Swivel Cable Assembly with Loop Holding for Multi-Batch Processing
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Solution Overview
Problem
Existing cable assembly systems, known as swivel machines, face inefficiencies and safety issues due to the need for complex cable guidance and limited batch processing capabilities, particularly when forming and handling cable loops.
Innovation Solution
A cable assembly system with a cable conveyor device, pivot units, and processing stations that include a loop layer and holder, allowing for efficient formation and storage of cable loops, using grippers and drives to manage cable ends and prevent rollover, with a mobile storage unit for batch handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cable loops are formed and stored in traditional swivel machines, then space can be saved for long cables, but the machine becomes complex and can only handle one batch at a time
Solution Approach 1:
The cable processing system is divided into independent modular units: cable feed unit, loop forming unit with first pivot unit, processing station, second pivot unit, and storage unit. Each module performs a specific function and can operate independently, reducing overall system complexity while enabling multi-batch processing capability.
Solution Approach 2:
The patent introduces vertical stacking of processing stations and pivot units, utilizing the third dimension (height) to arrange multiple processing levels. This allows multiple cable batches to be processed simultaneously at different heights, transforming a single-batch horizontal layout into a multi-batch vertical configuration.
2Volume of moving object
If cable loops are formed during processing, then cable length is reduced and space is saved, but safety issues arise due to cable rollover
Solution Approach 1:
The loop holding device is positioned to preemptively prevent cable rollover before it occurs. The device maintains continuous contact with the cable loop, applying a restraining force that counteracts gravitational and inertial forces that would cause the loop to flip or deform during processing.
Solution Approach 2:
The loop holding device acts as an intermediary element between the loop forming unit and the processing station. It serves as a buffer that stabilizes the cable loop configuration, ensuring the loop maintains its shape and position while being transferred and processed, thereby preventing unsafe rollover conditions.
3Productivity
If multiple processing stations are arranged laterally, then cable ends can be processed efficiently, but the machine requires more space
Solution Approach 1:
The patent transitions from a horizontal arrangement of processing stations to a vertical stacking configuration. Multiple processing stations are arranged at different heights along the same longitudinal axis, allowing efficient lateral processing of cable ends while minimizing the machine's horizontal footprint by utilizing vertical space.
Solution Approach 2:
The pivot units are designed with multi-functional capability, serving both as cable guidance mechanisms and as support structures for processing stations. This integration reduces the need for separate lateral support structures, thereby reducing the overall machine footprint while maintaining processing efficiency.
4Manufacturing precision
If cable batches are processed individually, then processing precision is maintained, but productivity decreases
Solution Approach 1:
The cable processing system processes different batches through distinct modular segments (first pivot unit for loop forming, processing station, second pivot unit for trailing end). Each segment maintains precise control over its specific batch while the overall system handles multiple batches in parallel through vertical stacking, preserving processing precision while enabling multi-batch productivity.
Solution Approach 2:
The system enables continuous processing by overlapping batch operations across different vertical levels. While one batch is being processed at the processing station, another batch can be simultaneously looped at the first pivot unit, and a third batch prepared at the cable feed unit. This continuous pipeline operation maintains precision for each batch while significantly improving overall productivity.
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
A system (1) for assembling cables comprises two pivoting units (5, 6) and a processing station (21, 22) for processing cable ends, a loop layer (7) for forming cable loops (3) from the cable (2), a loop stretcher (8), and a loop holder (9) formed by a gripper (20) for securing the cable loop (3). The loop layer (7) and the second pivoting unit (6) are designed such that the fully assembled cable loop (3) can be placed on the cable storage unit (10) by means of the respective cable grippers (15, 19). The cable storage unit (10), designed as a conveyor belt, comprises holding elements (30, 31) for holding both cable ends of the cable loop (3).