Cable Twisting Machine for Flexible Looped Wire Sequences
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Solution Overview
Problem
Existing cable processing machines are limited in their ability to produce flexible and varied cable sets and harnesses, as they are optimized for large quantities of the same twisted cable group, making it difficult to economically produce loop-shaped cables with continuous twisting and requiring pre-twisted cable groups, which are expensive.
Innovation Solution
A cable processing machine with a control unit, cable tip processing, handling system, and twisting station that can process looped cables to create twisted cable groups in a predefined sequence, allowing for flexible production of individual cables and twisted or stranded cable groups, reducing the need for pre-twisted materials and enabling continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If machines are optimized for large quantities of the same twisted cable assemblies, then production efficiency for fixed batch sizes is improved, but flexibility to produce varied cable sequences deteriorates
Solution Approach 1:
The patent implements a dynamic production system where the cable processing machine can be reconfigured through software control to produce different cable sequences, combinations, and specifications. The system transitions from static batch production to dynamic on-demand production, allowing the same machine to efficiently produce varied cable assemblies by changing production parameters rather than physical reconfiguration
Solution Approach 2:
The invention changes production parameters such as cable selection criteria, twisting specifications, and sequence arrangements through programmable control. By modifying these parameters software-controlled, the system achieves versatility without sacrificing productivity, as the same hardware platform can rapidly adapt to different production requirements through parameter adjustment
2Ease of manufacture
If pre-twisted cable groups are used, then production cost is reduced, but the need for additional processing steps increases
Solution Approach 1:
The patent merges the cable cutting, cable twisting, and cable assembly operations into a single integrated processing machine. This consolidation eliminates the need for separate pre-twisting operations and reduces the number of processing steps required, as all operations are performed in one continuous process within the same equipment platform
Solution Approach 2:
The system performs preliminary cable preparation actions including cutting and positioning cables to exact specifications before twisting. This preliminary action ensures that cables are ready for immediate twisting without requiring pre-twisted materials, reducing both cost and processing complexity by preparing cables in their final configuration before the twisting operation
3Adaptability or versatility
If looped cables are twisted continuously from one end to the other, then production flexibility is improved, but the complexity of moving the loop's reversal point increases
Solution Approach 1:
The patent extracts the reversal point movement function from the cable itself and transfers it to the machine's control system. By programmatically controlling which end of the loop is processed and in what sequence, the system achieves continuous twisting flexibility without physically moving the reversal point, simplifying the mechanical complexity while maintaining production adaptability
Data Source
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AI summary
The invention relates to a cable processing machine (1) for producing a predefined sequence of twisted cable groups (2, 2e, 2f, 2g), wherein the cable processing machine (1) comprises a control unit, a cable tip processing unit (10) for processing a cable, a handling system (40) and a twisting station (30).