Cable Straightening Roller Control for Diameter-Based Alignment
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Solution Overview
Problem
Existing cable straightening devices suffer from inadequate precision in adjusting the straightening mechanism, leading to insufficient straightening of electrical or optical cables, which complicates further processing and increases effort.
Innovation Solution
A straightening device with a movable first and second row of rollers, equipped with a measuring device, such as an ultrasonic or laser sensor, to determine the cable diameter, and a control unit to adjust the rollers based on the measured diameter, ensuring precise straightening without excessive stress, and incorporating a monitoring unit for quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spacing between roller rows is fixed, then the device structure is simple, but the straightening precision varies along the cable
Solution Approach 1:
The patent implements a dynamic adjustment mechanism where the spacing between roller rows can be continuously varied along the cable length. The second roller row is positioned at a variable distance from the first roller row, allowing the straightening geometry to adapt to different cable sections and maintain precision throughout the entire cable rather than having fixed spacing.
Solution Approach 2:
The straightening device divides the cable into multiple sections by using multiple roller rows with different orientations and spacings. Each roller row processes a specific segment of the cable, with the second roller row positioned at a variable distance to handle different cable sections differently, thereby achieving uniform straightening precision across the entire cable length.
2Manufacturing precision
If the cable is not positioned exactly between roller rows, then the device operation is simple, but the straightening precision deteriorates
Solution Approach 1:
The patent applies local quality by having the second roller row positioned at a variable distance from the first roller row, creating different local straightening zones. This variable spacing allows each local section to be optimized for the cable's position and curvature at that specific location, compensating for positioning variations and maintaining overall straightening precision without requiring exact cable placement.
3Manufacturing precision
If the roller rows are moved closer together, then the straightening effect is improved, but the risk of plastic deformation increases
Solution Approach 1:
The patent uses dynamic spacing control where the second roller row is positioned at a variable distance from the first roller row. This allows the system to apply stronger straightening effects (smaller spacing) only where needed while maintaining larger spacing in other areas, thereby achieving effective straightening without causing plastic deformation through excessive compression throughout the entire cable.
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
The solution provides precise and consistent straightening of cables, preventing plastic deformation and ensuring they can be inserted into predefined spaces without issues, thereby improving the efficiency of cable processing.
Implementation Method 1
A straightening device with a movable first and second row of rollers, equipped with a measuring device, such as an ultrasonic or laser sensor, to determine the cable diameter
Implementation Method 2
equipped with a measuring device, such as an ultrasonic or laser sensor, to determine the cable diameter
Implementation Method 3
The wires are typically supplied to the cable processing machine on reels or as bundles. In a first step, they are unwound from the reel or bundle. The unwound wires are more or less curved and twisted, which complicates further processing steps with the cable processing machine. To straighten the wire as much as possible, it is typically pulled through a straightening device.
Data Source
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AI summary
The invention relates to an aligning device (15) for straightening a line (11), comprising an aligning system (20) having a first row of rollers (21) and a second row of rollers (31) which can be moved relative to one another. The aligning device (15) comprises a measuring unit (40) for determining a line diameter and/or a tensile force measuring means (70). The invention also relates to a method for adjusting the aligning system (20) and a method for setting the aligning system (20), as well as a wire processing machine having at least one aligning device (15).