Twisted Cable End Alignment for Precise Plug Housing Assembly
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Solution Overview
Problem
Existing cable alignment apparatuses struggle to efficiently align twisted cable ends in the correct rotational position, particularly for twisted pair cables like UTP, which is crucial for proper assembly into plug housings.
Innovation Solution
A dual cable alignment apparatus with two clamping jaws and a central web allows simultaneous alignment of both cable ends by rolling them into the correct rotational position using lateral motion, facilitated by individually controllable drives and optical detection for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotary gripping apparatus applies pressure to rotate twisted cable ends, then the rotational position can be adjusted, but the alignment process requires multiple steps and is time-consuming
Solution Approach 1:
The patent combines both cables into a single clamping unit with two clamping jaws that can simultaneously rotate both cables to their correct rotational positions in one operation, eliminating the need for separate alignment steps for each cable and significantly reducing alignment time while maintaining precision
2Manufacturing precision
If cable grippers fix one cable at a time sequentially, then each cable can be positioned individually, but the overall alignment process becomes multi-step and slower
Solution Approach 1:
The invention merges the alignment operations for both cables into a single simultaneous operation using one clamping unit with two clamping jaws, allowing both cable ends to be rotated and positioned at the same time, thereby halving the alignment cycle time while maintaining individual precision for each cable
Solution Approach 2:
The clamping jaws are designed to continuously rotate both cables simultaneously in one coordinated motion, eliminating idle time between sequential operations and ensuring that both cables are aligned in a continuous, uninterrupted process
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 apparatus efficiently aligns both cable ends quickly and precisely, reducing process time and ensuring easy insertion into plug housings, while accommodating cables of varying thicknesses and diameters.
Implementation Method 1
moving the engagement means (clamping jaws, central web) past one another causes a rolling motion of the cable clamped between them
Data Source
AI summary
A dual cable alignment apparatus (10) for rotationally aligning assembled cable ends of two cables (3,4) of a twisted cable harness (2), the cable alignment apparatus (10) comprising two clamping jaws (7,8) and a central web (9) disposed between the clamping jaws (7,8). Each of the two clamping jaws (7,8), which can be moved towards one another in the closing direction (s), can clamp a cable (3,4) between the central web (9) and the clamping jaws (7,8). The clamping jaws (7,8) are further designed to be movable laterally past the central web (9) for changing the rotational position by rolling the cable (3,4) clamped between them. The clamping jaws (7,8) can be moved independently of one another in the lateral direction by means of their own lateral drives (16,17), ensuring that each cable (3,4) can be brought precisely and reliably into the desired rotational position.