Automated Cable Bundle Winding Device with Segmented Tensioning
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Solution Overview
Problem
Existing methods for wrapping adhesive tape around cable bundles are not fully automated, leading to inefficiencies and potential human intervention, which can affect the quality and consistency of the wrapping process.
Innovation Solution
A winding device with a rotating outer ring and winding rotor, tensioning device, infeed unit, feed unit, and control device that allows for fully automated wrapping of cable bundles with adhesive tape, including a cutting unit for seamless tape management and centering mechanisms to ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automated methods are used for wrapping adhesive tape around cable bundles, then device complexity is reduced, but productivity and manufacturing precision deteriorate due to human intervention and inconsistency
Solution Approach 1:
The wrapping device is divided into distinct functional modules: a tensioning device with separate grippers for clamping and tensioning, a winding unit with an independent winding rotor, a feed unit for tape supply, and a control unit. Each module operates semi-independently, allowing for modular automation that improves productivity while managing complexity through functional separation.
Solution Approach 2:
The winding rotor is designed to automatically wind the adhesive tape around the cable bundle through its own rotational movement, while the tensioning device automatically maintains consistent tension. The system feeds and wraps the tape through self-contained mechanical actions controlled by a program, reducing the need for continuous human intervention and thereby increasing productivity.
2Manufacturing precision
If manual wrapping methods are used, then device complexity is lower, but manufacturing precision and quality consistency worsen due to human variability
Solution Approach 1:
The control unit receives signals from sensors that monitor the wrapping process, including the position of the winding rotor, the tension applied by the tensioning device, and the feed rate of the adhesive tape. This feedback enables the control unit to adjust parameters in real-time, ensuring consistent wrapping quality and precision while managing the complexity through automated closed-loop control.
Solution Approach 2:
The system maintains manufacturing precision by dynamically adjusting critical parameters such as the rotational speed of the winding rotor, the tension force applied by the tensioning device, and the feed rate of the adhesive tape. These parameter changes are controlled automatically to ensure consistent wrapping quality across different cable bundles, overcoming the limitations of manual wrapping variability.
3Manufacturing precision
If a tensioning device is added to pretension the cable bundle, then manufacturing precision of wrapping improves, but device complexity increases
Solution Approach 1:
The tensioning device is segmented into two independent grippers: a first gripper for clamping the cable bundle and a second gripper for applying tension. This segmentation allows each gripper to perform its specific function optimally, improving wrapping uniformity while managing the complexity through functional division rather than a single complex tensioning mechanism.
Solution Approach 2:
The tensioning device employs dynamic control where the second gripper can be moved along the cable bundle to apply tension at different positions, and the tension force can be adjusted during the wrapping process. This dynamic adjustment capability ensures uniform wrapping precision while the automated control manages the complexity of the moving and force-applying mechanisms.
Data Source
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AI summary
The invention relates to a winding device (2) for fully automated wrapping of a cable bundle (17) with an adhesive tape (19), comprising a winding unit (4) with an outer ring (5) open on one side, on the inside of which an annular winding rotor (6) open on one side is rotatably arranged relative to the outer ring about an axis of rotation extending in the longitudinal direction (x) of the winding device (2), wherein a holder (7) for receiving an adhesive tape roll (8) is rotatably attached to the winding rotor (6); a clamping device for clamping the cable bundle (17) in the longitudinal direction of the winding device (2); a feed unit (13) by means of which the winding unit (4) is movable transversely to the longitudinal direction (x) of the winding device (2) between a working position in which the winding unit (4) encloses the clamped cable bundle (17) and a retracted position in which the clamped cable bundle (17) is arranged outside the winding unit (4);A feed unit (15) by means of which the winding unit (4) can be moved in the longitudinal direction of the winding device (2); a control device by means of which the winding unit (4), the clamping device, the feed unit (13) and feed unit (15) can be controlled for fully automated wrapping of the cable bundle (17). The invention further relates to a method for fully automated wrapping of a cable bundle (17) with an adhesive tape (19).