Laser Cable Diameter Monitoring to Prevent Wire-Cutter Jamming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable production methods result in cables with insulation layers outside tolerance limits, leading to potential damage to machinery due to jamming, belt destruction, or electrical hazards, and existing solutions have not adequately addressed these issues.
Innovation Solution
A cable abnormality detection system using a laser sensor measurement system, roller assembly, and control system with memory and processor to measure cable diameter and insulator jacket thickness, comparing these measurements to tolerance limits and initiating remedial actions such as stopping the cable or sending alerts when out of tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cable production processes are used without precision control, then production speed and flexibility are improved, but cable insulation layer thickness varies outside tolerance limits causing machinery damage
Solution Approach 1:
The patent implements a laser sensor measurement system that measures cable diameter and insulator jacket thickness in real-time during production. The system compares measurements against upper and lower tolerance limits before the cable proceeds to the wire-cutting machine, preventing out-of-tolerance cables from causing machinery damage while maintaining continuous production flow
Solution Approach 2:
The control system receives measurement data from the laser sensor, compares it with predetermined tolerance limits, and provides feedback by sending signals to stop the cable or send alerts when measurements fall outside acceptable ranges. This closed-loop feedback mechanism ensures manufacturing precision without significantly reducing productivity
2Productivity
If cable diameter is not monitored, then production flow is maintained, but cables outside upper tolerance limits cause machinery jamming and belt damage
Solution Approach 1:
The system performs preliminary measurement and verification of cable diameter using laser sensors before the cable enters the wire-cutting machine. By checking dimensions in advance and stopping the cable or sending alerts when out of tolerance, the system prevents oversized cables from jamming guide tubes or damaging belts, thereby protecting machinery while maintaining continuous production flow
3Device complexity
If cable insulation thickness is not monitored, then production is simplified, but cables below lower tolerance limits cause electrical hazards and fires
Solution Approach 1:
The laser sensor measurement system performs preliminary measurement of insulator jacket thickness before the cable reaches the wire-cutting machine. The control system compares measurements against lower tolerance limits and provides feedback by stopping the cable or sending alerts, preventing cables with insufficient insulation from causing electrical hazards or fires while maintaining manageable system complexity
Solution Approach 2:
The control system implements a feedback mechanism that receives measurement data from the laser sensor, compares it with predetermined lower tolerance limits, and sends stop signals or alerts when measurements fall below acceptable ranges. This ensures electrical safety without significantly increasing device complexity
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
Prevents damage to machinery by ensuring cables within tolerance limits, reducing the risk of jamming, belt damage, and electrical hazards, and providing real-time detection and remediation.
Implementation Method 1
The laser sensor measurement system measures a cable diameter and insulator jacket coating thickness of a cable
Implementation Method 2
laser sensor measurement system measures a cable diameter
Data Source
AI summary
A system for cable abnormality detection is disclosed. The system includes a laser sensor measurement system for measuring a cable diameter and insulator jacket coating thickness of a cable and a guide assembly for guiding entry of the cable through the laser sensor measurement system. The system further includes a control system with a memory and a processor that executes computer-executable instructions and causes the processor to: measure the cable diameter with respect to upper limits of the cable diameter; determine that the cable diameter is outside of the upper limits using the cable diameter measurements and cable parameter tolerances; and initiate a signal to stop the cable from advancing, in response to determining that the cable diameter is outside of the upper limits.