Integrated Cable Winder for Processing Time Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable processing machines face difficulties in handling long cable sections efficiently, leading to increased processing time and mechanical issues such as uncontrollable bending radii and high cable tensile forces during transport.
Innovation Solution
A device and method that integrates a winder with a rotating winding plate and a laying unit, allowing for simultaneous processing and winding of cable ends, with a belt drive to measure and advance cable length, and pneumatically controlled clamping to manage the coil, enabling parallel processing and efficient transfer without increasing total processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate winding device is used downstream of the cable processing machine, then the cable section can be wound into a coil, but the cycle time or total processing time increases correspondingly long
Solution Approach 1:
The patent combines the winding device with the cable processing machine into an integrated unit. The winding device is positioned downstream of the processing stations within the same machine frame, allowing the cable to be processed at the stations and then immediately wound into a coil without being transferred to a separate device. This integration eliminates the time delay associated with separate winding operations while maintaining proper coil formation quality.
2Device complexity
If the drum remains stationary while the cable is being pushed in, then there are few moving masses, but uncontrollable bending radii occur when the various winding layers are pushed in and pressed together
Solution Approach 1:
The patent employs a rotating winding drum instead of a stationary one. The drum rotates in the direction of cable winding, dynamically adapting to the winding process. This rotation allows the cable to be guided smoothly onto the drum surface, ensuring consistent bending radii across all winding layers. The dynamic motion of the drum prevents the cable from being forced or pressed together uncontrollably, maintaining precision while keeping the mechanical design relatively simple.
3Ease of manufacture
If there are no minimum bending radii when the cable enters and exits the drum, then the winding process is simpler, but the cable may be damaged or the coil quality deteriorates
Solution Approach 1:
The patent implements guided cable entry and exit paths with specific geometric configurations that enforce minimum bending radii. Guide rollers and support elements are positioned to create optimal cable routing, ensuring that the cable maintains appropriate curvature throughout the winding process. This controlled parameter approach (bending radius) prevents cable damage and maintains coil quality without significantly complicating the winding process.
4Length of moving object
If long cable sections are handled with conventional machines, then the cable tray must be as long as the cable section, but this increases the machine size and handling difficulty
Solution Approach 1:
The patent segments the cable handling process into distinct functional zones within the integrated machine. The cable processing stations are arranged in sequence along the cable path, with each station handling a specific task. The winding drum is positioned at the end of this sequence, creating a compact linear arrangement that accommodates long cable sections without requiring an excessively long overall machine structure. This segmented approach allows efficient handling of long cables while controlling machine footprint.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The device has a storage unit (23) whose winding gripper (22) holds a coil. A joining unit (27) provides the coil with a beam. The storage unit is movable between the coil and the storage, using a linear guidance (29) and a drive (28). The joining device is arranged at the storage unit. A band station has a band gripper with a blade for holding and cutting of the band. The band lies around the coil using roll grippers. An independent claim is also included for a method for receiving a winder and for transporting to storage of a coiled cable section.