Telecentric Cable End-Face Imaging for Accurate Layer Cutbacks
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Solution Overview
Problem
The installation of electrical cables is a manual process prone to errors, which can lead to failures in the electrical cable or cable accessories, resulting in defects such as stray knife cuts, incorrect cutbacks, and contamination.
Innovation Solution
An electrical-cable-preparation system with modular components, including an imaging device with a telecentric lens, a handheld rotatable tool head with rollers and a cutting tool, and a gripper module, is used to accurately measure and cut the electrical cable layers for coupling to cable accessories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual installation process is used, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical operations with an automated cable preparation system that uses imaging devices, computer vision, and automated cutting mechanisms. The system captures images of cable cross-sections, processes them through software algorithms, and automatically controls cutting tools to achieve precise cuts without manual intervention, thereby improving manufacturing precision while maintaining operational ease.
Solution Approach 2:
The system enables the cable preparation process to be self-regulating through automated feedback loops. The imaging device captures real-time images of the cable cross-section, the computer vision software analyzes the image to determine optimal cut locations, and the system automatically adjusts cutting parameters and executes cuts without requiring continuous manual monitoring or adjustment, allowing the process to serve itself.
2Manufacturing precision
If automated cable preparation system is used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single unified system. The imaging device serves both as a measurement tool and as a guide for the cutting operation. The computer vision software performs multiple tasks including image processing, feature detection, cut location determination, and parameter calculation. This multi-functionality reduces the need for separate dedicated devices for each operation, thereby managing device complexity while achieving high manufacturing precision.
Solution Approach 2:
The system merges the imaging, analysis, and cutting functions into an integrated automated workflow. The imaging device, computer vision software, and cutting mechanism are combined into a coordinated system where the output of one component directly feeds into the next, eliminating the need for separate manual operations and reducing overall system complexity through functional integration.
3Measurement precision
If telecentric lens is used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical-based telecentric lens system. Instead of using physical measurement tools that require manual positioning and calibration, the telecentric lens captures optical images of the cable cross-section with built-in depth of field control, eliminating the need for complex mechanical adjustment mechanisms while achieving high measurement precision.
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
The system reduces defects and improves the accuracy of cable preparation, leading to more reliable electrical connections and reduced failure rates in power grids.
Implementation Method 1
a telecentric lens optically coupled to the camera, wherein the telecentric lens comprises a non-angular field of view configured to reduce, in the image, distortion from parallax associated with at least one portion of the end-face of the electrical cable
Data Source
AI summary
Techniques, systems and articles are described for preparing electrical cables for connections to a power grid. In one example, a cable-cross-section-measurement tool includes a housing defining a cavity, wherein the housing is configured to position an end-face of an electrical cable within the cavity; a camera disclosed within the cavity of the housing, wherein the camera is configured to capture an image of the end-face of the electrical cable; and a telecentric lens optically coupled to the camera, wherein the telecentric lens comprises a non-angular field of view configured to reduce, in the image, distortion from parallax associated with at least one portion of the end-face of the electrical cable that is oriented at an oblique angle relative to an optical axis of the telecentric lens.