Cable Processing Machine Sensor System for Automated Parameter Determination
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Solution Overview
Problem
Existing cable processing machines struggle to accurately detect both inner conductor and external diameters, especially in asymmetrical cables, leading to suboptimal processing parameters and potential damage during insulation stripping, as they rely on contact detection methods that can result in 'overshooting' and are limited to specific cable types.
Innovation Solution
A machine that automatically identifies cables using external diameter and internal cross-section measurements, comparing these values to a table memory to determine processing parameters, allowing for precise processing of various cable types, including those with multiple layers, through the use of sensors like inductive ring sensors and potentially additional sensors for increased accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If contact detection methods are used to identify inner conductor diameter, then the processing machine can determine processing parameters, but the measurement precision deteriorates due to overshooting and asymmetrical cable positioning
Solution Approach 1:
The patent replaces mechanical contact-based detection with optical measurement systems. External diameter sensors and internal structure sensors (such as electromagnetic or capacitive sensors) measure cable dimensions without physical contact, eliminating the overshooting problem inherent in mechanical contact methods and enabling precise measurement of both external and internal dimensions simultaneously.
Solution Approach 2:
The system performs preliminary measurement of both external diameter and internal cross-section parameters before the insulation stripping process begins. These measurements are used to pre-determine the processing parameters, ensuring accurate setup without requiring continuous adjustment or contact-based verification during the actual processing.
2Measurement precision
If continuous measurement during each insulation stripping process is performed, then processing parameters can be determined, but the productivity deteriorates due to slow cutting process
Solution Approach 1:
The system performs comprehensive measurements of external diameter and internal structure once at the beginning of the process, before insulation stripping commences. The processing parameters are determined from these preliminary measurements, allowing the subsequent insulation stripping to proceed at full speed without continuous measurement or adjustment, thereby maintaining both accuracy and productivity.
3Device complexity
If only inner conductor diameter is detected, then the measurement system remains simple, but the adaptability deteriorates for cables with more than two layers
Solution Approach 1:
The patent employs sensors capable of detecting multiple parameters simultaneously - external diameter sensors measure the overall cable dimension while internal structure sensors (electromagnetic, capacitive, or other non-contact sensors) detect the inner conductor cross-section and intermediate layers. This multi-functional measurement system can handle cables with two layers, three layers, or more, making the processing machine universally adaptable to various cable types without requiring additional specialized equipment for each cable structure.
4Measurement precision
If external diameter sensor and internal cross-section sensor are combined, then cable identification accuracy improves, but the device complexity increases
Solution Approach 1:
The patent combines external diameter measurement and internal cross-section measurement into an integrated measurement system. The control unit receives signals from both external sensors and internal structure sensors, processes the combined data, and automatically determines the cable type and processing parameters. This merging of measurement functions into a unified system improves identification accuracy while managing complexity through integrated control logic.
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 enables reliable and efficient processing of diverse cables by minimizing changeover times, reducing tool wear, and ensuring high-quality finished products by accurately determining processing parameters without continuous measurement, thus preventing damage and wastage.
Implementation Method 1
a first sensor (2) for determination of an inner conductor cross-section of the cable (1) is provided, in particular an electromagnetic ring sensor
Implementation Method 2
a second sensor (12) for determination of an external diameter of the cable (1), in particular a scanning device or a sensor for contactless measurement
Data Source
AI summary
The invention relates to a machine and a method for a processing machine for longitudinal objects, in particular for cables and wires, which permits the reliable identif ication of a cable, wire or profile material inserted into the processing machine. On the basis of the identif ication of the cable, of the wire or of the profile material, the machine or the method determines the coordinated processing parameters in an automatic or automated manner. The processing parameters thus determined can subsequently be used without problems and as known per se for the automatic or automated actuation of the processing machine for processing the inserted cables, wires or profile materials.