Cable Gripper Setup Memory for Safe Processing Station Alignment
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Solution Overview
Problem
Existing cable processing devices require complex and potentially hazardous setup processes, especially for crimping stations, which can be challenging for operators to perform safely and efficiently, often necessitating manual adjustments and visual checks between control consoles and processing stations.
Innovation Solution
A cable processing device with a feed unit that allows manual positioning of the cable gripper to desired locations, which is then stored and automatically relocated during normal operation, featuring a protective hood that de-energizes actuators during setup to ensure safety, and intuitive user guidance with buttons and save functions for precise positioning and parameter storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual positioning of the cable gripper is implemented during setup mode, then ease of operation is improved, but device complexity increases due to additional control modes and positioning mechanisms
Solution Approach 1:
The cable gripper positioning system transitions between two dynamic states: automatic positioning during normal operation and manual positioning during setup mode. The feed unit can be switched between automated motor-driven movement and manual handwheel adjustment, allowing operators to choose the appropriate mode based on operational requirements. This dynamic adaptability resolves the contradiction by providing ease of operation through manual adjustment while maintaining automated precision during production.
Solution Approach 2:
The system incorporates self-service capabilities through the setup mode, where operators can independently position and calibrate the cable gripper without requiring external assistance or complex programming. The manual positioning mechanism allows direct adjustment of the cable gripper position, and the control system automatically stores these positions for future automated operations, enabling operators to service and configure the system themselves.
2Ease of operation
If protective hood is opened for setup operations, then ease of operation is improved, but safety deteriorates due to exposed moving parts
Solution Approach 1:
The system requires preliminary action in the form of activating setup mode before allowing the protective hood to be opened. When setup mode is activated, the control system de-energizes all actuators and prevents automatic cable processing operations. This preliminary safety measure ensures that even though the protective hood is open providing accessibility, no harmful automatic movements can occur, thus resolving the safety concern.
Solution Approach 2:
The control system acts as an intermediary between the protective hood state and the actuator operation. It monitors whether setup mode is active and uses this information to control the energization of actuators. This intermediary control mechanism ensures that the protective hood can be opened for accessibility while the control system mediates to prevent any harmful automatic operations, maintaining safety throughout the setup process.
3Manufacturing precision
If precise positioning of cable gripper is achieved manually, then manufacturing precision is improved, but loss of time increases due to manual adjustment requirements
Solution Approach 1:
The control system creates a digital copy or memory of the manually positioned cable gripper location. When the operator manually positions the cable gripper during setup, the control system stores these position coordinates in its memory. During automated production, the system retrieves and executes these stored positions, allowing rapid reproduction of the precise positioning without requiring repeated manual adjustments, thus reducing time loss while maintaining precision.
Solution Approach 2:
The manual positioning performed during setup is a preliminary action that establishes the precise positions for all subsequent automated operations. By carefully positioning the cable gripper during the initial setup phase and storing these positions, the system prepares all necessary positioning data in advance. This preliminary precise positioning eliminates the need for repeated time-consuming adjustments during production, resolving the contradiction between achieving precision and minimizing time loss.
4Adaptability or versatility
If setup parameters are stored in control system, then adaptability is improved, but device complexity increases due to data storage and retrieval mechanisms
Solution Approach 1:
The control system creates digital copies of the machine settings and cable gripper positions during setup and stores them in memory. These stored parameters serve as templates that can be quickly retrieved and applied during automated production. This copying and storage mechanism enables the system to adapt to different cable types and processing requirements by simply loading different stored parameter sets, providing adaptability without requiring complex reconfiguration procedures or additional hardware.
Data Source
AI summary
A cable processing device for assembling cables includes processing stations, a feed unit having a cable gripper, and a machine controller. When the feed unit is in a setup mode, the cable gripper can be moved manually to one of the processing stations into a desired position. After the desired position has been established, this position is stored in the machine controller so that, thereafter, the cable gripper can be brought automatically into this position in the normal operating mode of the cable processing device. In order to move the cable gripper in the normal operating mode, the feed unit has servo or stepper motors equipped with encoders. Furthermore, the cable processing device has a protective hood. When the protective hood is in the open position and cable processing device is in the setup mode, the machine controller de-energizes the actuators for operating the processing stations and the feed unit.