Induction-Welded Cable Tie Tool for Controlled Thermoplastic Bonding
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Solution Overview
Problem
Automated cable material installation tools face issues with sharp edge hazards and waste generation from ratchet heads, and difficulty in controlling weld quality due to rapid vibration and high clamping forces in ultrasonic welding.
Innovation Solution
A system featuring a pair of cable jaws with a dispensing track, a tensioning motor, an induction coil, and a power supply to securely wrap and bond thermoplastic cable material around elongate members using an electromagnetic field, with optional metallic or ferromagnetic inserts to enhance bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If ratchet head cable material installation is used, then automated cable bundling is achieved, but sharp edge hazards and large waste are produced
Solution Approach 1:
The patent replaces the mechanical ratchet head system with an induction welding system that uses electromagnetic fields to join cable material. The induction coil generates an electromagnetic field that heats and welds the thermoplastic cable material, eliminating the need for mechanical ratchet heads with sharp edges. This substitution maintains automation while removing the harmful sharp edge hazard.
2Strength
If ultrasonic welding is used, then cable material bonding is achieved, but weld quality is difficult to control due to rapid vibration and high clamping forces
Solution Approach 1:
The patent replaces ultrasonic welding (which uses mechanical vibration) with induction welding that uses electromagnetic fields. The induction coil generates an electromagnetic field that directly heats the thermoplastic cable material at the weld zone, melting and bonding the material without requiring rapid mechanical vibration or high clamping forces. This provides better control over weld quality.
Solution Approach 2:
The patent changes the welding mechanism from mechanical vibration-based (ultrasonic) to electromagnetic field-based (induction). By changing the fundamental parameter of how heat is applied - from mechanical energy conversion to direct electromagnetic heating - the system achieves controlled weld quality without the complications of rapid vibration and high clamping forces required in ultrasonic welding.
3Manufacturing precision
If induction welding with metallic insert is used, then controlled weld quality is achieved, but device complexity increases
Solution Approach 1:
The patent introduces a metallic or ferromagnetic insert as an intermediary element at the weld zone. This insert acts as a mediator that concentrates and enhances the electromagnetic field from the induction coil, improving heat generation and weld quality control. The insert is positioned between the overlapping cable material segments and facilitates more effective induction heating, achieving better weld control despite the added component.
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 system effectively bonds thermoplastic cable material without sharp edges or excessive waste, providing controlled and efficient cable bundling and tensioning, improving weld quality and reducing operational hazards.
Implementation Method 1
an induction coil to apply an electromagnetic field
Implementation Method 2
the insert is heated by the induction coil to bond the overlapping segment of thermoplastic cable material
Data Source
AI summary
A system includes a body having a pair of cable jaws. The pair of cable jaws further includes a dispensing track on an inner circumference of the pair of cable jaws to retain a segment of a thermoplastic cable material. The system includes a piston. The piston is configured to secure an overlapping segment of the thermoplastic cable material at the weld area. An induction coil is configured to apply an electromagnetic field. The system includes a power supply.