Split Cable Carrier With Self-Aligning Guides for Automated Handling
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Solution Overview
Problem
Existing cable handling systems are cumbersome, prone to manual errors, and unsuitable for automated processes due to complex structures and the need for manual cable insertion and precise realignment, especially when dealing with flexible or thin cables.
Innovation Solution
A material carrier comprising two separate carrier elements that can be securely attached via magnetic, adhesive, or mechanical forces, allowing for direction-independent movement and easy alignment, with identification features and beveled surfaces for precise positioning, enabling automated handling and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cable insertion and gripping devices are used, then cable handling is possible, but the process is time-consuming and prone to errors
Solution Approach 1:
The carrier is divided into a modular system with separate carrier body and attachment elements that can be independently handled and assembled. The cable management system is segmented into identification features, gripping surfaces, and attachment mechanisms that can be independently optimized and manufactured.
Solution Approach 2:
The carrier incorporates self-aligning features such as guide rails, positioning pins, and complementary geometric shapes that automatically align the cable and carrier during insertion without requiring manual positioning or adjustment by the operator.
2Reliability
If complex gripping devices are used to secure the cable, then the cable can be moved, but precise re-fixing is required for directed movement
Solution Approach 1:
The carrier integrates multiple functions into a single unified structure: the cable gripping surface, alignment features, identification markers, and attachment mechanisms are merged into one component that performs all functions simultaneously, eliminating the need for separate gripping devices and alignment tools.
Solution Approach 2:
The carrier acts as an intermediary element between the cable and the handling system, providing a standardized interface with built-in alignment and securing features that simplify the interaction between the cable and processing equipment without requiring complex gripping mechanisms.
3Adaptability or versatility
If cables are moved as loose components, then flexibility is maintained, but precise re-fixing is required at each station
Solution Approach 1:
The carrier is pre-equipped with alignment features, positioning elements, and identification markers before the cable is attached. These pre-configured features ensure that when the cable-carrier assembly is moved to different stations, the precise alignment is automatically maintained without requiring re-fixing or adjustment.
Solution Approach 2:
The carrier design provides universal compatibility with multiple processing stations through standardized interfaces, geometric alignment features, and repeatable positioning mechanisms that work across different equipment, allowing the cable to be moved freely while maintaining precise alignment at each station.
4Ease of operation
If prior art carriers are used with flexible cables, then cable handling is possible, but handling becomes even more challenging
Solution Approach 1:
The carrier incorporates flexible components and thin-film structures that can adapt to the cable's flexibility while maintaining structural integrity. The design includes flexible attachment mechanisms and compliant gripping surfaces that work effectively with flexible cables without requiring complex rigid handling devices.
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 material carrier simplifies and streamlines cable handling, reduces wear and tear, and ensures reliable, efficient, and automated cable management throughout the assembly process, particularly for flexible or thin cables, by providing stability and ease of alignment and identification.
Implementation Method 1
The at least two carrier elements can be releasably secured to one another in the assembled state using retention forces. Retention forces can include magnetic forces
Implementation Method 2
Retention forces can include adhesive forces
Implementation Method 3
Retention forces can include static friction forces
Data Source
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AI summary
The present invention relates to a material carrier (1) for a thread-like material (3) comprising at least a first and a separate second carrier element (10, 10'), wherein the first and the second carrier element (10, 10') form the material carrier (1) in the assembled state, and at least one guide (11) on the first and/or the second carrier element (10, 10') which extends through the material carrier (1) along a first direction (X) in the assembled state, and in which the thread-like material (3) can be arranged, wherein the material carrier (1) can be attached to the thread-like material (3) and can be moved with it in a direction-independent manner.