Cable Collet Assembly for Misshaped End Component Positioning
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Solution Overview
Problem
The insertion of components like shielding ferrules and seals on cables is inefficient due to low productivity and misshaped cable ends, making it difficult to align and secure components effectively.
Innovation Solution
A collet mechanism with an expandable portion and resilient legs that moves between closed and expanded positions to securely position and align components on cables, reshaping the cable end for easy component insertion and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If components are inserted by hand on misshaped cable ends, then manipulation difficulty increases, but productivity remains extremely low
Solution Approach 1:
The collet mechanism dynamically changes between expanded and closed states. In the expanded state, it allows easy component insertion by providing a large opening. In the closed state, it secures the component firmly on the cable. This dynamic transformation resolves the contradiction between ease of operation and productivity.
Solution Approach 2:
The system performs preliminary shaping of the cable end using a forming die before component insertion. This preliminary action corrects misshaped cable ends, ensuring they are properly formed for subsequent automated component insertion, thereby improving both ease of operation and productivity.
2Ease of operation
If cable ends are misshaped, then component alignment becomes difficult, but manual manipulation increases complexity
Solution Approach 1:
A cable end forming die is used to preliminarily shape misshaped cable ends before component insertion. This preliminary action corrects deformities in the cable end, ensuring proper alignment and fit for components, thereby reducing manipulation complexity and improving ease of operation.
Solution Approach 2:
The collet acts as an intermediary tool that holds the component during insertion. It provides a controlled interface between the component and the cable, facilitating proper alignment even when cable ends are initially misshaped, thus reducing manipulation complexity.
3Productivity
If automated insertion is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The automated insertion system uses a dynamic collet mechanism that automatically transitions between expanded and closed states. This dynamic behavior is controlled by a simple actuation system, achieving high productivity without excessive device complexity. The mechanism self-regulates during the insertion process.
Solution Approach 2:
The collet mechanism serves multiple functions: it expands to facilitate component insertion, contracts to secure the component, and can be integrated with cable forming operations. This multi-functionality reduces the need for separate devices, thereby increasing productivity while limiting the increase in overall device complexity.
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
Enhances productivity by facilitating easy and secure insertion of components on cables, even when ends are misshaped, by conforming the cable to the collet's circular shape, ensuring smooth transitions and efficient assembly processes.
Implementation Method 1
Resilient legs are provided on the expandable portion. The resilient legs have fixed ends and free ends. The expandable portion is movable between a closed position, in which the resilient legs have a first outside diameter, and an expanded position, in which the resilient legs have a second outside diameter
Implementation Method 2
The free end of the collet is moved into engagement and compresses the end of the cable to secure the collet to the cable and causing the end of the cable to conform to a circular shape of the conductor receiving opening of the collet
Data Source
AI summary
A device and method of positioning a component on a cable. The method includes: moving a collet into position on the component; engaging the component with the collet; moving the collet with the component positioned thereon into alignment with an end of the cable; securing the collet to the end of the cable; moving the component from the collet to the cable; and removing the collet from the end of the cable.