Funnel System for Shielded Cable Sleeve Installation
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Solution Overview
Problem
The manual process of installing solder sleeves on shielded cables is labor-intensive, prone to damaging the exposed shield, and involves high variability due to internal components and large tolerance values, leading to inconsistent quality and increased labor costs.
Innovation Solution
An automated system using a funnel system with robotic end effectors and grippers to feed the shielded cable through a solder sleeve, ensuring a smooth surface for the cable to slide through and preventing damage, while a computer-controlled system positions and melts the sleeve in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a manual process is used to install solder sleeves on shielded cables, then flexibility and adaptability are maintained, but labor intensity increases and quality consistency deteriorates
Solution Approach 1:
The automated installation system is divided into distinct functional modules: a funnel system for guiding the cable, a heating element for melting the sleeve, and a control system for coordinating operations. This segmentation allows each component to perform its specific function efficiently while maintaining overall system manageability despite the automation complexity.
2Object-affected harmful factors
If a protective jacket slug is used to prevent shield damage during sleeve installation, then shield protection is improved, but the number of processing steps increases and cycle time extends
Solution Approach 1:
The protective jacket slug is completely removed from the process. Instead of using a separate protective element that must be installed and then removed, the funnel system directly guides the cable through the sleeve installation process without requiring any protective slug, thereby eliminating the associated processing steps and reducing cycle time while still preventing shield damage.
Solution Approach 2:
The funnel system acts as an intermediary between the cable and the solder sleeve. It provides a controlled pathway that guides the cable through the sleeve installation process, preventing direct contact between the cable shield and potentially damaging elements, thus replacing the need for a protective jacket slug.
3Ease of manufacture
If large tolerance values are used for solder sleeves to accommodate variability, then manufacturing ease is improved, but the risk of shield damage increases due to internal component snagging
Solution Approach 1:
The funnel system serves as a mediator that controls the interaction between the cable and the solder sleeve. It ensures proper alignment and guided insertion, preventing the cable shield from snagging on internal components of the sleeve even when large tolerance values are used. This intermediary mechanism allows the benefits of manufacturing flexibility while protecting against reliability issues.
Solution Approach 2:
The funnel system prepares the path for cable insertion before the actual sleeve installation occurs. By pre-positioning and guiding the cable through the funnel, the system ensures that the cable is properly aligned and protected before it encounters the solder sleeve and its internal components, preventing snagging and damage.
4Manufacturing precision
If multiple separate steps are used to score and remove jacket segments, then precise control is achieved, but the number of operations increases and labor cost rises
Solution Approach 1:
The funnel system combines multiple functions into a single integrated component: it guides the cable, positions the solder sleeve, and facilitates the melting process. This consolidation eliminates the need for separate operations to score and remove jacket segments, maintaining precision while significantly improving productivity by reducing the number of discrete steps required.
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
The automated process ensures repeatable and consistent quality, reduces labor costs, and minimizes the risk of damaging the shield or conductors during sleeve installation.
Implementation Method 1
positioned at a distance from the funnel extension, and heating the sleeve in the processing zone until the sleeve is melted over the exposed shield
Data Source
AI summary
A method utilizes a funnel system and robotic end effector grippers to feed an unjacketed portion of a shielded cable through a sleeve. The funnel is designed with one or more thin extensions (hereinafter “prongs”) on which a sleeve is placed prior to a cable entering the funnel. Preferably two or more prongs are employed, although a single prong may be used if properly configured to both guide a cable and fit between the sleeve and cable. The prongs close off the uneven surface internal to a sleeve and provide a smooth surface for the cable to slide along and through the sleeve, preventing any damage to the exposed shielding. The sleeve is picked up and held on the prongs using a robotic end effector. If the sleeve is a solder sleeve, the robotic end effector has grippers designed to make contact with the portions of the solder sleeve that are between the insulating rings and the central solder ring.