Automated Cable Bundling With Chip-Based Welding Parameter Matching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated cable bundling tools face challenges in adjusting welding parameters effectively when material characteristics, cable geometry, or bundle size change, leading to inconsistent welding quality and potential damage to cables.
Innovation Solution
A system equipped with programmable chips embedded in the cartridge, jaw, and welding horn, which are read by a processor to automatically adjust settings such as jaw size, safety codes, and welding parameters, ensuring compatibility and optimal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If automated cable bundling tools use fixed welding parameters, then the device complexity is reduced, but the welding quality consistency deteriorates when material characteristics or cable geometry change
Solution Approach 1:
The patent applies preliminary action by pre-storing optimized welding parameters in programmable chips within components (cartridge, jaw, welding horn) before use. When components are attached to the tool, the processor automatically reads these pre-stored parameters and configures the welding settings, eliminating the need for manual adjustment and ensuring consistent welding quality across different materials and geometries without increasing operational complexity.
Solution Approach 2:
The system implements self-service through automatic parameter configuration. The processor autonomously reads component identification data from programmable chips, retrieves corresponding welding parameters from memory, and adjusts welding settings without operator intervention. This self-configuring capability maintains welding quality consistency while keeping the device operationally simple.
2Manufacturing precision
If welding parameters are manually adjusted for different materials and geometries, then the welding quality consistency is improved, but the loss of time increases
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated electronic parameter configuration system. The processor reads component identification data from programmable chips and automatically configures welding parameters, substituting manual operator actions with electronic automation. This eliminates time-consuming manual adjustments while maintaining welding quality consistency across different materials and cable geometries.
3Adaptability or versatility
If the tool is designed to accept multiple component types, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The patent implements universality through a standardized interface design that allows the tool to accept multiple component types (different cartridges, jaws, welding horns). The processor automatically identifies the attached component type through programmable chip reading and retrieves appropriate parameters from memory, enabling multi-component compatibility without requiring complex manual configuration or increasing operational complexity.
4Reliability
If programmable chips with encrypted data are used in components, then the reliability of component compatibility is improved, but the device complexity increases
Solution Approach 1:
The patent applies feedback through an automatic verification system. The processor reads encrypted identification data from programmable chips in attached components, decrypts the data using stored keys, and verifies component compatibility. Based on this verification feedback, the system either accepts the component and loads appropriate parameters or rejects it with an error message. This automated feedback loop ensures reliable component compatibility while keeping the interface simple for operators.
Data Source
AI summary
A system includes a tool for installing a cable material around a set of elongate members. The tool includes a housing; a cartridge detachably connected to the housing; and a jaw detachably connected to the housing. The cartridge has a length of cable material. The jaw is configured to extend around the set of elongate members to install the length of cable around the set of elongate members. A welding horn is detachably connected to the housing. At least one processor is configured to read a programmable chip. The programmable chip stores a set of parameters for at least one of the cartridge, the jaw, or the welding horn.