Automatic Cable Assembly Cartridge System for Error Reduction
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Solution Overview
Problem
The current process of assembling electrical cables is heavily dependent on human intervention and is based on serial activities, making it inefficient and prone to errors, as it requires manual handling and tool usage at each stage of the assembly process.
Innovation Solution
An automatic cable assembly system that utilizes a cartridge moving along an assembly line, with modular machines and actuators performing specific tasks such as cutting, stripping, and soldering, while a central controller coordinates the process using bar code readers and RFID technology to manage the movement and processing of cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling and tool usage is used at each stage of the assembly process, then human flexibility and adaptability are maintained, but human error increases and efficiency decreases
Solution Approach 1:
The system enables self-service automation where the robotic arm autonomously performs cable assembly operations including gripping, positioning, and connector attachment without human intervention. The automated system serves itself by integrating sensors, controllers, and actuators that work together to complete the assembly process, thereby reducing human error while maintaining high automation levels
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system that uses computer-controlled mechanical arms, sensors, and actuators. This substitution eliminates human handling errors while maintaining precision through programmable motion control and automated positioning mechanisms
2Productivity
If serial activities are used in the assembly process, then each task can be performed carefully, but the overall production time increases and efficiency decreases
Solution Approach 1:
The robotic system maintains continuous useful action by eliminating idle time between assembly operations. The automated arm continuously moves between components, performs operations without interruption, and transitions smoothly between tasks, thereby increasing assembly speed while reducing total production time through uninterrupted workflow
Solution Approach 2:
The system performs preliminary actions by pre-positioning components and pre-programming assembly sequences before actual assembly begins. The robotic arm is pre-configured with toolpaths, and components are pre-arranged in optimal positions, allowing the assembly process to proceed rapidly without delays for positioning or reconfiguration
3Manufacturing precision
If manual assembly is used, then flexibility in handling different cable specifications is maintained, but consistency and precision decrease
Solution Approach 1:
The robotic assembly system achieves universality through a multi-functional platform that can handle various cable specifications using the same automated arm. The system incorporates adjustable grippers, reconfigurable tooling, and programmable control that adapt to different cable types, connectors, and assembly requirements, maintaining manufacturing precision across diverse products without requiring separate manual processes for each specification
Data Source
AI summary
An automatic-robotic-system-for-cable assembly system and method is provided. The method and system are configured to use a cartridge which holds one or both ends of the cable. The cartridge moves along an automatic cable assembly line, with the line segmented into different stages, at which a process is performed by a specific machine. Different machines, such as actuators or modular machines, perform operations on the cartridge at the different stages. In preparation for or as part of the operations, the actuators or modular machines may apply one or more forces to the cartridge, causing one or more of the following to occur: moving an end of the cartridge to a modular machine, rotating an end of the cable, tipping the ends of the cable, etc. In this way, use of the cartridge enables the automatic assembly of the cables held in the cartridge.