Cable Straightening Device Roller Distance Feedback
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Solution Overview
Problem
Existing straightening devices for cables in cable processing machines are prone to incorrect adjustments, leading to poorly finished cable ends, as they rely on manual settings that are error-prone and costly when automated.
Innovation Solution
A straightening device with a measuring and indicator system that allows for precise adjustment of roller distance and angle, using a measuring device connected to a control unit and an indicator device providing visual, acoustic, and tactile feedback to ensure correct alignment without high costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual adjustment of roller distance is used, then device complexity is reduced, but manufacturing precision deteriorates due to error-prone settings
Solution Approach 1:
The patent implements a feedback mechanism where a measuring device continuously monitors the actual roller distance and compares it with the target value. The indicator device provides visual feedback (green/red lights) to the operator, guiding manual adjustments until the correct distance is achieved. This closed-loop feedback system maintains high precision without requiring complex automated adjustment mechanisms.
Solution Approach 2:
The system enables the operator to perform self-service adjustment by providing real-time feedback on the roller distance. The measuring and indicator devices empower the user to independently achieve precise settings through intuitive visual guidance, eliminating the need for complex external control systems while maintaining high adjustment accuracy.
2Manufacturing precision
If fully automatic motor-driven adjustment is used, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
Instead of using complex motor-driven automatic adjustment, the patent employs a feedback-based manual adjustment system. The measuring device provides real-time information about the actual roller distance, and the indicator device guides the operator's manual adjustments. This approach achieves high precision through information feedback rather than through complex automated actuation mechanisms.
Solution Approach 2:
The patent introduces an intermediary information system (measuring device + indicator device) that mediates between the operator and the adjustment process. This intermediary provides the necessary precision information without requiring the operator to directly manage complex motor control systems, thus achieving high precision with simpler overall device architecture.
3Ease of operation
If manual adjustment without guidance is used, then ease of operation is reduced due to error-prone settings, but device complexity is minimized
Solution Approach 1:
The patent significantly improves ease of operation by implementing real-time feedback through the indicator device. The visual signals (green light for correct distance, red light for incorrect distance) provide intuitive guidance to the operator, making the adjustment process straightforward and error-free. This feedback mechanism adds minimal complexity while dramatically improving operational ease.
Solution Approach 2:
The patent uses color changes (green and red lights) to provide intuitive visual feedback during adjustment. The green light clearly indicates when the correct roller distance is achieved, while the red light indicates when adjustment is needed. This simple color-coded signaling system greatly enhances ease of operation without requiring complex user interfaces or control systems.
Data Source
AI summary
A straightening device for straightening cables includes two rows of rollers, an adjusting device for manually adjusting a distance between the rows of rollers, a measuring device for recording the distance between the rows of rollers, and an indicator device with which deviations of the actual value of the distance between the rows of rollers, determined by the measuring device, from a nominal value is visually indicated. The indicator device has two optical error indicating elements for indicating too high and/or too low an actual value compared with the nominal value of the distance, as well as an optical ‘correct’ indicating element for indicating that the actual value of the distance corresponds with the nominal value.