Cable Tip Sensing for Thermally Stable Crimping Alignment
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Solution Overview
Problem
Existing wire processing machines face challenges in maintaining precise alignment of cable tips during crimping due to heat-related expansion of the machine frame, which causes positional drift, and existing solutions are either unsuitable for detecting changes or require complex and resource-intensive image recognition systems.
Innovation Solution
A wire processing machine equipped with a crimping press, a wire feeder, and a wire tip sensor that detects the cable tip's presence using a sensor plane, allowing for precise movement and alignment, even under changing environmental conditions, using a cable tip sensor integrated into a waste channel or with optical detection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image recognition-assisted positioning is used to detect cable end position, then positioning accuracy can be improved, but device complexity and computational requirements increase significantly
Solution Approach 1:
The patent extracts the detection function from complex image recognition systems and implements it through a simple optical sensor that detects only the presence or absence of the cable end at a specific detection location. This separates the essential detection function from unnecessary complexity, achieving accurate positioning without requiring powerful computational hardware or complex optical systems.
Solution Approach 2:
The patent replaces expensive, complex image recognition systems with inexpensive, simple optical sensors. The simple sensor provides sufficient detection capability for cable end positioning without requiring powerful processors or complex algorithms, significantly reducing system cost and complexity while maintaining adequate measurement precision.
2Reliability
If complex lighting and optical sensors are mounted close to ensure reliable detection, then detection reliability is improved, but ease of manufacture and installation deteriorates
Solution Approach 1:
The patent introduces an intermediary detection location that is spatially separated from the crimping process location. The cable end is detected at the detection location, then the cable feed device transports it to the crimping process location. This intermediary step allows the sensor to be mounted in a convenient, accessible position rather than requiring precise mounting close to the crimping tool, significantly easing manufacturing and installation.
Solution Approach 2:
The patent divides the cable processing into separate stages: detection at a first location, then transport to a second crimping location. This segmentation allows the optical sensor to be positioned independently from the crimping tool, making the system easier to manufacture and assemble while maintaining reliable detection through the separated detection stage.
3Device complexity
If adapter plate alignment gauge system is used for manual positioning, then device complexity is reduced, but manufacturing precision and alignment accuracy deteriorate under thermal drift conditions
Solution Approach 1:
The patent implements an automated feedback system where the optical sensor detects the cable end position, and this detection information is used by the control device to automatically adjust the cable feed device's movement. This closed-loop feedback ensures precise alignment compensation for thermal drift without requiring complex manual adjustment mechanisms, maintaining high precision while keeping the system relatively simple.
Solution Approach 2:
The patent replaces manual mechanical alignment systems with an automated system combining simple optical detection and computer-controlled movement. The control device automatically processes sensor signals and adjusts cable positioning, eliminating the need for complex manual alignment gauges and operator intervention, thereby maintaining precision while reducing operational complexity.
Data Source
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AI summary
A cable processing machine (100) comprises a crimping press (150), wherein the crimping press (150) comprises a process location (P) at which a crimping operation of a crimp contact (20) located in the crimping press (150) onto an end region (11) of a cable (10) can be carried out; a cable feeding device (120) with a cable holder (125), wherein the cable holder (125) is configured to grip the end region (11) of the cable (10);and a cable tip sensor (160) which is fixed to the crimping press (150) at a detection location (E), wherein the detection location (E) is in a known positional relation to the process location (P), and wherein the cable tip sensor (160) is configured to detect a cable tip (15) at the end region (11) of the cable (10) in a sensor plane (162) of the cable tip sensor (160), wherein the cable feed device (120) is configured to move the end region (11) of the cable (10) to the detection location (E) and to move the cable tip (15) towards the sensor plane (162) of the cable tip sensor (160) until the cable tip (15) is detected in the sensor plane (162), and thereafter to move the end region (11) of the cable (10) to the process location (P) of the crimping press (150). moved.;