Rotary Gripping Device for Cable Harness Alignment
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Solution Overview
Problem
Existing methods fail to ensure precise rotational alignment of assembled cable ends, particularly in twisted cable harnesses with multiple cables, which is crucial for successful assembly into connector housings.
Innovation Solution
A method and device utilizing a rotary gripping device with adjustable gripper jaws to rotate and align each cable end of a twisted cable strand into a predetermined target rotational position, allowing for independent alignment and holding of each cable end, facilitated by a detection system for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual cables are inserted individually into connector housing chambers, then assembly flexibility is maintained, but rotational alignment precision of cable ends cannot be ensured in twisted cable strands
Solution Approach 1:
The alignment device segments the cable strand by using multiple independent cable grippers (at least one per cable to be aligned) that can individually grasp and rotate each cable end independently. This allows precise rotational alignment of each cable end while maintaining the ability to process multiple cables in sequence, resolving the contradiction between alignment precision and device complexity.
Solution Approach 2:
The device performs preliminary untwisting of cable ends before insertion into the connector housing. By pre-aligning the rotational position of cable ends and holding them in the correct orientation, the system ensures precise alignment is achieved before the critical insertion step, eliminating the need for complex real-time alignment mechanisms during assembly.
2Device complexity
If twisted cable strands are used to reduce harness complexity, then cable harness compactness is improved, but rotational position control of cable ends becomes unpredictable
Solution Approach 1:
The alignment device changes the rotational parameter of each cable end independently by allowing free rotation during the alignment process. The cable grippers enable each cable to be rotated to its specific target angular position, transforming the unpredictable rotational state of twisted cables into a precisely controlled state suitable for connector assembly.
3Ease of operation
If cable ends are freely rotatable during alignment, then rotational position adjustment is enabled, but stability of cable position during processing is reduced
Solution Approach 1:
The cable grippers provide dynamic control by transitioning between different grip states: during alignment, they allow free rotation for position adjustment; during holding, they firmly grasp the cable ends to maintain stability. This dynamic adaptability resolves the contradiction between ease of rotational adjustment and position stability during processing.
Solution Approach 2:
The detection device monitors the actual rotational position of cable ends and provides feedback to the control device, which adjusts the rotation and gripping forces accordingly. This closed-loop control ensures cable ends reach the target rotational position accurately while maintaining stability once aligned, balancing adjustability and position control.
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
The present invention relates to a method and a device for aligning pre-assembled cable ends (111, 121) of a cable strand (100), in particular a twisted one, with at least two cables (110, 120), wherein, to align the free, in particular untwisted, cable end (111) of a cable (110) to be aligned into a desired rotational position, the entire cable strand (100) is rotated by means of a rotary gripping device (30) on a section (101) adjoining the cable ends, in particular a twisted section, and each already aligned cable (110) remains held in its desired rotational position on a section (112) of its free, in particular untwisted, cable end (111) by means of a respective cable gripper (10, 20).