Conductor Foil Marking Assembly for Automated Heat-Weld Wrapping
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Solution Overview
Problem
Existing marking technologies for conductors require high manpower, are not suitable for automatic integration into conductor preparation devices, and face issues with legibility, surface curvature, and orientation dependence, with direct marking losing information upon conductor shortening.
Innovation Solution
A device with a gripper and heating jaw assembly that wraps and welds a foil tape around the conductor using a transport mechanism, ensuring a wrinkle-free, tight fit, and allowing for automatic integration into conductor preparation devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual marking techniques are used, then flexibility and adaptability are maintained, but productivity is low and manpower requirements are high
Solution Approach 1:
The patent combines the foil tape dispensing unit, heating jaw assembly, and gripper mechanism into an integrated marking device that can be mounted on conductor preparation equipment. This merging of functions enables automatic marking while maintaining compact dimensions suitable for integration into existing production lines, thereby increasing productivity without proportionally increasing overall system complexity.
Solution Approach 2:
The marking device is designed with universal applicability by featuring adjustable foil tape widths, programmable marking positions, and compatibility with various conductor types and diameters. The heating jaw assembly can accommodate different conductor sizes through adjustable clamping mechanisms, allowing a single device to perform multiple marking tasks across different product variants, thus improving productivity without requiring separate specialized equipment for each application.
2Manufacturing precision
If direct printing on conductor is used, then device complexity is reduced, but marking legibility and durability deteriorate due to surface curvature and color variations
Solution Approach 1:
The patent introduces a foil tape as an intermediary carrier for the marking information. Instead of printing directly on the conductor surface, the marking is first applied to the flat foil tape, which then wraps around the conductor. This intermediary approach ensures consistent marking legibility regardless of conductor surface curvature or color, as the foil tape provides a uniform, flat printing surface that can be precisely positioned and wrapped tightly around the conductor.
Solution Approach 2:
The foil tape is designed as a flexible thin film that can conform to the conductor's cylindrical surface while maintaining the flatness of the printed marking. The foil's flexibility allows it to wrap tightly around conductors of various diameters, ensuring the marking remains legible and durable. The thin film structure enables precise positioning and tight adhesion to the conductor surface without distorting the printed information.
3Reliability
If foil tape wrapping is used, then marking durability and legibility are improved, but device complexity and installation space requirements increase
Solution Approach 1:
The marking device is designed with a nested structure where the foil tape dispensing unit, heating jaw assembly, and gripper mechanism are arranged in a compact, space-efficient configuration. The heating jaws are positioned to close around the conductor with the foil tape already in place, creating a nested arrangement of functional elements. This nesting minimizes the overall footprint of the marking device, reducing installation space requirements while maintaining all necessary functions for durable foil tape marking.
4Extent of automation
If manual conductor preparation and marking are used, then adaptability to different conductor types is maintained, but productivity and automation level are low
Solution Approach 1:
The marking device incorporates dynamic, adjustable elements including programmable foil tape feed rates, adjustable heating jaw temperatures and pressures, and movable gripper positions. These dynamic features allow the automated system to adapt to different conductor types, diameters, and material properties without requiring manual reconfiguration. The system can be programmed with different parameters for various conductor specifications, maintaining versatility while achieving high-level automation through consistent, repeatable processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables fully automatic marking of conductors with improved legibility and durability, reducing manpower requirements and addressing issues related to surface curvature and orientation, while maintaining marking integrity even when the conductor is shortened.
Implementation Method 1
the two jaws in a closed position are configured to exert pressure on each other in the first transverse direction and to emit heat, and wherein portions of the weldable foil side of the foil tape are brought into abutment with each other or configured to abut each other under a pressure of the jaws and a heat of the jaws welds or is configured to weld portions
Implementation Method 2
heat is then applied by heating elements, which liquefies the adhesive of the foil at the contact point
Data Source
AI summary
A device for marking a conductor includes: a gripper for gripping the conductor extending in a longitudinal direction; a heating jaw assembly having two jaws spaced from each other in an open position in a first transverse direction transverse to the longitudinal direction; and a transport mechanism for dispensing a foil tape extending along the first transverse direction on a first side of the heating jaw assembly, a foil side of the foil tape facing away from the heating jaw assembly being weldable by heat and a foil side of the foil tape facing the heating jaw assembly including a marking of the conductor; and a gripper mechanism for moving the gripper along a second transverse direction transverse to the longitudinal direction and transverse to the first transverse direction when the heating jaw assembly is in the open position. The gripper moves the gripped conductor.