Electrical Cable Shield Braid Folding With Forming Sleeve
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Solution Overview
Problem
Existing methods for processing electrical cable shield braids lack flexibility and do not provide satisfactory results, especially with asymmetrical cable structures, leading to issues such as protrusion beyond connector components and poor electrical contact.
Innovation Solution
A method involving brushing the cable shield braid in the direction away from the processing end, using a molded sleeve to define a folding position that deviates from the stripping position, and incorporating a stop surface to improve folding and contact with connector components, allowing for various cable types and geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pliers-like tool is used to radially expand and bend the cable shield braid, then the cable shield braid can be folded, but the method is not suitable for all connector types and does not always lead to satisfactory results, particularly with multi-core cables with an asymmetrical cross-section
Solution Approach 1:
The device employs a rotatable brush assembly that can dynamically adjust its orientation and rotation direction to accommodate different cable geometries and connector types. The brush rotates in the direction opposite to cable feed, and this rotational direction can be changed to handle asymmetrical cable structures effectively.
Solution Approach 2:
The invention changes the physical state and motion parameters of the brush tool - specifically its rotation direction and angular orientation - to adapt to different cable configurations. By reversing the brush rotation direction, the system can handle both symmetrical and asymmetrical cable cross-sections.
2Ease of operation
If the cable shield braid is folded directly onto the cable sheath, then the process is simple, but it does not allow for the insertion of a support sleeve or other connector component between the cable sheath and the cable shield braid
Solution Approach 1:
The device performs preliminary actions by first brushing the cable shield braid straight out and then folding it backwards over the cable sheath before support sleeve insertion. This sequence of operations prepares the cable shield braid in a controlled manner to accommodate subsequent assembly steps.
Solution Approach 2:
The invention inverts the conventional folding sequence by first folding the cable shield braid backwards over the cable sheath, and only then inserting the support sleeve. This reversed sequence enables proper assembly while maintaining operational simplicity.
3Adaptability or versatility
If manual brushing with rotating brushes is used to fold the cable shield braid, then the method can be suitable for asymmetrical cable structures, but it is difficult to automate for mass production
Solution Approach 1:
The brush assembly is designed to automatically adjust and self-regulate during operation. The brush rotates in the direction opposite to cable feed and automatically adapts to the cable geometry, eliminating the need for complex manual intervention while maintaining effectiveness on asymmetrical structures.
Solution Approach 2:
The invention replaces manual mechanical brushing operations with an automated brush mechanism driven by controlled rotation in the direction opposite to cable feed. This substitution maintains the effectiveness of manual brushing while enabling automation for mass production.
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
Enhances flexibility in processing cable shield braids, ensuring proper contact with connector components and preventing protrusion, thereby maintaining electrical integrity and assembly efficiency.
Implementation Method 1
a cable shield braid of the cable, which is exposed along a longitudinal axis of the cable starting from a cable end to be processed up to a first stripping position, is folded by brushing by means of at least one drivable brush in the direction of a cable end facing away from the cable end to be processed
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for processing an electrical cable (2), according to which a braided cable shield (6) of the cable (2), which is exposed along a longitudinal axis (L) of the cable (2) from a cable end (5) which is to be processed to a first stripping position (PA1), is, by means of brushing with at least one drivable brush (10), folded back towards a cable end facing away from the cable end (5) to be processed. According to the invention, a defined fold-back position (PU) for the braided cable shield (6) is determined along the longitudinal axis (L) of the cable (2). Before and/or during brushing, a front end of the forming sleeve (12), said front end facing the cable end (5) to be processed, is placed onto the cable (2) and positioned at the fold-back position (PU) in order to fold back the braided cable shield (6) onto the forming sleeve (12) starting from the fold-back position (PU). According to the invention, the fold-back position (PU) is determined in such a way that the fold-back position (PU) deviates from the first stripping position (PA1) and/or that the forming sleeve (12) has an end-face stop surface (20) for the braided cable shield (6).