Optical Cable-End Rotation Alignment for Twisted Harness Assembly
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Solution Overview
Problem
Existing cable alignment technologies face challenges in efficiently aligning the assembled ends of twisted cable strands in the correct rotational position, particularly for UTP cables, due to the need for precise angular positioning and the complexity of the assembly process.
Innovation Solution
A dual cable alignment apparatus with two rotating modules, each equipped with a rotary cable gripper and a rotating apparatus, allows for precise rotation and adjustment of cable ends about their longitudinal axis, utilizing an optical detection system to ensure accurate alignment, and includes a drive mechanism for adjusting the distance between the cable ends to facilitate efficient alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotary gripping apparatus applies pressure to the cable strand at the twisted cable area to rotate the cable ends, then the rotational position can be adjusted, but the alignment process becomes complex and time-consuming due to multiple sequential steps
Solution Approach 1:
The alignment apparatus divides the cable handling into separate functional modules: a first cable gripper for gripping one cable end, a second cable gripper for gripping the other cable end, and a rotary gripping apparatus for rotation. This segmentation allows each component to perform its function independently, simplifying the overall control logic and reducing process complexity while maintaining alignment precision
Solution Approach 2:
The patent combines the gripping and rotation functions into an integrated system where the rotary gripping apparatus can rotate cable ends that are already gripped by the cable grippers. This merging of functions eliminates the need for separate positioning and rotation operations, reducing the number of sequential steps and simplifying the alignment process
2Ease of operation
If cable grippers fix only one cable at a time to guide the other cable end, then individual cable control is achieved, but the alignment time increases due to sequential processing
Solution Approach 1:
The apparatus employs dynamic control where cable grippers can grip and release cables flexibly, and the rotary gripping apparatus can rotate cables to different positions dynamically. This dynamic operation allows the system to adapt to different cable configurations and perform multiple operations in parallel, significantly reducing alignment time while maintaining individual cable control
Solution Approach 2:
The system maintains continuous useful action by having both cable grippers operate simultaneously on their respective cables, and the rotary gripping apparatus continuously adjusting rotational positions. This parallel continuous operation eliminates idle time between sequential steps, reducing total alignment time while preserving individual cable control capabilities
3Reliability
If the untwisted areas of the cable ends are kept as short as possible for UTP cables, then signal transmission quality is improved, but the alignment of short cable ends in the correct rotational position becomes particularly demanding
Solution Approach 1:
The patent replaces manual alignment operations with an automated mechanical system consisting of cable grippers and a rotary gripping apparatus. This mechanical automation provides precise control over cable rotation and positioning, making the alignment of short cable ends straightforward and accurate, thereby maintaining signal transmission quality without increasing alignment difficulty
Solution Approach 2:
The apparatus incorporates a detection apparatus that provides feedback on the rotational position of cable ends. This feedback mechanism allows the system to automatically adjust and verify the alignment of short cable ends, making the process less demanding while ensuring the correct rotational position is achieved for optimal signal transmission
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 apparatus enables quick and precise alignment of cable ends, reducing the time required for the alignment process and ensuring correct rotational positioning, which is essential for successful assembly into plug housings, thereby improving the efficiency of the cable assembly process.
Implementation Method 1
an optical detection apparatus for ascertaining the rotational position of the cable ends
Data Source
AI summary
A dual cable alignment apparatus aligns assembled cable ends provided with contact elements on two cables of a twisted cable strand in a predetermined correct rotational position. The alignment apparatus includes two cable rotating modules arranged on an apparatus frame and equipped with rotary cable grippers for rotating each assembled cable end about its longitudinal axis, and an optical detection apparatus for determining the corresponding rotational position of the assembled cable ends. To adjust the distance between the assembled cable ends, a cable rotating module is displaceable by a drive on the apparatus frame, whereby it is ensured that each assembled cable end can be brought into the desired rotational position precisely and reliably, and an optimal shadow image of the two contact elements can be detected for position detection.