Cable Assembly Head with Integrated Optical Position Measurement
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Solution Overview
Problem
Existing devices for equipping electrical cables with grommets lack the ability to automatically determine the correct position and alignment of cable assemblies on the cables, which affects quality control and productivity.
Innovation Solution
A device with an assembly head that moves forward to apply the cable assembly and backward to measure its position, using a measuring system with a transmitter and receiver to assess alignment and accuracy, allowing for real-time feedback on correct placement and potential errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If quality control measurement is implemented to determine cable assembly position, then manufacturing precision is improved, but productivity is reduced due to requiring the assembly head to return to starting position before cable can continue processing
Solution Approach 1:
The measurement of cable assembly position is performed during the backward movement of the assembly head from end position to starting position, rather than requiring a separate measurement step after assembly. This preliminary action during the return trip eliminates idle time and maintains productivity while ensuring quality control.
Solution Approach 2:
The assembly head continuously performs useful work during its entire cycle: forward movement for assembly, backward movement for measurement. No part of the cycle is wasted, as the return journey is utilized for position verification, enabling continuous processing without halting the production flow.
2Measurement precision
If the cable end is held stationary during measurement, then measurement precision is improved, but the complexity of the positioning system increases
Solution Approach 1:
Instead of moving the cable end during measurement, the invention inverts the approach by moving the assembly head (with integrated measurement devices) relative to the stationary cable end. This simplifies the positioning system by eliminating the need for complex cable handling mechanisms while maintaining high measurement precision.
3Manufacturing precision
If the assembly head moves backward for measurement, then measurement can be performed, but time is lost during the return movement
Solution Approach 1:
The position measurement is performed as a preliminary action during the necessary return movement of the assembly head, before the cable proceeds to the next processing step. This ensures that any positioning issues are detected and corrected before subsequent operations, preventing rework and actual time loss.
Solution Approach 2:
The backward movement of the assembly head is transformed from idle time into a productive measurement phase. Every phase of the assembly head cycle performs a useful function: forward for assembly, backward for measurement, maintaining continuous value addition without extending the overall cycle time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise quality control without halting productivity, ensuring accurate placement of cable assemblies, detecting misalignments, incorrect grommets, and other assembly issues, while allowing the cable to continue processing without waiting for the assembly head to return to the starting position.
Implementation Method 1
using a measuring system with a transmitter and receiver to assess alignment and accuracy
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
A fitting module (1-2) has a fitting head (40) that can be moved from starting position into end position and back, that fits stationary wires with wire fittings. A transmitter (101) and receiver (102) are mounted on fitting head. A wire together with wire fitting is measured utilizing a beam (103) transmitted by transmitter and received by receiver, during movement of fitting head from end position into starting position to generate measurement results and fitting faults are detected during an evaluation of measurement results. An independent claim is included for method for measuring electric wires with wire fittings.