Automated Cable Length Measurement Using Light Barrier Detection
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Solution Overview
Problem
The existing methods for determining the length of electrical lines in industrial settings are error-prone and complex, particularly in systems with numerous cables and cryptic naming conventions, leading to difficulties in accurate documentation and identification of cable ends and connections.
Innovation Solution
A method and device that measure the length of electrical lines by cutting them to an initial length, assigning an identifier, and calculating the length of subsequent lines based on the identifier, using detection units like light barriers and memory units to record and associate the identifier with the length, allowing for precise determination and marking of cable lengths for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual marking and documentation of electrical lines is performed, then identification of cable ends and connections is achieved, but errors increase and documentation becomes complex and difficult to maintain
Solution Approach 1:
The patent replaces manual marking and documentation processes with an automated optical measurement system. A measurement device with optical sensors automatically detects cable lengths and records them in a database, eliminating the need for manual measurement, marking, and documentation. This substitution of mechanical/manual processes with automated optical-electronic systems directly resolves the contradiction by improving accuracy while reducing documentation complexity.
Solution Approach 2:
The measurement device is designed to automatically perform multiple functions: it measures cable length, identifies the cable, records the data in a database, and generates documentation without human intervention. This self-service capability allows the system to handle its own documentation needs, improving reliability through automation while minimizing the complexity of external documentation systems.
2Measurement precision
If precise manual measurement and documentation of each cable is performed, then accurate length determination is achieved, but time consumption and error probability increase
Solution Approach 1:
The measurement device continuously measures cable lengths as cables are fed through the system, rather than requiring discrete manual measurements. The optical sensors continuously track the cable position and length, automatically recording data without interruption. This continuous automated measurement maintains high precision while dramatically reducing the time required compared to discrete manual measurements and documentation.
Solution Approach 2:
The system replaces time-consuming manual measurement and documentation processes with automated optical measurement and electronic database recording. The measurement device automatically captures length data and stores it in a database, eliminating the time required for manual writing, calculation, and verification while maintaining or improving measurement precision.
3Difficulty of detecting and measuring
If cable lengths are determined using existing methods with light barriers, then detection of cable presence is achieved, but determination of starting measuring points becomes complex and requires additional initial setup
Solution Approach 1:
The measurement device integrates multiple functions into a single system: the light barrier serves both to detect cable presence and to establish the starting measuring point automatically. The control unit processes the light barrier signal to simultaneously trigger measurement and define the origin point, eliminating the need for separate procedures to establish measuring points and reducing overall system complexity.
Solution Approach 2:
The system performs preliminary automatic setup of the measuring point when the cable is first detected by the light barrier. The control unit automatically establishes the starting point for length measurement based on the initial detection signal, eliminating the need for manual configuration or complex initial setup procedures. This preliminary automatic action simplifies the overall measurement process.
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
This approach simplifies the assembly of electrical lines by reducing errors and improving documentation, enabling efficient identification and connection of cables in electrical assembly arrangements, while minimizing waste and logistical complexities.
Implementation Method 1
the detection of a starting point for the length measurement by means of a light barrier
Data Source
Figure 1
Figure 2~3b
Figure 4a~6
AI summary
The invention relates to a method for determining the length of a line, comprising the steps of: determining (S3) a length (l1) of a first electrical line (L1), determining (S4) an identifier of the first electrical line (L1), determining (S5) a length (l2) of a second electrical line, which is intended for installation in an electrical mounting arrangement, on the basis of the length (l1) of the first electrical line (L1) and an initial length (l0) determined by the identifier.