Cable Shield Braid Brushing for Interference-Free Crimping
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Solution Overview
Problem
Existing methods for processing braided shields in cables, such as coaxial cables, result in shield strands becoming trapped or protruding during crimping, leading to malfunctions and defects due to parallel positioning and deformation techniques.
Innovation Solution
A method involving counter-rotating brushes to form a vertex or crown on the braided shield, followed by alignment with forming jaws to create an L-shape, ensuring precise and interference-free crimping by adjusting the shield braid's distribution and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the braided shield is positioned and folded over a support sleeve using a longitudinal brush system or mechanical slip-on system, then the shield strands are aligned parallel to the cable, but shield strands become trapped in the crimping area or protrude from the crimping area during subsequent crimping
Solution Approach 1:
The patent applies preliminary action by creating a crown (vertex) in the braided shield before crimping occurs. The brush system forms this crown structure in advance, which then guides the shield strands away from the crimping area during the subsequent crimping process, preventing them from becoming trapped or protruding.
Solution Approach 2:
The patent segments the braided shield into different regions: a crown area formed by the brushes and a crimping area. This segmentation is achieved by positioning the support sleeve at a specific location and using the brushes to create a vertex, effectively dividing the shield into zones with different functions - the crown directs strands away while the crimping area remains clear for reliable contact application.
2Object-generated harmful factors
If vertical compressed air or a longitudinal brush is used to deform the braided shield, then shield wires are moved out of the required area, but shield wires still protrude from the outer conductor in the longitudinal direction causing malfunctions
Solution Approach 1:
The patent creates the crown structure in advance using the brush system before crimping. This preliminary formation of the vertex ensures that shield strands are directed away from the crimping area and remain properly contained, preventing them from protruding in the longitudinal direction and causing malfunctions in the final product.
Solution Approach 2:
The support sleeve acts as an intermediary element that facilitates the crown formation. It provides a reference surface for the brushes to create the vertex and helps position the braided shield correctly, ensuring that the crown forms at the right location and orientation to prevent shield wire protrusion.
3Reliability
If the crown is formed as far or as large as possible over the circumferential surface of the cable, then the risk of shield braid interference during crimping is reduced, but the complexity of brush system positioning and adjustment increases
Solution Approach 1:
The support sleeve serves multiple functions: it provides a mechanical reference surface for crown formation, positions the braided shield correctly, and defines the location where the vertex should be created. This multi-functionality simplifies the overall system design by eliminating the need for separate positioning mechanisms, reducing device complexity while maintaining reliable crimping.
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
Enables reliable and precise processing of braided shields, reducing interference during crimping and enhancing the stability of the shield braid, allowing for efficient assembly of outer conductor contacts.
Implementation Method 1
counter-rotating at least two brushes of a brush system in a plane transversely, in particular perpendicularly, to the first direction, and moving the rotating at least two brushes along a third direction, in particular perpendicularly, towards the cable, so that the at least two rotating brushes brush the exposed shielding braid at the circumference of the cable into a vertex
Data Source
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AI summary
The present invention relates to a method for brushing the braided shield (14) of a cable (10), comprising the steps of: introducing and positioning the cable (10) with the exposed braided shield (14) in a support (2) along a first direction (X), counter-rotating (D) at least two brushes (4) of a brush system (3) in a plane (YZ) transversely, in particular perpendicularly, to the first direction (X), and moving the rotating at least two brushes (4) along a third direction (Z), in particular perpendicularly, towards the cable (10), such that the at least two rotating brushes (4) brush the exposed braided shield (14) at the circumference of the cable (10) into a vertex (15). The invention further relates to a device (1) for brushing the braided shield (14) of a cable (10).