Speed Adjusting Cable Assembly with Sensor Feedback
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Solution Overview
Problem
Existing cable feeder systems lack the ability to automatically adjust the speed of cable payout during installation, leading to inconsistent slack management and potential inefficiencies in the cable pulling process.
Innovation Solution
A speed adjusting cable assembly that includes a motor-driven roller system with a rotatable boom arm and sensor, where the controller adjusts the speed of the rollers based on the measured angle of the boom arm relative to a plane, maintaining a preset slack level between the cable feeder and the conduit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional cable feeder system is used without speed adjustment capability, then the system structure remains simple, but the cable payout speed cannot be controlled leading to inconsistent slack management
Solution Approach 1:
The system employs a sensor to detect the angle of the boom arm which indicates cable slack conditions, and feeds this information back to a controller that automatically adjusts the roller speed. This closed-loop feedback mechanism enables automatic slack management without requiring manual intervention, resolving the contradiction between ease of operation and device complexity.
Solution Approach 2:
The cable feeder transitions from a static, fixed-speed system to a dynamic, variable-speed system. The roller speed is continuously adjusted based on real-time slack detection, allowing the system to adapt to changing cable installation conditions. This dynamic adjustment capability improves slack management while the automation reduces operational complexity.
2Productivity
If cable payout speed is manually controlled, then the system structure remains simple, but installation efficiency decreases due to inconsistent speed management
Solution Approach 1:
The sensor continuously monitors cable slack by detecting boom arm angle and provides feedback to the controller. This enables automatic speed adjustment that optimizes cable payout rate, preventing both excessive slack and tension conditions. The automated feedback-controlled speed management significantly improves installation efficiency compared to manual control.
Solution Approach 2:
The cable feeder system performs self-adjustment of payout speed based on real-time slack detection. The controller automatically modifies roller speed without requiring operator intervention, allowing the system to service itself and maintain optimal installation speed throughout the cable feeding process, thereby improving productivity.
3Stability of the object's composition
If the cable feeder operates at constant speed, then the control system remains simple, but slack consistency deteriorates during cable installation
Solution Approach 1:
The sensor detects variations in cable slack through boom arm angle measurement and provides continuous feedback to the controller. The controller responds by adjusting roller speed to maintain consistent slack levels throughout the cable installation process. This feedback mechanism ensures slack stability despite changes in installation conditions.
Solution Approach 2:
The system dynamically changes the operational parameter of roller speed based on detected slack conditions. When slack increases, the roller speed is increased to maintain consistent cable tension. When slack decreases, speed is reduced. This parameter adjustment ensures consistent slack composition throughout the cable feeding process.
Data Source
AI summary
A speed adjusting cable assembly in accordance with some example embodiments is configured for use with a cable feeder having at least one motor-driven roller configured to pay out cable. The assembly includes a frame, a boom arm pivotally connected thereto by a shaft, a cable guide on the boom arm configured to allow at least one cable to pass therethrough, a sensor in communication with the shaft and configured to measure a rotational position of the boom arm relative to a plane, and a controller in communication with the sensor. The controller is configured to control a speed at which the at least one roller rotates to feed the cable through the cable feeder based upon information received from the sensor. A method of use is also provided.