Cable Tip Sensing for Precise Crimping Under Thermal Drift
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable processing machines struggle to maintain 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 and correcting this drift or are impractically expensive and computationally intensive.
Innovation Solution
A cable processing machine equipped with a crimping press, a cable feeding device, and a cable tip sensor that moves the cable end to a detection location to ensure accurate positioning, using a known positional relationship to correct the target value for crimping, and employs either capacitance or optical detection methods to reliably align the cable tip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image-recognition-aided positioning with optical sensors is used to detect cable tip position, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex optical sensing systems with a simple mechanical reference edge on the adapter plate. The cable tip sensor detects the cable tip position mechanically relative to this reference edge, eliminating the need for mounted optical sensors and complex lighting systems while maintaining sufficient measurement precision for the application.
Solution Approach 2:
The patent uses a simple, inexpensive adapter plate with a reference edge instead of expensive optical sensor systems. The adapter plate serves as a disposable or replaceable component that provides the necessary reference for position detection without requiring costly optical infrastructure.
2Measurement precision
If image-recognition-aided positioning with complex lighting and optical sensors is implemented, then measurement precision is improved, but loss of time increases due to computationally intensive image evaluation
Solution Approach 1:
The patent replaces computationally intensive image recognition with simple mechanical detection. The cable tip sensor directly detects the physical position of the cable tip relative to the reference edge on the adapter plate, providing immediate feedback without requiring computational image processing.
Solution Approach 2:
The adapter plate with its reference edge serves itself as the measurement standard. The reference edge is directly visible to the cable tip sensor, eliminating the need for external lighting systems and complex detection algorithms. The system uses readily available light and simple sensor detection instead of active illumination and image processing.
3Ease of operation
If hand adjustment of adapter plate is used to position cable tip, then ease of operation is improved, but manufacturing precision deteriorates due to inability to compensate for thermal drift
Solution Approach 1:
The patent introduces a feedback mechanism where the cable tip sensor continuously monitors the actual position of the cable tip relative to the reference edge on the adapter plate. The control system uses this feedback information to automatically adjust the cable holder position, compensating for thermal drift and maintaining precise insertion depth without requiring manual intervention.
Solution Approach 2:
The patent dynamically adjusts the position of the cable holder based on detected positional drift. The system monitors changes in cable tip position over time and modifies the cable holder's position accordingly to maintain the required insertion depth precision, adapting to thermal expansion and contraction of the machine frame.
4Measurement precision
If sensor is mounted close to process location for reliable detection, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the need for mounting sensors close to the process location with a mechanical reference system. The reference edge on the adapter plate provides a stable reference that extends the detection zone, allowing the cable tip sensor to be mounted at a more convenient location while maintaining reliable detection through the reference edge alignment.
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
Ensures reliable longitudinal alignment of the cable end in the crimp contact, even under changing environmental conditions, by accurately detecting and correcting for positional changes, thus maintaining the required precision of 0.1 mm insertion depth.
Implementation Method 1
employs either capacitance or optical detection methods to reliably align the cable tip
Implementation Method 2
employs either capacitance or optical detection methods to reliably align the cable tip
Data Source
AI summary
A cable processing machine includes a crimping press that includes a process location at which a crimping operation of a crimp contact located in the press can be performed on a cable end region; a cable feeding device having a cable holder configured to grip the cable end region; and a cable tip sensor fixed to the press at a detection location different from the process location and having a known positional relationship to the process location. The sensor is configured to detect a cable tip at the cable end region in a sensor plane of the sensor. The cable feeding device is configured to move the cable end region to the detection location and there to advance the cable tip towards the sensor plane until the cable tip is detected in the sensor plane, and thereafter moves the cable end region to the process location of the press.