct rotational position. This also creates the basis for the cable ends with the contact elements to be easily inserted into cells of a connector housing. The aforementioned rotational position can be determined by an angle around the cable's longitudinal axis. The angle indicates how much the cable would have to be rotated around its longitudinal axis from its actual position to achieve its desired position.

[0008] Once the cable, which extends along its longitudinal axis in the closed position, is clamped between the central web and one of the clamping jaws, the lateral movement process can begin. If both terminated cable ends need to be aligned, both clamping jaws can be moved simultaneously. Other operating modes are also conceivable. For example, only one of the clamping jaws can be moved first, and only after the first cable end in question has reached the correct rotational position is the other clamping jaw moved to adjust the second cable end. It is also conceivable for only one of the clamping jaws to be moved in the lateral direction. For example, if one of the terminated cable ends specifies a reference position to which the cable end of the other cable is aligned.

[0009] For closing, i.e., for establishing the closed position, and preferably also for opening the clamping jaws, the dual cable alignment device can have at least one feed drive. If only one feed drive is used, the clamping jaws can be geared together in such a way that both clamping jaws can be moved with the feed drive. However, it is advantageous if a separate feed drive is provided for each clamping jaw. This design even allows for processing cables of different thicknesses. The respective feed drive can be pneumatic or electromechanical, for example.

[0010] The two clamping jaws are preferably positioned one above the other or next to each other with respect to the longitudinal axis, at least in an initial or open position and after completion of the closing process, i.e., in the closed position before lateral movement. The clamping jaws positioned in this way are therefore arranged overlapping or covering each other, as viewed in the closing direction.

[0011] The central web can be arranged fixedly in the cable alignment device at least temporarily, in particular at least during the lateral movement for changing the rotational position.

[0012] A separate lateral drive can be provided for the at least one laterally movable clamping jaw, allowing the clamping jaws to be moved laterally independently of one another using their own drives. Each lateral drive can be individually controlled. Preferably, two lateral drives are provided, with each clamping jaw assigned an individually controllable lateral drive. This ensures that each cable is precisely and reliably brought into the desired rotational position. The lateral drive can have a threaded rod drive. Furthermore, linear guides can be provided for precise guidance of the clamping jaws for lateral movement.

[0013] An advantageous dual cable alignment device is achieved when the clamping jaws and the center bar each have clamping surfaces that run parallel to each other. The clamping surfaces can be flat. To ensure reliable rolling movement during lateral movement, profiled clamping surfaces can be provided. These clamping surfaces can be provided with a profile, preferably formed by grooves or notches.

[0014] The grooves or slots of the profiling can form a pattern with numerous parallel lines. It is also conceivable to have two groups of parallel lines intersecting to form a diamond-shaped pattern.

[0015] The grooves or notches of the profile can be arranged transversely to the longitudinal axis and preferably diagonally on the clamping surfaces. It may be particularly preferred if the grooves or notches assigned to the respective clamping jaws are oriented transversely and preferably at right angles to the grooves or notches assigned to the central web.

[0016] The clamping jaws and the center bar can be coated with an elastomer to increase friction, creating advantageous clamping surfaces. Such coated gripping elements can ensure smooth winding, even for cables with smooth outer sheaths that are difficult to handle. Alternatively, the clamping jaws and the center bar, especially if they are made of metallic materials, can be roughened in the area of ​​the clamping surfaces to increase friction.

[0017] The center bar can have an inlet section that tapers toward the rear end. The rear end is the end facing the twisted section of the cable harness. The tapered inlet section defines an inlet geometry for the two cables at the cable ends. This inlet section connects to a clamping section surrounding the clamping surfaces at the rear. The inlet section can be formed, for example, by bevels in the center bar. The two cables at the cable ends can rest against the bevels, forming a type of cable triangle.

[0018] For greater variability of the cable alignment device, it may be advantageous if the center bar is replaceable and preferably automatically replaceable.

[0019] Another embodiment relates to a cable alignment device in which the central web has stepped, spaced-apart web segments for selectively defining different clamping surfaces. The clamping surfaces of the individual web segments can be spaced at different distances from each other. This allows different cables to be processed with the same device. This central web is thus formed as a column that is stepped relative to the web axis. The central web with the stepped, spaced-apart web segments can be inserted stepwise between the clamping jaws by means of an adjusting device, depending on the selected step.

[0020] At least one clamping segment of the central web can have grooves or notches to form a profile on the contact surfaces. The grooves or notches of the central web can interact with corresponding grooves or notches of the clamping jaws in such a way that, during a lateral movement, the clamping jaws and the central web can be partially retracted, interlocking, and thus the next larger step does not impede the movement of the clamping jaw.

[0021] The clamping jaws and / or the center bar can be equipped with sensors to measure the torsional moment applied to the clamped cable, making it easy to detect cable torsion and prevent unwanted torsion. Such sensors are particularly useful when handling very thin cables, as such cables must not be subjected to excessive twisting. Force sensors that measure in the lateral direction (z-direction) are preferred.

[0022] Furthermore, the dual cable alignment device can comprise a detection device for determining the respective rotational position of the assembled cable ends. The detection device can preferably be an optical detection device.

[0023] The rotational positions of the cable ends are preferably determined at least before the alignment process begins. Based on knowledge of the actual state, the extent to which the cable must be rotated can be calculated. The distance required for the lateral travel movement can be calculated taking the cable diameter into account. Preferably, after the initial adjustment using the lateral method, a check is made to determine whether the rotational position has actually been reached. Otherwise, the adjustment process must be repeated. Alternatively, it is also conceivable that the rotational position is monitored permanently or at least throughout the entire alignment process. A cable end monitored in this way allows control without prior calculation of the required travel distance; in this case, the clamping jaw is continuously moved laterally and the travel process is stopped when the correct rotational position is reached.

[0024] For example, the optical detection device can comprise a camera. Alternatively, the optical detection device can be or comprise a scanning unit or an image capture module with at least one line sensor. The pre-assembled cable ends are preferably inserted into the image capture module before the alignment process begins.

[0025] A further aspect of the invention relates to an arrangement for handling cables with the previously described dual cable alignment device and with a component gripping unit with two individually controllable cable grippers for grasping the correctly aligned pre-assembled cable ends and for feeding the pre-assembled cable ends to connector housings. Component assembly can, for example, take place in a connector housing with two cells. However, two connector housings are also conceivable, into which the respective cable ends are each inserted.

[0026] The two clamping jaws and the center bar of the dual cable alignment device can also be used for assembly if necessary, by the two clamping jaws and the center bar assuming the functions of cable grippers. This can be achieved, for example, by the center bar being divisible or consisting of two parts, and by the split-separated bar halves or parts each interacting with the associated clamping jaws to create individual gripping units in such a way that they can each be moved more or less individually to connector housings for the assembly process. The invention then relates to a method for the rotationally correct alignment of pre-assembled cable ends of two cables of a particularly twisted cable harness using the cable alignment device described above.The process is characterized by clamping each cable between gripping devices, and by moving the gripping devices past each other, causing the clamped cables to roll, thereby changing the rotational position of the pre-terminated cable ends and thus aligning the respective pre-terminated cable ends. The gripping devices are the clamping jaws mentioned above and the center bar.

[0027] In one embodiment, the gripping means are moved past each other until the desired rotational position of the respective pre-assembled cable end is reached. It is advantageous if only one of the gripping means is moved per cable, while the other gripping means remains stationary or stationary. The latter gripping means can be formed by a common component arranged centrally between two laterally movable gripping means.

[0028] The rotational position of the pre-assembled cable ends can be monitored using an optical detection device that uses a shadow image of the contact elements to detect their position. The shadow image is preferably generated from the shadow width or contour of the contact elements and the rotation angle of a scanning unit of the optical detection device.

[0029] A particularly advantageous method results when the rotational position of the pre-assembled cable ends is monitored by means of the optical detection device, which uses a shadow image of the two contact elements of the cable ends to detect the position, wherein when determining the rotational position of the pre-assembled cable ends, the area of ​​the shadow image in which an overlap of the shadow contours of the two contact elements occurs is excluded from the examination.

[0030] It can also be advantageous to pre-align the assembled cable ends and only then determine the rotational position of the assembled cable ends for the first time using the optical detection device. This can further shorten the process time for the alignment procedure. The pre-alignment can be performed manually, for example, by an operator.

[0031] The cable rolling motion caused by the gripping devices passing each other can cause the cable ends to become further apart. This aspect can be useful. For example, the cable ends that are now further apart can be gripped more easily by cable grippers. The cable ends can be at approximately the same height in the closed position or at the start of the alignment process. The terminated cable ends can assume different heights during or after the alignment process. The fully aligned terminated cable ends can be gripped by cable grippers at different heights and brought to the desired location for assembly, e.g., into the cells of a connector housing.

[0032] Further individual features and advantages of the invention will become apparent from the following description of exemplary embodiments and from the drawings. They show: Figure 1 shows a perspective view of a dual cable alignment device according to the invention for the rotationally correct alignment of pre-assembled cable ends of two cables of a twisted cable harness with a central web and two clamping jaws in a closed position, Figure 2 shows a perspective view of the twisted cable harness with aligned pre-assembled cable ends, Figures 3a-3c show representations of an inventive dual cable alignment device in schematic front views, corresponding to individual work steps, Figures 4a-c show perspective views of the dual cable alignment device of Figure 1 during individual work steps, Figure 5the dual cable alignment device from Figure 1in a side view with fully aligned pre-assembled cable ends, Figure 6 the dual cable alignment device in plan view, Figure 7 a perspective view of a dual cable alignment device with an optical detection device for determining the rotational positions of the pre-assembled cable ends, Figure 8 a perspective view of an arrangement with the dual cable alignment device and the optical detection device according to Figure 7 and with a component gripping unit with two cable grippers, Figure 9 a side view of an arrangement with the dual cable alignment device and the component gripping unit with two cable grippers, Figure 10 a perspective view of the arrangement according to Figure 9, Figure 11 a perspective view of a central web and two clamping jaws for the dual cable alignment device according to a further embodiment, Figure 12 the central web and the clamping jaws in a plan view, Figure 13 a perspective view of a central web and two clamping jaws for the dual cable alignment device according to a further embodiment, Figure 14 the central web and the clamping jaws in a plan view, Figure 15 a perspective view of a central web shaped as a stepped column and two clamping jaws for a further dual cable alignment device, Figure 16 the central web shaped as a stepped column and the clamping jaws in a plan view, Figure 17 a variant of a clamping jaw for the dual cable alignment device, Figure 18 an alternative embodiment of the clamping jaw of Figure 17Figure 19 shows schematic front views of the dual cable alignment device in different positions, Figure 20 shows a force / displacement curve, Figure 21 shows an alternative force / displacement curve, Figure 22 shows a simplified representation of a test situation for determining the rotational position of pre-assembled cable ends with a shadow image, Figure 23a / b shows a simplified representation of the test situation with a shadow image when a contact part is rotated, and Figure 24 shows a simplified representation of a test situation with a shadow image according to a preferred embodiment with pre-aligned contact elements

[0033] Figure 1shows a cable alignment device 10 for aligning the cable ends of two cables 3, 4 of a twisted cable harness 2 extending along a longitudinal axis L in the correct rotational position. Therefore, for the sake of simplicity, the term "dual cable alignment device" is also used below for the cable alignment device 10 handling two cables 3, 4. The respective cable is usually an electrical cable containing, for example, a solid conductor made of copper or steel or wire strands and an insulation sheath for the conductors.

[0034] The Figure 1The Cartesian coordinate system shown serves as an aid for understanding the directions and the main movements of the components of the dual cable alignment device 10. The dual cable alignment device 10 comprises two clamping jaws 7 and 8 which are movable transversely to the longitudinal axis L, in opposite directions between an initial or open position and a closed position in the y-direction. The longitudinal axis L also corresponds to the direction in which the respective longitudinal axes of the cable ends of the cables 3, 4 run. The closing movement for creating the closed position is indicated by arrows s. The dual cable alignment device 10 further comprises a central web 9 arranged between the clamping jaws 7, 8. In the Fig. 1 In the closed position shown, the two cables 3, 4, which run approximately parallel to the axis, are held by the cable alignment device 10. One cable 3, 4 is clamped between the central web 9 and one of the clamping jaws 7, 8.

[0035] The cable alignment device 10 shown here is used in particular for the subsequent assembly of connector housings with pre-assembled cable ends. Crimp contacts are attached as contact elements 5, 6, as an example, to the respective stripped cable ends of the twisted cable harness 2.

[0036] As from Figure 1 can be removed, the pre-assembled cable ends of cables 3 and 4 are not aligned and are oriented obliquely relative to the vertical and horizontal. They can be aligned in the correct rotational position using the dual cable alignment device 10, described in detail below. Figure 2 shows a cable harness 2 with prefabricated cable ends of the cables 3, 4 aligned in this way, whereby the cable ends with the contact elements 5, 6, however, lie on a common horizontal plane.

[0037] When in Figure 2The twisted cable harness 2 shown is a so-called UTP cable. Contact elements 5, 6 with rectangular or diamond-shaped outer contours in cross-section are attached to the free ends of the cables 3, 4. However, the contact elements 5, 6 could also have other non-round cross-sections. Round contact elements usually do not require any alignment of their rotational position. Furthermore, grommets 35 are attached to the ends of the cables 3, 4, for example. Of course, grommets can be omitted if required. The twisted section of the cable harness 2 is designated 13. The short untwisted section with the pre-assembled cable ends of the cables 3, 4 adjoins this twisted section 13 at the front. 14, 15 designate sections of the cables 3, 4 in which the clamping jaws 7, 8 and the central web 9 act on the respective cable.However, the dual cable alignment device 10 can also be used to process untwisted cable strands composed of two cables.

[0038] The basic structure and functionality of the dual cable alignment device 10 is shown in the Figures 3a to 3c removable. Figure 3a shows the dual cable alignment device 10 in a starting position. In this position, the cable ends of the cable harness can be inserted into the dual cable alignment device 10. One cable 3, 4 is then located between each of the clamping jaws 7, 8 and the centrally arranged center web 9. The two clamping jaws 7, 8 are then moved towards each other by means of feed drives (not shown here). The corresponding closing directions or movements are indicated by arrows s1 and s2. To close the clamping jaws 7, 8, it is advantageous to provide two feed drives so that the feeding can be carried out individually for each clamping jaw 7, 8. This also has the advantage that cables of different thicknesses can be processed if necessary. Figure 3b shows the situation after closing. In the closed position, the cables 3 and 4 are clamped between the center bar 9 and one of the clamping jaws 7 and 8.

[0039] After the closing position has been created, the assembled cable ends of cables 3 and 4 are usually not yet in the correct rotational position. The corresponding misalignments are shown in Fig. 3b indicated by angles α 1 and α 2 . For alignment, the clamping jaws 7, 8 are now moved in a lateral direction, while the central web 9 remains stationary. The corresponding lateral movement of the clamping jaws 7, 8 is indicated by arrows w 1 and w 2 . In the case shown here, the clamping jaws 7, 8 perform an opposing, but not coupled, movement. Depending on the misalignment and the desired target position, movements in the same direction are also conceivable. Under certain circumstances, only one of the clamping jaws 7, 8 is moved.

[0040] The clamping jaws 7, 8 and the central web 9 each have clamping surfaces 20, 21, 22, 23 running parallel to one another. The clamping surfaces 20, 21, 22, 23 are flat in the present case, for example. As the engagement means 7, 9; 8, 9 move past one another, the clamped cables 3, 4 are set into a cable rolling movement. To enable the cable rolling movement, the cables have an outer contour that is approximately circular in cross-section, predetermined, for example, by the cable sheath. The opposing clamping surfaces 20, 22; 21, 23 each define a type of path along which the cables can unwind. The cable 3 rolls downwards when the clamping jaw 7 is moved laterally in the w 1 direction. The cable 4 rolls upwards when the clamping jaw 8 is moved laterally in the w 2 direction. According to the lateral method, the Figure 3 cThe situation shown here shows the misalignment of the pre-assembled cable ends of cables 3 and 4 being corrected. Obviously, cables 3 and 4 are no longer at the same height. Due to the cable rolling movements, cables 3 and 4 are displaced upwards or downwards.

[0041] The lateral travel distance by which the respective clamping jaws 7, 8 must be moved up or down depends essentially on the angle α1, α2. These angles can be detected using detection devices to determine the rotational position of the cables. Such detection devices are explained in more detail below. The cable diameter is often known in advance and does not necessarily have to be specifically recorded. Based on knowledge of the actual state, i.e., based on the angle value α1, α2, and taking the cable diameter into account, it can be calculated to what extent the cable must be rotated and, consequently, how large the required travel distance must be.

[0042] The Figures 4a to 4c show the dual cable alignment device 10 of Figure 1 in the same positions analogous to Fig. 3a-3c . In Figure 1 and in the Figures 4a to 4c Additionally, the respective drives for moving the individual components are also visible. 18, 19 denote the feed drives for closing and opening the clamping jaws 7, 8. The feed drive 18, which can be pneumatic or electromechanical, moves the clamping jaw 7 for feeding in the s 1 direction, while the feed drive 19 moves the clamping jaw 8 for feeding in the s 2 direction ( Fig. 4a). The two clamping jaws 7, 8 are designed to be movable laterally past the central web 9 by means of lateral drives 16, 17 in order to change the rotational position of the pre-assembled cable ends of the cables 3, 4. Each clamping jaw 7, 8 is assigned its own individually controllable lateral drive 16, 17 for lateral movement. The clamping jaws 7, 8 can be moved independently of one another in the w 1 and w 2 directions by means of their own drives 16, 17. This ensures that each cable 3, 4 is brought into the desired rotational position precisely and reliably. The lateral drives 16, 17 are designed here as threaded rod drives with threaded rods 36, for example. Other linear drives, such as those with linear motors, can also be used for the lateral drives 16, 17. Pneumatic or hydraulic lateral drives are also conceivable.

[0043] The clamping jaws 7, 8 and the central web 9 have flat clamping surfaces for applying pressure to the cables 3, 4. To increase friction, the clamping jaws 7, 8 and the central web 9 can be coated with an elastomer, creating advantageous clamping surfaces that enable slip-free rolling of the cables 3, 4. As an alternative to the coating, it is also conceivable to roughen the clamping surfaces of the clamping jaws 7, 8 and the central web 9, which are made of metallic materials, in the area of ​​their clamping surfaces, which can also increase friction for optimal cable rolling movements.

[0044] Further design details of the dual cable alignment device 10 can be found in the Figures 5 and 6 be taken.

[0045] To check whether the assembled cable ends of the cables 3, 4 are in the correct rotation position after the alignment process, the Figure 7shown optical detection device 11 can be used. However, this optical detection device 11 can also be used to detect the actual states of the cable ends, ie the misalignments essentially characterized by the angles α1, α2 at the beginning of the alignment process (cf. Fig. 3b) can be determined. The optical detection device 11 comprises an image capture module with a scanning unit with line sensors. The optical detection device 11 further has a test head 40, which is cylindrical in this example and contains the line sensors and which can be rotated about its axis in a manner known per se. For this purpose, for example, an image capture module can be used, as is already known from EP 1 304 773 A1. With regard to details of the structure and the basic mode of operation, reference is made to this document. The present optical detection device 11 differs from the known detection device primarily in that it is particularly well suited for detecting pre-assembled cable ends of two cables. This aspect will be discussed in more detail below, particularly with reference to Figures 23 to 25.

[0046] After adjusting the angular position by laterally moving the clamping jaws 7, 8, the rotational position of the terminated cable end of each cable 3, 4 is checked using the optical detection device 11 to determine whether the desired position has actually been achieved. Otherwise, the adjustment process must be repeated.

[0047] As from Figure 7 As can be seen, the cable alignment device 10 is equipped with linear guides 37, which ensure lateral linear movements with high precision.

[0048] After completion of the alignment process, in which the pre-assembled cable ends of the two cables 3, 4 were aligned in the correct rotational position using the previously described dual cable alignment device 10, and the correct rotational position of the pre-assembled cable ends was determined or verified by the optical detection device 11, the actual assembly can be carried out as the next step. For assembly, the pre-assembled cable ends of the cables 3, 4 are grasped by a component gripper unit 12 and guided to connector housings (not shown), which are located in Figure 8 The contact elements 5, 6 are inserted, for example, into cells of a connector housing.

[0049] The dual cable alignment device 10 is thus part of a cable handling assembly designated 1, which is hereinafter referred to as the "assembly assembly" for the sake of simplicity. The assembly assembly 1 comprises the dual cable alignment device 10, the optical detection device 11, and the assembly gripping unit 12.

[0050] The assembly gripper unit 12 has two cable grippers 30, 31 for gripping the pre-assembled cable ends of the cables 3, 4 and for feeding the pre-assembled cable ends, aligned in the correct rotational position, to connector housings. Each of the cable grippers 30, 31 is individually controllable and can be moved in the x, y, and z directions. The fact that the cable grippers 30, 31 can be moved independently of one another using corresponding actuators ensures that the cables, which are usually at different heights after the alignment process, can be gripped. A third gripper 32 is also provided to relieve strain on the cable harness 2 during assembly.

[0051] Further details of the assembly gripping unit 12 for the assembly arrangement 1 are shown in the Figures 9 and 10 For example, in Figure 9The directions of movement of actuators are indicated by double arrows, with which the cable grippers 30, 31 can be moved. By means of actuators designated 50, the cable grippers 30, 31 can be moved up and down in the z-direction in order to grasp the cables 3, 4 located at different heights. Actuators 49 are used to move the cable grippers 30, 31 in the x-direction; actuators 51 are used to move the cable grippers 30, 31 in the y-direction. Figure 9 Actuators 48 for opening and closing the cable grippers 30, 31 can be seen.

[0052] The cable grippers 30, 31 grip the cables 3, 4 in front of the components that act on the cables (clamping jaws 7, 8, center bar 9). Since these components 7, 8, 9 act on a comparatively large cable section - with respect to the cable's longitudinal axis L - for the cable rolling movements, the cable grippers 30, 31 have only limited space to grip the cables 3, 4. Therefore, each of the cable grippers 30, 31 has offset front parts 33 that connect the respective gripper jaws 38 of the cable grippers to the gripper supports 39. The offset cable grippers 30, 31 are also well suited to Figure 10 recognizable.

[0053] To ensure reliable rolling movement of the cable during lateral movement, the two clamping jaws 7, 8 and the central web 9 can be provided with profiled clamping surfaces. Clamping surfaces with such profiles formed by grooves or notches are available in the Figures 11 to 16 In the example shown in the Figures 11 and 12The grooves of the profiles run in the z-direction, i.e., perpendicular to the longitudinal axis L of the cable alignment device 10. The profile is formed by grooves running parallel to one another. The grooves of the clamping surface 20 of the clamping jaw 7 are designated 24; the grooves of the clamping surface 22 of the central web are designated 34. The clamping surfaces 21 and 23 assigned to the other cable are designed similarly. Obviously, the grooves 24, 35 of the opposing clamping surfaces 20 and 22 - viewed in the y-direction - cover each other. This arrangement is particularly well suited in Figure 12 As the following Figure 16 concerning a further embodiment, the grooves can also be arranged offset from one another in the cable alignment device 10.

[0054] The Figure 11The clamping jaws 7, 8 shown are designed as one-piece components. The components, preferably made of metallic materials, consist of jaws containing the clamping surfaces 20 and 21, respectively, connecting arms 28, and connecting parts 29, with the connecting parts 29 forming spindle nuts for the previously mentioned threaded rod drives.

[0055] From the Figures 11 and 12 It can then be seen that the central web 9 has a tapered inlet section 25 adjoining the clamping section comprising the clamping surfaces 22, 23, which faces the twisted region 13 of the cable harness 2. The inlet section 25 is formed by bevels that create a favorable inlet geometry.

[0056] An alternative design of profiling is shown by the Figures 13, 14. The profiles of the clamping surfaces 20, 21, 22, 23 of the two clamping jaws 7, 8 and the central web 9 also run transversely to the longitudinal axis L, as in the previous embodiment, but here diagonally. Figure 13 As shown, the diagonal grooves 24 of the clamping jaw 7 are oriented at right angles to the grooves 34 associated with the central web 9. The same applies to the clamping jaw 8. Here, too, the grooves of the clamping jaw 8 are oriented at right angles to the grooves associated with the central web.

[0057] The Figures 15 and 16relate to a further arrangement with clamping jaws 7, 8 and central web 9 for the cable alignment device 10. The central web 9 has stepped web segments for selectively defining different clamping surfaces 22, 23; 22', 23'; 22", 23". The central web 9 is formed as a stepped column with respect to a web axis running in the z-direction. The clamping surfaces 22, 23 of the first web segment, the clamping surfaces 22', 23' of the second web segment, and the clamping surfaces 22", 23" of the third web segment are obviously spaced apart at different distances. With such an arrangement, cables of different thicknesses can be aligned in the correct rotational position. By means of a drive (not shown here), the central web 9 can be inserted between the clamping jaws 7, 8. The retraction and extension movement of the central web 9 would occur in the direction of the z-axis. In Figure 15The clamping jaws 7, 8 are located at the height of the first web segment of the central web 9. To reach the next larger step or the step after that, the central web 9 must be displaced by a corresponding distance in the z-direction. The clamping segment of the central web 9 has grooves 34 that interact with corresponding grooves 24 of the clamping jaws 7, 8 in such a way that during an alignment process for the correct rotational alignment of the pre-assembled cable ends, the clamping jaws 7, 8 and the central web 9 can be partially retracted into one another during a lateral movement, thus ensuring that the next larger step does not impede the movement of the clamping jaws 7, 8.

[0058] The Figures 17 and 18 show a clamping jaw 8 equipped with sensors for determining the torsional moment applied to the cable. Of course, the second clamping jaw is normally designed in a similar manner.

[0059] Thanks to such sensors, excessive torsion of the cable in the closed position during the lateral movement process to change the rotational position and thus unwanted twisting of the cable can be prevented. In the embodiment according to Figure 17 Strain gauges are arranged as sensors on a top and bottom side of the connecting arm 28. A recess is provided in the connecting arm 28 to make the deformation more easily visible to the strain gauges and thus to be able to precisely measure the force in the z-direction. From this force, the torsion of the cable during alignment can be deduced. In the alternative embodiment according to Figure 18The connecting arm 28 has integrated pressure sensors 27. The two-part clamping jaw 8 consists of the connecting arm 28 with the jaw molded onto it for defining the clamping surface 21, and the connecting part 29. The deformation of the gripper jaw 8 in the z-direction can alternatively be determined, for example, via an actual / target comparison of the clamping surfaces of the outer jaws. The position of the clamping surface in the z-direction is measured and compared with the target position.

[0060] It may be that the measured deformation or force only allows a limited direct conclusion about the torsion of the cable end. Clamping the cable can deform the insulation, which leads to flexion of the insulation when the clamping jaw is moved in the z-direction. In addition to the torsional moment of the cable, the flexion resistance can also act against the force of the clamping jaw (force in the z-direction). Such phenomena and how they can be counteracted are described in the Figures 19a to 19d shown, whereby this is explained here using the example of the cable 3 on the left in the figures.

[0061] In Figure 19a the clamping jaws 7, 8 are in the closed position, in which the clamping jaw 7 touches the cable 3. If the clamping jaw 7 is now moved further in the direction of the arrow s, a deformation of the insulation of the cable sheath of the cable 3 ( Figure 19b). During the lateral movement of the clamping jaw 7 in the direction of the arrow w, the cable 3 is set into a rolling motion, during which a flexion takes place. Figure 19c shows, the cable can be brought into the correct rotation position despite the walking.

[0062] Another method involves briefly moving the clamping jaw 7 in the opposite direction. This counter movement is Figure 19d indicated by the arrow r. Since the flexion resistance always acts against the direction of movement, the flexion resistance can be eliminated by briefly moving back. The retraction of the clamping jaw serves to isolate the torsional moment of the cable from the flexion resistance. This results in a process according to the Figures 19a, 19b, 19c and 19d . If a threshold value for the force in the z-direction is exceeded ( Fig. 19c ), the return movement ( Fig. 19d ) is triggered. After retracting, the movement in the w-direction (cf. Fig. 19c). There may be a very small area where only the torsional moment of cable 3 acts. What can always be seen, however, is a clear drop in the magnitude of the force (i.e., a drop in F) and, as the return travel continues, a curve offset by twice the amount of the flexion resistance.

[0063] The resistance caused by walking can be quantified in two ways. First, the offset of the force / displacement curve can be considered. Such a force / displacement curve is shown in Figure 20 shown. Since the theoretical force / displacement curve of the cable (dotted line) passes through the zero point, the displacement is largely attributable to the flexion resistance. This essentially corresponds to the process according to the Figures 19a, 19b and 19c . A force / displacement curve for the process according to the Figures 19a, 19b, 19c and 19d shows Figure 21 The outward journey is represented by a solid line and the return journey by a dashed line.

[0064] The rotational position of the assembled cable ends is monitored by an optical detection device 11, which uses a shadow image of the two contact elements 5, 6 of the cable ends 14, 15 to detect the position. Figure 22A test situation with a shadow image is shown as an example. The optical detection device 11 comprises a light curtain 11 and a line sensor 42 opposite it. The prefabricated cable ends of the two cables are located between them, whereby in this case the contact elements 5 and 6 are shown in simplified form as almost rectangular cross-sectional areas. In the present exemplary embodiment, the contact elements 5 and 6 have a diamond-shaped outer contour; in other words, the cross sections of the contact elements 5 and 6 are drawn as parallelograms. The parallelograms obviously do not run perpendicular to the light curtain, which is close to a real situation where the cable ends can be slightly tilted. The optical detection device 11 is rotatable about an axis of rotation extending in the direction of the x-axis. The line sensor 42 records an image after each rotation of the optical detection device 11, whereby the Figure 22The composite shadow image shown is created. The axis of the shadow image, designated ω, corresponds to the angle of rotation of the optical detection device 11.

[0065] The process for aligning the pre-assembled cable ends of two UTP cables in the correct rotational position can, for example, be as follows: The finished UTP cable is inserted into the cable alignment device 10, and the untwisted cable ends are clamped by the clamping jaws 7, 8 in the manner described above (closed position). For strain relief, the twisted section of the cable can be held at a certain distance from the arrangement with the clamping jaws 7, 8 and the center bar 9. The optical detection device 11 is then moved into a test position (see previous Fig. 7). There, the optical detection device 11 rotates the test head 40 around the contact elements 5, 6 and checks the rotational position of the contact elements. The test head 40 has the light curtain 41 and the associated line sensor 42 to generate shadow images of the contact elements 5, 6. While the test head 40 rotates around the contact elements 5, 6, the captured shadow images are recorded. The shadow edges of the thus illuminated contact elements are designated 44.

[0066] In a conventional manner, the shadow contour is examined for local minima 45 in order to determine the rotational position of the contact elements 5, 6. However, since there are now two contact elements 5, 6, the two shadow contours 43 overlap when the test head 40 rotates around the contact elements 5, 6. However, according to a starting position, the shadow edges can be assigned to the contact elements 5, 6. The area of ​​expected overlap is excluded from the examination. This is the rotation angle range of the test head 40 in which the contact elements 5, 6 are expected to lie on top of each other (from the perspective of the line sensor). This overlap area is shown in Figure 22 marked 46.

[0067] If the contact elements 5, 6 run approximately parallel to the rotational axis of the test head 40 and have a rectangular cross-section in the section plane of the light curtain 41, then the minima 45 of a contact part 5, 6 are offset from each other by 90°. In this ideal situation, the local minima repeat every 180°. Therefore, it is not necessary to search the entire 360° range for the minima. If the contact elements 5, 6 with a rectangular cross-section run at a small angle (e.g., 5°) to the rotational axis of the test head 40, the detected cross-section may, under certain circumstances, be slightly distorted into a parallelogram if the tilt axis runs diagonally.

[0068] As long as the minimum 45° angle does not deviate too much from 90°, this situation can be accommodated by the tolerance range of the cable alignment device 10. If the cross-section of the rectangular contact element is severely distorted into a parallelogram, the current rotational position can also be calculated. The subsequent assembly process could potentially be complicated by a bent cable tip, and the preceding processing process would therefore be faulty. Therefore, an error message is often preferred.

[0069] If there are problems detecting the minima 45, the affected contact element 5, 6 can be rotated slightly by the cable alignment device, and the test head 40 scans the new shadow contour. The shadow contour of the rotated contact element 5, 6 has changed its shape and shifted along the angular axis of the shadow diagram. This is shown in the Figures 23 and 24shown. If a minimum of 45 had been located in the overlap area, it would now be outside it.

[0070] In order to shorten the test time, it is also conceivable that the test head 40 includes a second light curtain (not shown) with an associated line sensor, wherein this second light curtain would be positioned offset by 90° to the first light curtain.

[0071] After the test, the cable alignment device 10 rotates the cable ends to the desired angular position. At the end of the alignment process, the contact elements 5, 6 can be aligned differently relative to each other, depending on the intended sockets.

[0072] After the correct rotational alignment is complete, the assembly gripper unit 12, comprising two individually controllable cable grippers 30, 31, grips the cable ends at their respective z-positions, and the optical detection device is moved away from the test position. Before or during the move-away, the contact elements 5, 6 are scanned to determine the positions of the contact element tips in a known manner. The cable grippers 30, 31 then insert the contact elements 5, 6 into the designated slots or cells on the connector housing, with the assembly process being adapted to the positions of the tips.

[0073] In a further preferred embodiment of the alignment process, the contact elements can be fed to the cable alignment device 10 in a pre-aligned state. Thanks to this measure, the angular range through which the cable alignment device 10 must be able to rotate the contact elements 5, 6 can be reduced to ±20°. The examination area of ​​the test head 40 can also be reduced because—as shown in Figure 25—with pre-aligned contact elements 5, 6, a local minimum of 45° per contact part is sufficient to determine the rotational position. Pre-aligned in this way, contact elements 5, 6 with an asymmetrical cross-section can also be processed well.

Claims

1. Cable alignment apparatus (10) for aligning assembled cable ends of two cables (3, 4) of a cable harness (2), in particular a twisted cable harness, in the correct rotational position, comprising the cable alignment apparatus (10): two clamping jaws (7, 8) and a central web (9) arranged between the clamping jaws (7, 8), wherein one cable (3, 4) in each case can be clamped between the central web (9) and one of the clamping jaws (7, 8), and wherein for changing the rotational position at least one of the, and preferably both, clamping jaws (7, 8) is or are designed to be movable laterally past the central web (9).

2. Cable alignment apparatus (10) according to claim 1, characterized in that a separate lateral drive (16, 17) is provided for at least one laterally movable clamping jaw (7, 8).

3. Cable alignment apparatus (10) according to claim 1 or 2, characterized in that the clamping jaws (7, 8) and the central web (9) each have clamping surfaces (20, 21, 22, 23) running parallel to one another, wherein the clamping surfaces (20, 21, 22, 23) are preferably profiled and wherein the clamping surfaces (20, 21, 22, 23) are particularly preferably each provided with a profiling preferably formed by grooves or slots (24, 34).

4. Cable alignment apparatus (10) according to any of claims 1 to 3, characterized in that the clamping jaws (7, 8) and the central web (9) are made of metallic materials which is roughened in the area of the clamping surfaces (20, 21, 22, 23) or that the clamping jaws (7, 8) and the central web (9) are coated in the area of the clamping surfaces (20, 21, 22, 23).

5. Cable alignment apparatus (10) according to any of claims 1 to 4, characterized in that the central web (9) comprises a tapering inlet portion (25) adjoining a clamping surface (22, 23).

6. Cable alignment apparatus (10) according to any of claims 1 to 5, characterized in that the central web (9) has web segments separated from one another in a step-like manner for selectively presetting different clamping surfaces (22, 23, 22', 23', 22", 23").

7. Cable alignment apparatus (10) according to claim 6, characterized in that at least one clamping segment of the central web (9) has grooves or slots (34', 34") which cooperate with corresponding grooves or slots (24', 24") of the clamping jaws (7, 8) in such a manner that, during a lateral movement, the clamping jaws (7, 8) and the central web (9) can be retracted in a partially interlocking manner.

8. Cable alignment apparatus (10) according to any of claims 1 to 7, characterized in that the clamping jaws (7, 8) and / or the central web (9) are equipped with sensors (26, 27) for determining the torsional moment applied to the clamped cable (3, 4).

9. Cable alignment apparatus (10) according to any of claims 1 to 8, characterized in that it further comprises a preferably optical detection apparatus (11) for determining the respective rotational position of the cables (3, 4).

10. Arrangement (1) for handling cables, having a cable alignment apparatus (10) for aligning assembled cable ends of two cables (3, 4) of a cable harness (2), in particular a twisted cable harness, in the correct rotational position according to any of claims 1 to 8 and an assembly gripping unit (12) with two individually controllable cable grippers (30, 31) for gripping and feeding to plug housings or to cells of a plug housing the assembled cable ends (14, 15) of the cables (3, 4) aligned in the correct rotational position.

11. Method for aligning assembled cable ends of two cables (3, 4) of a cable harness (2), in particular a twisted cable harness, in the correct rotational position, using the cable alignment apparatus (10) according to any of claims 1 to 9, and optionally for assembling plug housings with assembled cable ends of two cables (3, 4) of the cable harness, in particular a twisted cable harness, characterized in that: - each of the cables (3, 4) is clamped between engagement means (7, 8, 9), and - the clamped cables (3, 4) are set into a cable rolling motion by the engagement means (7, 8, 9) moving past one another, whereby the rotational position of the assembled cable ends of the cables (3, 4) is changed and thus the respective assembled cable end (14, 15) is aligned, wherein the engagement means are the clamping jaws and the central web.

12. Method according to claim 11, characterized in that only one of the engagement means (7, 8) is moved per cable (3, 4) and the other engagement means (9) remains stationary.

13. Method according to claim 11 or 12, characterized in that the rotational position of the assembled cable ends is monitored by means of an optical detection apparatus (11) which uses a shadow image of the two contact elements (5, 6) of the cable ends (14, 15) for position detection, wherein, when determining the rotational position of the assembled cable ends (14, 15), the area of the shadow image at which an overlap of the shadow contours of the two contact elements (5, 6) occurs is excluded from the examination.

14. Method according to claim 13, characterized in that the assembled cable ends (14, 15) are pre-aligned and only thereafter is the rotational position of the assembled cable ends (14, 15) determined by means of the preferably optical detection apparatus (11).

15. Method according to any of claims 11 to 14, characterized in that the assembled cable ends (14, 15) assume different heights during or after the alignment procedure, and in that the ready-aligned assembled cable ends (14, 15) are in each case gripped by cable grippers (30, 31) at the different heights and brought to the desired height for assembling.