Automated Cable Coiling With Gantry and Swarm Robots

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional cable-coiling operations in submarine communications cable manufacturing are time-consuming, labor-intensive, and prone to musculoskeletal disorders, necessitating a more efficient and automated solution.

Innovation Solution

An automated cable-coiling system utilizing a gantry, cable-guiding sub-system, and a swarm of cable-handling robots equipped with rakes to coil cables in spirally wound, vertically stacked layers, controlled by an electronic controller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional manual cable-coiling operations are used, then workers can handle the cable directly, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improvecoiling speedVSAvoidoperational time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The cable-coiling system is designed to operate autonomously without human intervention. The electronic controller automatically coordinates the movable head, robots with rakes, and cable engine to complete the coiling process, eliminating the need for manual operations and significantly reducing operational time

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with an automated electronic control system that coordinates multiple robotic components. The electronic controller substitutes human labor by managing the complex coordination between the movable head, cable engine, and robots with rakes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If manual cable-coiling operations are used, then workers can perform the task, but it is prone to musculoskeletal disorders

Engineering Contradiction:

Improveworker safetyVSAvoidmusculoskeletal disorders

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The system performs all cable-coiling operations autonomously, eliminating human exposure to physically demanding tasks. The robots with rakes and automated movable head handle the cable manipulation, completely removing workers from environments that cause musculoskeletal disorders

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Human mechanical operations are replaced with robotic systems that have no susceptibility to musculoskeletal disorders. The automated coordination of robots and mechanical components eliminates the need for workers to perform repetitive manual labor

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If automated cable-coiling system is implemented, then manual labor is reduced, but the device complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The automated system is divided into distinct functional modules: a movable head for guiding, a cable engine for feeding, multiple robots with rakes for manipulation, and an electronic controller for coordination. This segmentation allows each component to perform a specific function, managing overall complexity through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electronic controller serves multiple functions by coordinating the movable head, cable engine, and robots with rakes. This centralized control system manages various operations including cable feeding, positioning, and coiling, reducing the need for separate control systems for each component

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If conventional coiling methods are used, then simple equipment is required, but neat and tight packing of cable loops is difficult to achieve

Engineering Contradiction:

Improvecable loop packing qualityVSAvoidcoiling system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Manual cable manipulation is replaced with robotic systems equipped with rakes that can precisely control cable placement. The automated coordination ensures consistent, neat, and tight packing of cable loops in spirally wound vertically stacked layers, achieving high manufacturing precision through robotic control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system controls cable coiling parameters including layer formation, spiral winding pattern, and vertical stacking arrangement. By precisely controlling these parameters through electronic coordination, the system achieves neat and tight packing of cable loops that is difficult to accomplish with manual methods

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4190733B1Cable-coiling system

Publication Date: 2025.11.12 ALCATEL SUBMARINE NETWORKS

Figure 1
Figure 2A~2C
Figure 3

AI summary

An automated system for coiling a large (e.g., >1000 km) length of cable (402) in a cable tank (100). In an example embodiment, the system comprises a gantry (430) positioned above the cable tank and a swarm of robots (350n) deployed on the floor of the tank (100). The gantry (430) operates to controllably move a touchdown point of the cable (402), which is being fed into the tank (100) by a cable engine (330). Each of the robots (350n) is equipped with a rake (630) that can be used to push or pull downed sections of the cable (402) on the floor of the tank (100). An electronic controller (310) operates to control the speed of the cable engine (330) and movements of the gantry (430) and individual robots (350n) to coil the cable (402) in the tank (100) in spirally wound, vertically stacked layers. Different embodiments of the system may be used for cable coiling at the cable factory and on the deck of a cable-laying ship.