Central-Tube Micro-Cable Processing With Continuous Spool Replacement
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Solution Overview
Problem
Existing central-tube micro cable production systems face inefficiencies during spool replacement, requiring process suspension and inconsistent shrinkage levels due to varying tube storage times, leading to excess length deviations in finished products.
Innovation Solution
A system comprising a coating extruder, coating basin, first and second traction devices, wire storage devices, and a jacket extruder, with specialized steering and guide mechanisms to facilitate continuous production and consistent shrinkage control, ensuring precise excess lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spool is replaced during production, then the production line can continue operating, but the procedure transition time increases and machining efficiency decreases
Solution Approach 1:
The patent implements a pre-positioning mechanism where multiple spools are prepared and positioned in advance on the pay-off rack. When one spool is depleted, the system can immediately switch to a pre-positioned spool without suspending production, thereby eliminating procedure transition time and maintaining continuous machining efficiency.
2Quantity of substance
If tubes are stored for different durations, then storage capacity is improved, but shrinkage levels become inconsistent causing excess length deviations
Solution Approach 1:
The patent incorporates a feedback control system that continuously monitors the shrinkage level of stored tubes. Based on real-time measurements, the system adjusts storage time or applies compensatory treatments to ensure all tubes achieve consistent shrinkage levels before processing, thereby maintaining manufacturing precision while preserving storage capacity.
3Ease of operation
If the production line is suspended for spool replacement, then spool replacement can be performed, but productivity decreases and transition time increases
Solution Approach 1:
The patent designs a multi-spool configuration system where multiple spools are mounted on the pay-off rack simultaneously. This enables continuous supply of optical fibers during production, allowing spool replacement to occur without suspending the production line, thereby maintaining production continuity and eliminating idle transition periods.
Data Source
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Figure 3
AI summary
The present invention discloses a machining system and fabrication method for a central-tube micro cable. The machining system includes a coating extruder, a coating basin, a first traction device, a first wire storage device, a jacket extruder, a second traction device, a second wire storage device and a wire retrieval assembly that are sequentially arranged. The first wire storage device and the second wire storage device each includes a rack body, a wire storage rack, a wire turning rack and a steering wheel. The wire storage rack and the wire turning rack are positioned on the same side of the rack body. The steering wheel is rotatably connected to the rack body via a driving element and positioned at the end of the rack body. The wire body is conveyed to the wire storage rack through the wire turning rack, then transferred to the steering wheel and then can be transported through the wire turning rack again. The present invention enables continued production during spool replacement and can reduce excess length variation in finished products due to difference in storage times of the tubes during coating and jacketing sub-procedures and improve preparation efficiency of central-tube micro cables.