Cable Wire Selection for Precise Automated Tip Processing
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Solution Overview
Problem
The manufacturing of electronic connectors requires various processing steps for cable wires, such as insulated jacket cracking, shield trimming, and contact crimping, which are often labor-intensive and prone to errors.
Innovation Solution
An automated method for cable wire processing involves a cable selection tool that moves to contact a set of cable wires, selectively positioning one wire for processing while bending others out of the way, allowing for efficient application of processing operations within a defined working region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated cable wire processing is implemented, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The automated cable wire processing system is divided into distinct functional modules: a cable wire holder for positioning, a cable selection tool for identification and selection, and a tip processing tool for execution of processing operations. This segmentation allows each module to perform its specific function independently, improving overall productivity while managing device complexity through modular design.
Solution Approach 2:
The cable selection tool is designed to perform multiple functions: it selects cable wires based on their positions, guides them to appropriate processing stations, and coordinates with the tip processing tool. This multi-functionality reduces the need for separate dedicated devices for each task, thereby improving productivity without proportionally increasing device complexity.
2Manufacturing precision
If manual cable wire processing is used, then device complexity is low, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The system incorporates position detection capabilities that monitor the location of cable wires and provide feedback to the control system. This feedback mechanism ensures that the cable selection tool accurately identifies and selects the intended cable wire, and that the tip processing tool applies processing operations with high precision, thereby improving manufacturing precision through automated control.
Solution Approach 2:
The cable selection tool automatically identifies and selects cable wires based on their positioned locations without requiring manual intervention. The system self-regulates the selection and processing sequence, ensuring consistent manufacturing precision while reducing human error, though this automation increases device complexity compared to manual processing.
3Productivity
If multiple cable wires are processed simultaneously, then productivity increases, but measurement precision and control difficulty increase
Solution Approach 1:
The processing system handles multiple cable wires by segmenting them into individually addressable positions on the cable wire holder. The cable selection tool sequentially or selectively processes cable wires at different positions, maintaining measurement precision for each individual wire while achieving high overall productivity through parallel capability of the system architecture.
Solution Approach 2:
The system applies different processing operations to different local positions of cable wires based on their specific requirements. The cable selection tool identifies cable wires at specific positions and directs them to appropriate processing stations, ensuring that each cable wire receives the correct processing with high precision while maintaining high throughput by handling multiple positions simultaneously.
Data Source
AI summary
A method for automated cable wire processing includes receiving a set of two or more cable wires, including at least a first cable wire positioned at a selection position, and a second cable wire positioned away from the selection position. A cable selection tool is automatically moved to contact the set of two or more cable wires, such that contact between the cable selection tool and the first cable wire causes a tip portion of the first cable wire to extend into a working region, and contact between the cable selection tool and the second cable wire moves a tip portion of the second cable wire outside of the working region. One or more tip processing operations are applied to the tip portion of the first cable wire within the working region.