Cable processing machine and method for operating a cable processing machine

Abstract

The present invention provides a cable processing machine (100) for processing a blank cable (1) into a tooled cable (2). The cable processing machine includes manipulation tools (110, 120, 130), sensors (111, 121, 131), a display (200), and a control system (300). The control system (300) is configured to set a target configuration of the manipulation tools (110, 120, 130) based on a cable type (3) of the blank cable (1) being processed. The sensors (111, 121, 131) provide sensor signals (112, 122, 132) indicative of the actual configuration of the manipulation tools (110, 120, 130). The control system (300) is further configured to provide display data (310, 320, 330) based on the sensor signals (112, 122, 132) and the cable type (3), the display data being displayable on the display (200). Individual items of the display data (310, 320, 330) are displayable on the display (200) in an animated representation (5) of the tooled cable (2), in which potential failure modes for individual components of the tooled cable (2) are distinguishable from one another.

Description

[Technical Field]

[0001] The present invention relates to a cable processing machine according to the preamble of claim 1. The invention further relates to a method for operating a cable processing machine according to the preamble of claim 9, and to a computer program product relating to such a method. [Background technology]

[0002] Cable processing machines are often designed and programmed to mass-produce processed cables, e.g., electrical or optical cables, according to predefined specifications. For example, cable processing machines are programmed to create (electrical or optical) cable pieces of a specified piece-length with the cable insulation stripped at one or both ends over a specified strip-length. In some cases, as an example of a special operation in such cable processing machines, the stripped insulation does not need to be completely removed, but only partially stripped to preserve and protect the bare core of the electrical cable. In the latter case, the cable processing machine is programmed to move the stripped insulation portion (having a strip length) over the specified strip length, leaving a gap between the central cable portion where the insulation is not stripped and the partially stripped insulation portion. This is often referred to as partial stripping.

[0003] As shown in FIG. 1 , the (graphical) user interface of a cable processing machine typically displays the specifications (i.e., the target physical dimensions) of the cable piece to be produced. Furthermore, before starting a mass production run on the cable processing machine, an operator typically calibrates or adjusts the cable processing machine for the cable piece to be produced. To do this, the operator runs the cable processing machine to produce a sample piece and compares the (dimensions of) the produced sample piece with the desired dimensions of the cable piece. Based on the identified differences between the produced sample piece and the target to be achieved, the operator must determine which settings of the cable processing machine need to be modified or adjusted to minimize or eliminate the observed differences. Such modifications (e.g., the relative starting distance of the stripping blade or the pre-programmed cutting depth) can be input via the user interface. This modification or tuning, i.e., the process of adjusting the appropriate parameters, requires a certain level of skill and knowledge from the operator. A new sample piece is then produced, and it is verified whether the (dimensions of) the sample piece are within acceptable manufacturing margins. These adjustment and sample piece creation steps are repeated until the cable processing machine is finally properly adjusted for mass production. An inexperienced operator may select and adjust irrelevant setting parameters, leading to unnecessarily long calibration / adjustment times and ultimately to low production efficiency. Such incorrect setting adjustments not only result in waste but may even ultimately damage the machine and / or its tools. This can be described as a time-consuming, risky, and often trial-and-error process.

[0004] Therefore, there is a need for a cable processing machine and a method of operating such a machine that increases production efficiency by reducing or minimizing the (production) time spent calibrating the machine. This is the object of the present invention. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] European Patent Application Publication No. 3068002 Summary of the Invention [Means for solving the problem]

[0006] The object of the invention is solved by the features of the independent claims. Advantageous further developments are shown in the drawings and in the dependent claims.

[0007] According to one aspect, the present invention provides a cable processing machine for processing / converting a blank cable (i.e., an unprocessed cable including insulation) into a tooled cable (i.e., a processed cable), the cable processing machine including a manipulation tool, a sensor, a display, and a control system, wherein the control system is configured to set a target configuration of the manipulation tool based on a cable type of the blank cable to be processed and a desired target specification of the tooled cable, the sensor provides a sensor signal to the control system indicative of an actual configuration of the manipulation tool, the control system is further configured to provide display data based on the sensor signal and the cable type, the display data being displayable on the display, and individual items of the display data being displayable on the display in an animated representation of the tooled cable, in which potential failure modes for individual components of the tooled cable are distinguishable from one another. Advantageously, the present invention provides an operator with a continuous and / or guided human-machine interaction process to assist in adjusting the settings of the cable processing machine during a tuning or calibration phase prior to commencing mass production of the tooled cable in production. A further advantage of the present invention is that the display data depends on the sensor signals, allowing the most relevant failure modes to be filtered from a library of potential failure modes. This allows the adjustment steps for the cable processing machine to be properly adjusted for mass production to be minimized. For this purpose, the cable processing machine may include a memory or storage device connected to the control system for storing a library of cable failure modes.

[0008] Advantageously, in the animated representation of the tooled cable on the display, potential failure modes of the individual components of the tooled cable are distinguishable from one another, reliably assisting the operator in performing the technical task of calibrating the cable processing machine through a continuous and / or guided human-machine interaction process. The assistance provided by the present invention to the operator in performing the technical task is objectively, reliably and cohesively linked to the animated representation of the tooled cable on the display.

[0009] The control system and display according to the present invention are not only adapted to show the operator what the desired target tooled cable looks like (a graphical representation including dimensional values ​​such as diameter, length, etc.). They may additionally be adapted to show the operator, in animated form, what a typical deviant product portion looks like. Displaying the deviant product (or product portion) supports and guides the operator in identifying the relevant setting parameters to adjust. By selecting the appropriate displayed deviant product, the control system and display may subsequently show the operator which machine settings can be changed and how they can be changed to resolve the differences between the tooled test specimen (or sample) and the target tooled cable.

[0010] In one embodiment, the display includes a touchscreen configured to generate a failure mode control signal indicative of a failure mode of the tooled cable, and the control system is configured to adjust the configuration of the operating tool based on the failure mode control signal in response to each input from the operator via the touchscreen. Advantageously, the animated display includes various displayable options to guide and support the operator so that the option that best matches the detected failure is displayed via the touchscreen.

[0011] In one embodiment, the animation display includes a section-by-section view of the tooled cable for the above purposes, thereby displaying potential failure modes of the (section of) the tooled cable. Advantageously, this allows the operator to be guided to inconsistencies in the configuration of the operating tools set on the cable processing machine by comparing the state of the tooled cable test specimen with a predetermined target state. Even more advantageously, by providing a section-by-section view of the cable, the present invention helps the operator to systematically adjust the cable processing machine during the adjustment phase.

[0012] In another embodiment, each item of display data includes configuration parameters of the operating tool associated with the indicated failure mode. Advantageously, each item of display data may be a graphical representation of a particular portion of the tooled cable that indicates a potential failure mode of the tooled cable that does not meet quality standards. Examples of failure modes include flaws in the outer or inner insulation, sections of insulation that have not been removed, an improperly bent shield braid, a damaged or cut inner core conductor, a length difference relative to a target value, etc. The graphical representation guides and assists the operator in identifying the configuration parameters associated with the failure mode by comparing the created test specimen with the graphical representation.

[0013] In yet another embodiment, the configuration parameters are displayed in order of relevance for correcting the failure mode, and advantageously, the displayed order of relevance guides and supports the operator in selecting and adjusting the most relevant configuration parameters to eliminate any deviations between the test specimen and the target tooled cable.

[0014] In a further embodiment, as alluded to above, the configuration parameters can be changed by the operator, preferably via a touch screen, and the failure mode control signal can include information regarding the configuration parameters to be changed. Advantageously, the animated display guides and supports the operator in intuitively providing inputs to adjust the parameter settings. Furthermore, the provided inputs enable the control system to readjust the settings of the cable processing machine to produce tooled cable within acceptable quality margins.

[0015] In another embodiment, each item of display data includes interpretive advice regarding the relationship between the occurrence of a failure mode and the setting of the configuration parameters of the operating tool associated with that failure mode. Advantageously, the interpretive advice in the animated display guides and supports the operator and enhances the operator's understanding of the cable processing machine and the impact its parameter settings have on the final product produced.

[0016] In another embodiment, the control system includes an artificial intelligence unit that determines adjustments to the configuration of the manipulation tool based on the failure mode control signal. Preferably, the cable processing machine includes a detector, e.g., a camera, for inspecting the tooled cable for this purpose. Detector signals, e.g., photographs, representing the inspected tooled cable can be sent as inputs to the artificial intelligence unit in combination with sensor signals indicating the actual configuration of the manipulation tool. The detector signals and associated sensor signals can also be stored in a suitable database accessible to the artificial intelligence unit. Advantageously, the artificial intelligence unit may include intelligent algorithms (a category that includes heuristic methods, artificial neural networks, and evolutionary (genetic) algorithms) that provide as output to the control system failure mode control signals indicative of the failure mode of the tooled cable. The latter can be configured to adjust the configuration of the manipulation tool based on the failure mode control signal. Using the adjusted configuration, new test specimens are created and inspected, allowing the artificial intelligence unit to learn the association between specific failure modes and appropriate configuration settings. Furthermore, the artificial intelligence unit can learn to prioritize which configuration settings of the cable processing machine are preferable to adjust to mitigate failure modes. Furthermore, in addition to prioritizing various configuration settings, the artificial intelligence unit may provide recommended values ​​or ranges of values ​​for different configuration settings to mitigate failure modes.

[0017] According to a second aspect, the present invention provides a method of operating a cable processing machine for processing a blank cable into a tooled cable using a processing tool, the method including: (i) setting a target configuration of the processing tool based on a cable type of the blank cable to be processed and a desired target shape of the tooled cable; (ii) providing a sensor signal indicative of an actual configuration of the processing tool; (iii) providing display data based on the sensor signal and the cable type; and (iv) displaying individual items of the display data in an animated representation of the tooled cable, wherein potential failure modes of individual components of the tooled cable are distinguishable from one another in the animated representation.

[0018] According to a third aspect, the present invention provides a computer program product comprising instructions which, when executed by a computer, cause the computer to carry out a method according to the second aspect of the invention.

[0019] Further advantages, features and details of the present invention will become apparent from the following description in which embodiments of the invention are set forth with reference to the drawings.

[0020] The list of reference numbers, the technical content of the claims, and the drawings are part of this disclosure. The drawings are described consistently and comprehensively. The same reference numbers indicate the same elements, and reference numbers with different subscripts indicate functionally identical or similar elements. [Brief explanation of the drawings]

[0021] [Figure 1] 1 shows a schematic representation of a graphical user interface of a state-of-the-art cable processing machine; [Figure 2] 1 shows a first embodiment of a cable processing machine according to the present invention; [Figure 3] 1 shows a first embodiment of an animation display on a display according to the present invention; [Figure 4] 3 shows a second embodiment of an animation display on a display according to the present invention. [Figure 5] 3 shows a third embodiment of an animation display on a display according to the present invention. [Figure 6] 4 shows a fourth embodiment of an animation display on a display according to the present invention. [Figure 7] 5 shows a fifth embodiment of an animation display on a display according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0022] FIG. 2 shows a schematic diagram of an example of a cable processing machine 100 according to the present invention. The cable processing machine 100 is configured to process a blank cable 1 into a tooled cable 2. The blank cable (or raw cable) 1 can be an electrical or optical cable in an unprocessed state. The blank cable can be fed into the cable processing machine 100 from a wheel or bobbin, or can be provided as a length of cable introduced, for example, by a conveying mechanism. Using the operating tools 110, 120, 130 of the cable processing machine 100, the blank cable 1 is converted into a tooled cable (or processed cable) 2. The blank cable can be a specific cable type 3, which indicates the physical characteristics of the blank cable 1, such as the overall diameter of the cable, the thickness of the outer insulation, the diameter of the inner conductor, whether it is a single-core or multi-core cable, a coaxial core, or a braided cable, the flexibility of the cable, and the material properties of the insulating material (e.g., elastic modulus, hardness, tensile strength, flexural strength, tensile elongation, etc.).

[0023] The cable processing machine 100 includes (at least one) manipulation tool 110, 120, 130, sensors 111, 121, 131, a display 200, and a control system 300. The manipulation tools 110, 120, 130 of the cable processing machine 100 may be, for example, cutting blades, stripping blades, alignment grippers, clamping tools, rollers, etc. The control system 300 is configured to set a target configuration of the manipulation tools 110, 120, 130 based on the cable type 3 of the blank cable 1 to be processed. Such a target configuration includes not only the (predefined) physical starting positions of the tools relative to each other, but also the (preprogrammed) operating modes for tooling or processing the blank cable 1. Examples of such operating modes include the speed at which the blades approach the cable and the depth of cut into the insulation. Sensors 111, 121, 131 associated with each manipulation tool 110, 120, 130 provide sensor signals 112, 122, 132, respectively, indicative of the actual configuration of the manipulation tool. Control system 300 provides display data 310, 320, 330 to display 200 and graphical unit 210 of display 200, respectively, to display an animated representation 5 of tooled cable 2. Advantageously, potential failure modes of tooled cable 2 and each of its individual components are distinguishable from one another in the animated representation. Display 200 includes a graphical user interface, e.g., touchscreen 220, and is configured to generate a failure mode control signal 350 indicative of a failure mode of tooled cable 2. Based on the failure mode control signal 350, control system 300 is configured to adjust configuration settings of cable processing machine 100, e.g., configuration settings of manipulation tools 110, 120, 130.

[0024] FIG. 3 shows a first still image of an animated display 5 on a display according to the present invention. This still image shows a target tooled cable 3, in this case a cable segment with 4.00 mm long peeled ends on both sides. A section-by-section view of the tooled cable (e.g., the left cable end or the right cable end) can depict a graphical representation of a particular portion of the tooled cable 3 in animated form. For example, as shown in this figure, the graphical representation of a particular cable portion (left portion / right portion) can depict the target processed cable. Alternatively, a graphical representation of potential failure modes of a tooled cable that does not meet quality standards can be (dynamically) depicted. The graphical representation of potential failure modes of a tooled cable portion that does not meet quality standards can, in one embodiment, (dynamically) replace the graphical representation of the target processed cable in the animated display 5. In another embodiment, the animated display 5 of the tooled cable can include a pop-up window in which a graphical representation of potential failure modes of a tooled cable portion that does not meet quality standards is depicted. Such a pop-up window can be displayed upon selecting the appropriate section-by-section view.

[0025] FIG. 4 shows a second still image of the animated display 5 on the display according to the present invention. In this second still image, upon selecting the graphical representation of the left cable portion (see FIG. 3), a pop-up window appears containing graphical representations (e.g., icons) of potential failure modes of the left cable portion that do not meet the quality standards. For example, the failure of the left cable portion to meet the quality standards may be due to partial severing of the cable's core conductor caused by misalignment or placement of the cutting blade. As another example, the failure of the left cable portion to meet the quality standards may be due to an improper blade opening distance during stripping, leaving unstripped insulation at the cable end. The graphical representations of potential failure modes may include icons or low-resolution photographs, with or without accompanying explanatory text. In addition to the graphical representation of the tooled cable that does not meet the quality standards, the animated display 5 may also include graphical representations of mechanical components (that do not meet the quality standards), such as tools 110, 120, and 130 for manipulating the cable. The cognitive content of the graphical representation of potential failure modes is thereby related to the internal state of the cable processing machine and helps the operator to be able to operate the machine properly. Advantageously, presenting a graphical representation of potential failure modes of the cable section that does not meet the quality standard (left side) enables a continuous and / or guided human-machine interaction process, helping the operator to adjust the settings of the cable processing machine by comparing the created test pieces with the shown graphical representation.

[0026] As shown in the still image of animated display 5 in FIG. 5 , upon guided selection of a graphical representation of the non-conforming cable or cable segment that best matches the created test specimen, the animated display may display relevant tool settings or other machine settings related to the failure mode indicated in the graphical representation. For example, these relevant tool settings may be displayed as a pop-up upon selection of the failure mode of the (section-by-section) representation of the cable. Alternatively, the relevant tool settings may be displayed in place of an icon or graphical representation of the non-conforming cable (segment). In some embodiments, the configuration parameters may be presented as text (see FIG. 5 ). In alternative embodiments, the configuration parameters may be presented by (schematic) icons. Preferably, the configuration parameters are displayed in order of relevance for correcting the failure mode. Advantageously, the displayed order of relevance supports the operator in intuitively entering adjustments to tool and / or machine settings.

[0027] The failure modes of selected components or sections of the cable represent elements of the configuration of the operating tool. Misconfiguration of the operating tool usually leads to typical non-conforming characteristics of the tooled cable. Examples of components are:

[0028] - Cutting blade opening clearance at deepest cutting position ("Einschneideoeffnung") The opening clearance of the cutting blade while peeling off the insulation ("Oeffnung beim Abziehen") Disconnect pause time ("Einschneidepause") Peel-off acceleration ("Abziehbeschleunigung") Overstretching distance when fully / completely peeled off ("Ueberziehen bei Vollabzug")

[0029] Each particular configuration may be accompanied by numerical parameter values ​​for the configuration settings at which the test specimen was created, which may lead to non-compliance of quality standards for the created test specimen.

[0030] FIG. 6 shows a still image of another embodiment of an animated display 5 on the display. In this embodiment, the animated display provides instructions to assist the operator in adjusting parameter values ​​of the configuration settings to further guide and assist the operator in performing the technical task of adjusting the cable processing machine by guided selection of the graphical display that best matches the created test specimen. Advantageously, the instructions are graphical displays, such as arrows, that assist the operator in adjusting the parameters in the appropriate direction, up or down. Advantageously, the instructions may include a color element, such as a graduated color scale. As an example, color shading from red to yellow to green and / or from light to dark may assist the operator by indicating the amount of adjustment needed to (properly) adjust the cable processing machine. For example, reddish tones may indicate a relatively large amount of adjustment, while greenish tones may indicate a relatively small amount of adjustment, each indicating that the parameter is at (or near) its optimal value.

[0031] FIG. 7 shows a fifth still image of the animated display 5 on the display according to the present invention. As can be seen, in addition to displaying target values, such as the peel length (Abisolierlaenge) of the left cable section or the center length (Laenge) of the cable section, the animated display also graphically depicts specific sections of the tooled cable that have failure modes that do not meet the quality standards. As an example, the difference between the target peel length (4.00 mm) of the test section and the actual peel length (3.50 mm) of the test section is displayed. As another example, the difference between the target center length (400.00 mm) of the test section and the actual center length (399.50 mm) of the test section is displayed. In this embodiment, to further guide and assist the operator in performing the technical task of adjusting the cable processing machine through the guided selection of the (section-by-section) graphical representation of the non-conforming left cable section, the animated display may display, for example as a pop-up window, an overview of the "most recently used" tool settings for adjusting the cable processing machine for that particular cable section. In this example, three recently used components are shown: Measured peel length (Abisolierlaenge gemessen) ·Cutting opening (Einschneideoeffnung) Opening during detachment (Oeffnung beim Abziehen) Other component / tool ​​configuration examples are: Peeling-pressure Peeling speed Section blow-off - stop time (Teilstueck wegblasen:Nachlaufzeit)

[0032] Advantageously, the components (both their identification information and parameter values) displayed in the "most recently used" overview may depend on the operational mode function of the particular cable section. In other words, they may be different for the left cable end, the middle cable length, and the right cable length. Further advantageously, the order in which the components are displayed may be indicated so that the components most relevant to the adjustment of the cable processing machine are displayed at the top of the list.

[0033] Those skilled in the art will appreciate that the embodiments and methods shown in the drawings or described herein may also be combined and interchanged within the scope of the inventive concept. For example, the "most recently used" summary may also include (directional) instructions to assist the operator in adjusting parameter values ​​of configuration settings.

[0034] As a further example, the sensors 111, 121, 131 associated with each manipulation tool 110, 120, 130 may be optical, electrical, magnetic, electromagnetic, or piezoelectric sensors, etc., within the meaning of the present invention, and provide respective sensor signals 112, 122, 132 indicative of the actual configuration of the manipulation tool. These sensors may thus determine appropriate physical parameters, such as the position, distance, orientation, or speed of the associated tool, after control signals from the central control system 300 are executed to appropriately configure the tool. Within the meaning of the present invention, the sensors may also be (active) controllers that provide operating signals for open-loop control of the appropriate physical parameters. As an example of such open-loop control, the controller may provide operating signals to a stepper motor arranged to configure the associated tool. The sensor signals within the meaning of the present invention correspond in this case to operating signals for a stepper motor, since stepper motors are known to have built-in output steps and thus an inherent ability to control their position. This allows the stepper motor to be used as an open-loop position control without any feedback encoder, as the drive signal specifies the number of steps of movement to rotate. Therefore, the operating signal for driving the stepper motor in this example can be used as a sensor signal.

[0035] As yet another example, in one embodiment, rather than a schematic diagram of the failure mode as shown in Figures 4 and 5, the representation of the failure mode may be a photograph of a typical non-compliant tooled cable section. [Explanation of symbols]

[0036] 1 blank cable 2 Tour de Cable 3 Cable Types 5 Animation display 100 Cable Processing Machine 110 Operating tools - cutting blade 111 Sensor-Cutting Blade 112 Sensor signal - cutting blade 120 Operation Tool-Stripping Blade 121 Sensor-peeling blade 122 Sensor signal - peeling blade 130 Operation Tools - Alignment Gripper 131 Sensor-Alignment Gripper 132 Sensor Signal - Alignment Gripper 200 displays 210 Graphical Unit 220 Touchscreen 300 Control System 310 Display Data 320 Display Data 330 Display Data 350 Failure Mode Control Signal 360 Artificial Intelligence Unit

Claims

1. A cable processing machine (100) for processing a blank cable (1) into a tooled cable (2), comprising operating tools (110, 120, 130), sensors (111, 121, 131), a display (200), and a control system (300); the control system (300) is configured to set a target configuration of the manipulation tool (110, 120, 130) based on a cable type (3) of the blank cable (1) to be processed and a desired target specification of the tooled cable; the sensors (111, 121, 131) provide sensor signals (112, 122, 132) indicative of the actual configuration of the manipulation tool (110, 120, 130); the control system (300) is further configured to provide display data (310, 320, 330) based on the sensor signal (112, 122, 132) and the cable type (3), the display data being displayable on the display (200); The individual items of the display data (310, 320, 330) can be displayed on the display (200) in an animated representation (5) of the toured cable (2), in which potential failure modes for the individual components of the toured cable (2) are distinguishable from one another. Cable processing machine (100).

2. 2. The cable processing machine (100) of claim 1, wherein the display (200) includes a touch screen (220) configured to generate a failure mode control signal (350) indicating a failure mode of the tooled cable (2), and the control system (300) is configured to adjust the configuration of the operating tool (110, 120, 130) based on the failure mode control signal (350).

3. The cable processing machine (100) according to any one of claims 1 to 2, wherein the animation display (5) includes a section-by-section display of the tooled cable (2).

4. The cable processing machine (100) of any one of claims 1 to 3, wherein the individual items of display data (310, 320, 330) include configuration parameters of the operating tool associated with the failure mode being displayed.

5. The cable processing machine (100) of claim 4, wherein the configuration parameters are displayed in order of relevance for correcting the failure mode.

6. A cable processing machine (100) as claimed in claim 4 or 5, wherein the configuration parameters are changeable by an operator and / or, when claim 2 is relied upon, the failure mode control signal (350) includes information about the changed configuration parameters.

7. The cable processing machine (100) of any one of claims 1 to 6, wherein the individual items of the display data (310, 320, 330) include explanatory advice regarding the relationship between the occurrence of a failure mode and the setting of the configuration parameters of the operating tool (110, 120, 130) associated with that failure mode.

8. 3. The cable processing machine (100) of claim 2, wherein the control system (300) includes an artificial intelligence unit (360) that determines the adjustment of the configuration of the manipulation tool (110, 120, 130) based on the failure mode control signal (350).

9. A method of operating a cable processing machine (100) for processing a blank cable (1) into a tooled cable (2) using a processing tool (110, 120, 130), comprising: a) setting a target configuration of the manipulation tool (110, 120, 130) based on the cable type (3) of the blank cable (1) to be processed and the desired target shape of the tooled cable; b) providing a sensor signal (112, 122, 133) indicative of the actual configuration of said manipulation tool (110, 120, 130); c) providing display data (310, 320, 330) based on said sensor signals (112, 122, 133) and said cable type (3); d) displaying the individual items of said display data (310, 320, 330) in an animated representation (5) of said toured cable (2), in which potential failure modes of the individual components of said toured cable (2) are distinguishable from one another; A method comprising:

10. 10. A computer program product comprising instructions that, when said program is executed by a computer, cause said computer to carry out the method of claim 9.

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