CNC Cable Bending Machine Reducing Last Leg Length
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Solution Overview
Problem
Current CNC cable bending machines with integrated saws are limited by a fixed minimum last leg length, requiring a secondary trim operation to cut semi-rigid coax cable, which increases costs and inefficiencies.
Innovation Solution
The CNC cable bending machine is modified to allow the cable to be repositioned and cut closer to the bend die by retracting the wiper roller and clamp, shifting the cable out of the bend plane, and pulling it back to reduce the last leg length, eliminating the need for a secondary trim.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the saw blade is positioned at a fixed distance from the bend die to ensure accurate cutting, then cutting precision is improved, but the minimum last leg length increases requiring secondary trim operations
Solution Approach 1:
The system dynamically adjusts the position of the saw blade relative to the bend die by moving the carriage along the rail. The carriage can be positioned at different locations along the rail to accommodate different last leg length requirements, transforming a fixed-distance limitation into a dynamic, adjustable system that maintains cutting precision while enabling shorter last leg lengths
Solution Approach 2:
The cutting process is segmented into multiple possible positions along the rail. Instead of a single fixed cutting position, the system divides the cutting space into multiple segments corresponding to different carriage positions, allowing selection of the optimal position based on the required last leg length while maintaining accurate cutting
2Loss of substance
If the cable is pulled backwards to reduce last leg length, then material usage is improved, but the bent cable profile becomes distorted
Solution Approach 1:
The cable is repositioned to the correct cutting position before the bending operation is completed. By preliminarily adjusting the cable position while it is still accessible and not yet fixed in its final bent configuration, the system enables shorter last leg lengths without distorting the finished cable profile
Solution Approach 2:
The system uses dynamic control of the carriage position to manage cable retraction. The carriage moves the cable to precise positions along the rail, enabling controlled retraction to reduce last leg length while maintaining the integrity of the bent profile through computer-coordinated motion
3Manufacturing precision
If a secondary trim operation is performed to achieve required last leg length, then manufacturing precision is improved, but production time and cost increase
Solution Approach 1:
The positioning and cutting functions are merged into a single integrated operation. The carriage positions the cable and the saw blade cuts it in one coordinated action, combining what would otherwise be separate positioning and trimming operations into a single efficient step that achieves precise last leg length without requiring secondary trimming
Solution Approach 2:
The carriage-saw assembly serves multiple functions: it positions the cable, positions the saw blade, and performs the cutting operation. This multi-functional system replaces the need for separate positioning and trimming operations, reducing production time while maintaining precision
Data Source
AI summary
A computer numerical control (cnc) bending machine used to bend and then cut a specific programmed profile from a long length of cable comprising: a base, a carriage, a bend head and a saw; the carriage includes a spindle to rotate the cable, the carriage is also able to transport the cable in a linear fashion; the bend head comprises a clamp and a wiper roller and a bend die; after a last bend is formed, the clamp and wiper roller are retracted away from the bend die; the carriage is then able to then transport the cable forward away from the saw, the spindle is then able to rotate the cable out of the plane of the bend, the carriage is then able to transport the cable back toward the saw; the saw is then able to sever the cable such that a last leg length adjacent to the last bend which is shorter than the fixed distance between the saw and the bend die.