Laser Cutting Shielded Cables via Ring Mirror Reflection
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Solution Overview
Problem
Existing methods for cutting shielded cables are inefficient, leading to uneven cuts and high scrap rates due to the use of worn rotating knives, and lack automation in the assembly process.
Innovation Solution
A laser cutting device with a ring mirror device and laser beam deflection system that guides the laser beam in a 360-degree path around the cable, ensuring even cutting and precise control, combined with a 3D detection system and adjustable mirror arrangements for optimal beam guidance, allowing for high-speed and precise circumferential cuts without mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If rotating blades are used to remove shielding wires and foils, then automated removal is achieved, but the reject rate increases due to blade wear
Solution Approach 1:
The patent replaces the mechanical rotating blade system with a laser-based cutting system. The laser beam is guided along a circumferential path around the cable to cut the shielding layers without physical contact, eliminating blade wear and associated quality issues while maintaining automation.
Solution Approach 2:
The laser cutting process is divided into multiple sequential steps: first cutting the outer sheath, then cutting the shielding foil, and finally cutting the shielding wires. This segmented approach allows precise control over each layer removal process, improving reliability while maintaining automation.
2Manufacturing precision
If manual removal of shielding layers is performed, then quality control is maintained, but throughput decreases
Solution Approach 1:
The patent replaces manual mechanical removal with an automated laser cutting system that provides consistent, precise cuts across all layers. The laser process maintains high quality through controlled beam parameters while dramatically increasing throughput through automation and continuous processing capability.
Solution Approach 2:
The laser cutting process operates continuously without the interruptions associated with manual operations or blade changes. The laser beam can continuously cut through all shielding layers in sequence, maintaining both high quality and high throughput through uninterrupted processing.
3Productivity
If high power laser is used for cutting, then cutting speed increases, but energy consumption increases
Solution Approach 1:
The laser operates in periodic pulses rather than continuous high power mode. The pulsed laser delivers high peak power for efficient cutting during active periods while consuming minimal energy during pulse intervals, achieving high cutting speed with reduced overall energy consumption.
Solution Approach 2:
The laser parameters (power, pulse duration, frequency) are dynamically adjusted based on the specific layer being cut and the cutting progress. This optimization ensures high cutting speed when needed while minimizing energy consumption during less intensive phases of the cutting process.
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 solution enables reproducible, quick, and automated cutting of shielded cables with reduced scrap rates and minimal energy input, maintaining consistent quality across the entire circumference without damaging underlying layers.
Implementation Method 1
The ring mirror device (8) has a fully circumferential mirror wall (9) ... The laser beam deflection device (13) is designed to guide the laser beam (5) such that it enters the cutting chamber (10) through the laser inlet aperture (9b) and strikes the surrounding mirror wall (9). The laser beam deflection device (13) is also designed to guide the laser beam (5) such that it moves along a preferably closed path around the central axis (11) along the surrounding mirror wall (9).
Implementation Method 2
A laser unit (4) configured to generate a laser beam (5)... The laser beam deflection device (13) is also designed to guide the laser beam (5) such that it moves along a preferably closed path around the central axis (11) along the surrounding mirror wall (9), so that a shielded cable (1), which can be arranged or is already arranged along the central axis (11) inside the cutting chamber (10), is cut along its entire circumference by the laser beam (5) reflected from the surrounding mirror wall (9).
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
A laser cutting device (3) for shielded cables (1) comprises a laser unit (4) and a ring mirror unit (8) having a fully circumferential mirror wall (9) that defines a cutting chamber (10) and is penetrated by a central axis (11). The circumferential mirror wall (9) is open at its end faces (9a, 9b), forming a cable entry opening (9a) and a laser entry opening (9b). The mirror wall (9) reflects the laser beam (5) in the direction of the shielded cable (1). A laser beam deflection device (13) guides the laser beam (5) so that it enters the cutting chamber (10) through the laser entry opening (9b) and strikes the circumferential mirror wall (9).The laser beam deflection device (13) guides the laser beam (5) such that it moves 360° around the central axis (11) along the surrounding mirror wall (9), allowing the shielded cable (1) in the separation chamber (10) to be cut by the laser beam (5) along its entire circumference. A 3D scanning system using cameras is provided to capture the shape of the cable (1).