Telecentric Cable Cross-Section Measurement for Precise Cutback
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Solution Overview
Problem
The installation of electrical cables and cable accessories in power grids is prone to errors due to manual processes, leading to potential failures and defects such as stray knife cuts, incorrect cutbacks, and insulation issues, which can result in arcing and permanent faults.
Innovation Solution
An electrical-cable-preparation system with modular components, including a cable-preparation device equipped with a telecentric lens and computing device, automatically cuts and removes layers of electrical cables to ensure precise cutback lengths and depths, reducing defects and enhancing the reliability of cable terminations and splices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual processes are used for cable installation, then ease of operation is improved, but reliability deteriorates due to errors such as stray knife cuts, incorrect cutbacks, and insulation issues
Solution Approach 1:
The system enables self-service through automated cable preparation where the machine performs cutting, stripping, and measurement operations autonomously based on pre-programmed parameters, eliminating manual intervention while ensuring consistent high-quality results
Solution Approach 2:
Manual mechanical operations are replaced with an automated mechanical system equipped with precision cutting tools, telecentric cameras for optical measurement, and computer-controlled actuation, substituting human labor with a reliable automated mechanism
2Manufacturing precision
If automated cable preparation system with telecentric lens is used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
A telecentric lens acts as an optical intermediary between the cable end and camera sensor, providing distortion-free magnification that simplifies image analysis while maintaining high measurement precision, effectively mediating between the physical cable and digital measurement system
Solution Approach 2:
The automated preparation system is divided into modular functional segments including cutting mechanisms, stripping tools, imaging systems, and control software, allowing each component to be optimized independently while maintaining overall system precision
3Productivity
If automated cable preparation system is implemented, then productivity is improved, but device complexity increases due to multiple modular components
Solution Approach 1:
The system is segmented into independent modular components (cutting module, stripping module, imaging module, control module) that can be configured for different cable types and preparation requirements, enabling high productivity through automation while managing complexity through modularity
Solution Approach 2:
The automated preparation system is designed with universal capabilities to handle various cable types, sizes, and insulation materials through programmable control and interchangeable tools, achieving high productivity across diverse applications without requiring completely separate systems for each cable type
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 system accurately and efficiently prepares cable ends, minimizing defects and increasing the reliability of power grids by reducing the probability of failure events and extending the useful life of electrical cables and accessories.
Implementation Method 1
a telecentric lens optically coupled to the camera, wherein the telecentric lens comprises a non-angular field of view configured to reduce, in the image, distortion from parallax associated with at least one portion of the end-face of the electrical cable
Data Source
Figure 1A~1B
Figure 2
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AI summary
Techniques, systems and articles are described for preparing electrical cables for connections to a power grid. In one example, a cable-cross-section-measurement tool includes a housing defining a cavity, wherein the housing is configured to position an end-face of an electrical cable within the cavity; a camera disclosed within the cavity of the housing, wherein the camera is configured to capture an image of the end-face of the electrical cable; and a telecentric lens optically coupled to the camera, wherein the telecentric lens comprises a non-angular field of view configured to reduce, in the image, distortion from parallax associated with at least one portion of the end-face of the electrical cable that is oriented at an oblique angle relative to an optical axis of the telecentric lens.