Cable Aluminum Foil Laser Cutting Without Core Wire Damage
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Solution Overview
Problem
Existing methods for cutting the aluminum foil layer from multi-core cables are inefficient and difficult to control, especially when using rotating blades, which often result in cutting into the core wires.
Innovation Solution
A cable aluminum foil layer processing device using a laser generator and a rotating frame with a mirror to emit a laser beam that cuts the foil layer along its circumferential direction, controlled to avoid cutting the core wire, combined with a gripper for automated removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotating blade is used to cut the aluminum foil layer, then the cutting process is simple, but for multi-core cables with non-circular outer contour, the rotating blade cannot cut the aluminum foil layer properly and may cut into the core wire
Solution Approach 1:
The patent replaces the mechanical rotating blade cutting system with a laser cutting system. The laser generator emits a laser beam that is reflected by mirrors onto the aluminum foil layer, enabling precise cutting without mechanical contact. This substitution resolves the contradiction by providing both cutting capability and precise depth control through laser parameters, eliminating the risk of cutting into core wires while maintaining ease of operation.
Solution Approach 2:
The patent changes the cutting method from mechanical blade rotation to laser beam application with controlled parameters. By adjusting laser power, beam diameter, and scanning speed, the cutting depth is precisely controlled to match the aluminum foil layer thickness. This parameter-based control enables accurate cutting of non-circular multi-core cable contours without risking damage to internal core wires.
2Manufacturing precision
If manual methods are used to cut the aluminum foil layer, then the cutting depth can be controlled, but the efficiency is very low
Solution Approach 1:
The patent replaces manual mechanical cutting with an automated laser cutting system. The laser beam, guided by mirrors and controlled by a processing system, automatically traces the cable contour and cuts the aluminum foil layer with precise depth control. This automation dramatically improves productivity while maintaining the cutting depth control advantage of manual methods, eliminating the efficiency bottleneck.
3Productivity
If a rotating blade is used for single-core cables with circular outer contour, then the cutting is efficient, but it cannot be applied to multi-core cables with non-circular outer contour
Solution Approach 1:
The patent creates a universal cutting system that can handle both single-core and multi-core cables. The laser cutting method, controlled by a processing system that tracks the cable contour, adapts to any cross-sectional shape. Whether circular (single-core) or non-circular (multi-core), the system maintains high cutting efficiency while achieving versatility across different cable types, unlike the rotating blade which is shape-specific.
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
Automated cutting and removal of aluminum foil layers from multi-core cables with improved efficiency and precision, preventing damage to the core wires.
Implementation Method 1
a laser generator installed on the rotating frame emits a laser beam
Implementation Method 2
the laser generator installed on the rotating frame emits a laser beam to cut the aluminum foil layer
Implementation Method 3
The mirror on the rotating frame reflects the laser beam onto the aluminum foil layer
Data Source
AI summary
A cable aluminum foil layer processing device includes a cable clamp, a rotating frame, a laser generator, and a mirror. The cable clamp clamps and fixes a cable having a core wire wrapped by an aluminum foil layer. The rotating frame rotates around a rotation axis that coincides with an axis of the clamped cable. The laser generator installed on the rotating frame emits a laser beam. The mirror on the rotating frame reflects the laser beam onto the aluminum foil layer to cut the aluminum foil layer. During the cutting of the aluminum foil layer the rotating frame rotates once around the rotation axis to cut a cut line along a circumferential direction of the aluminum foil layer. A cutting depth of the laser beam is equal to or less than a thickness of the aluminum foil preventing the laser beam from cutting the core wire.