Optical Fiber Cable Production Line Integration
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Solution Overview
Problem
The existing optical fiber cable production process is inefficient due to separate cable producing and sheathing processes, leading to manual intervention, equipment stoppages, and low packaging efficiency, with the cable core needing separate storage and handling, resulting in suboptimal production efficiency.
Innovation Solution
A method and system for continuously producing optical fiber cables by integrating the cable core producing and sheathing processes, using a first cable storing device to manage cable core storage and tension, a cable rolling device for automatic winding, and a sealing device for efficient tray sealing, allowing for combined production and reduced manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cable producing process and sheathing process are kept separate, then each process can be independently controlled, but production efficiency is reduced due to manual intervention and equipment stoppages
Solution Approach 1:
The patent merges the cable producing process and sheathing process into a single integrated production line. The cable core produced by the cable producing equipment is directly conveyed to the sheath extrusion device without intermediate storage or manual handling. This integration eliminates the need for separate process control while maintaining operational simplicity, thereby resolving the contradiction between independent process control and production efficiency.
Solution Approach 2:
The integrated production line enables continuous operation where the cable core is produced and immediately processed through sheathing without interruption. The system maintains continuous material flow from the cable producing equipment through the sheath extrusion device to the cable rolling device, eliminating stoppages and manual intervention points that would otherwise break the continuous action.
2Adaptability or versatility
If manual intervention is used for cable core handling and storage, then flexibility in dealing with production issues is improved, but production efficiency decreases due to time-consuming manual operations
Solution Approach 1:
The system implements automated self-service mechanisms where the cable core is automatically conveyed from the cable producing equipment through the sheath extrusion device to the cable rolling device. The integrated line automatically manages material flow, tension control, and process coordination without requiring manual intervention, thereby maintaining adaptability while dramatically improving production efficiency.
Solution Approach 2:
The patent introduces an automated conveying system as an intermediary between the cable producing equipment and sheath extrusion device. This intermediary mechanism automatically handles the cable core, eliminating the need for manual handling while maintaining the flexibility to deal with production issues through automated control systems.
3Adaptability or versatility
If the cable core is stored in a warehouse and then taken out for sheathing, then production scheduling flexibility is improved, but production efficiency is reduced due to additional handling and conveyance steps
Solution Approach 1:
The integrated production line eliminates the warehouse storage step entirely by maintaining continuous material flow from cable producing equipment directly to the sheath extrusion device. This continuous action removes the interruption and additional handling that would occur with warehouse storage, thereby improving production efficiency while automated control systems maintain scheduling flexibility.
Solution Approach 2:
The patent extracts and eliminates the intermediate warehouse storage step from the production process. By removing this unnecessary intermediate stage, the system achieves direct conveyance from production to processing, eliminating handling time and improving efficiency while automated scheduling systems preserve the needed flexibility.
4Ease of operation
If equipment speed is reduced for manual tray unloading and loading, then manual operation feasibility is maintained, but production efficiency decreases due to speed limitations
Solution Approach 1:
The cable rolling device implements automated tray handling that performs unloading and loading operations without manual intervention. The device automatically receives the optical fiber cable from the sheath extrusion device, rolls it at the tray, and manages tray exchange, thereby eliminating the need to reduce equipment speed for manual operations while maintaining operational simplicity.
Solution Approach 2:
The automated cable rolling device acts as an intermediary between the sheath extrusion device and the finished product, handling tray operations automatically. This intermediary mechanism eliminates the bottleneck of manual tray unloading and loading, allowing the main production equipment to maintain high speed while automated systems manage the tray exchange process.
5Manufacturing precision
If manual packing and sealing operations are performed, then quality control is improved through inspection, but packaging efficiency remains relatively low
Solution Approach 1:
The sealing device implements automated sealing operations that perform quality control and packaging without manual intervention. The device automatically applies sealing plates to the finished optical fiber cable trays, maintaining quality standards through consistent automated application while dramatically improving packaging efficiency by eliminating manual operation bottlenecks.
Data Source
AI summary
A method for continuously producing an optical fiber cable includes: producing a cable core through cable core producing equipment; conveying the produced cable core to a first cable storing device; conveying the cable core from the first cable storing device to a sheath extrusion device, wherein an exterior of the cable core is covered with a sheath, and the optical fiber cable is obtained by processing; receiving the optical fiber cable from the sheath extrusion device by a cable rolling device, wherein the optical fiber cable is rolled at a tray, and a finished tray rolled with the optical fiber cable is obtained; checking whether the finished tray rolled with the optical fiber cable is qualified, and carrying an unqualified finished tray rolled with the optical fiber cable to a repairing area for repairing until qualified; and fixing sealing plates at a qualified finished tray through a sealing device.