Automated Shielded Cable Feeding for Precise Solder Sleeve Installation
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Solution Overview
Problem
The manual process of preparing shielded cables and installing solder sleeves is labor-intensive, prone to misalignment, and increases cycle time, leading to quality issues and increased labor costs.
Innovation Solution
A fully automated system with a cable delivery system and multiple workstations equipped with cable processing modules that automate the solder sleeve installation process, using a conveyor track and pallets to convey cables through successive operations for precise and efficient solder sleeve installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual feeding process is used, then operator flexibility is maintained, but alignment precision deteriorates and cycle time increases
Solution Approach 1:
The system uses sensors to automatically detect cable position and the feed mechanism to self-adjust cable insertion, eliminating the need for manual alignment operations while maintaining precision
Solution Approach 2:
Manual mechanical alignment operations are replaced with an automated system combining sensors for detection and a controlled feed mechanism for precise cable positioning and insertion
2Productivity
If manual cable processing is used, then labor costs are incurred, but cycle time increases and productivity decreases
Solution Approach 1:
The system performs cable positioning, insertion, and processing operations automatically through integrated sensors and actuators, enabling the equipment to service itself without manual intervention for each cable
Solution Approach 2:
The automated system enables continuous processing of cables through the production line, eliminating idle time between operations and maintaining constant productive action throughout the cable assembly process
3Reliability
If manual feeding is used, then equipment simplicity is maintained, but quality consistency deteriorates
Solution Approach 1:
Sensors continuously monitor cable position and provide feedback to the control system, which adjusts the feed mechanism to maintain consistent alignment and insertion quality across all cables
Solution Approach 2:
Manual operations subject to human variability are replaced with an automated sensor-controlled system that ensures repeatable, consistent cable positioning and processing for every unit
Data Source
Figure 1
Figure 2A~2C
Figure 3A
AI summary
An automated system (110, 111) for processing an end (10a) of a cable (10). The system includes: a cable delivery system (60); a cable processing module (30); a pallet (64) supported by the cable delivery system; a drive wheel (16) rotatably coupled to the pallet; a motor (72) operatively coupled for driving rotation of the drive wheel; and an idler wheel (18) rotatably coupled to the pallet and forming a nip with the drive wheel. The cable processing module includes cable processing equipment (24) configured to perform an operation on an end of a cable and a computer system (162). The computer system is configured to: (a) cause the drive wheel to rotate in a cable pushing direction to cause a specified length of cable to be inserted into the cable processing equipment; (b) activate the cable processing equipment to perform an operation on the inserted end of the cable; and (c) cause the drive wheel to rotate in a cable pulling direction to cause the specified length of cable to be removed from the cable processing equipment.