Pre-Wired Sheath Winding With Ultrasonic Cable Retention
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Solution Overview
Problem
Existing pre-wired sheath winding systems face challenges in preventing cable shrinkage during winding and cutting, making it impossible to visually inspect the cables and requiring manual or disruptive mechanical cutting to access them.
Innovation Solution
A system with an ultrasonic welding device that welds a portion of the sheath to the cables using a sonotrode, ensuring cables remain visible and accessible by preventing shrinkage, combined with a control unit to determine the sheath length and trigger welding and cutting at the right moment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pre-spun sheath is wound and cut using conventional winding systems, then the production speed is high, but the cables shrink during winding and cutting and become invisible from the outside
Solution Approach 1:
The ultrasonic welding is performed before the cutting operation to secure the cables in position. By welding the sheath to the cables at a predetermined location before cutting, the cables are prevented from shrinking or moving during subsequent handling and installation, ensuring they remain visible and accessible while maintaining high production speed
2Ease of operation
If manual cutting is used to access the cables, then the cables can be accessed, but the process is slow and laborious
Solution Approach 1:
The manual mechanical cutting process is replaced with an automated ultrasonic welding system. The ultrasonic welding device automatically welds the sheath to the cables at a precise location, and the welding process itself creates an accessible opening without requiring separate manual cutting operations, thereby maintaining cable accessibility while significantly improving processing speed
3Productivity
If machine cutting is used to cut the empty portion of the sheath, then cutting speed is improved, but it interferes with the winding and cutting system
Solution Approach 1:
The ultrasonic welding device is integrated into the existing winding and cutting system, combining multiple functions into a single coordinated process. The welding operation is performed at a specific location during the winding process, and the same integrated system then performs the cutting operation, eliminating the need for separate machine cutting equipment while maintaining high productivity
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
Ensures cables remain visible and accessible post-winding, eliminating the need for manual cutting and minimizing system interference, while maintaining efficient production speed.
Implementation Method 1
a sonotrode coupled to said generator, said sonotrode being adapted to convert the energy of said ultrasound into melting energy of the sheath
Data Source
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AI summary
The invention relates to a pre-wired sheath winding system, said sheath surrounding at least one cable, comprising a feed arm, a rotating drum for winding the pre-wired sheath brought by the feed arm in the form of a coil and a cutting device (23) for the sheath and each cable after the formation of the coil, said winding system being characterized in that it comprises a welding device (24) comprising an ultrasonic generator and a movable part in a direction transverse to the sheath comprising a sonotrode (27) coupled to said generator, said sonotrode being adapted to convert the energy of said ultrasound into sheath melting energy, the movable part being configured to bring the sonotrode into contact with the inside of the sheath to weld a portion of the sheath to a portion of at least one of said cables.