Wire Bundling Head Positioning for Twisted Wire Length Control
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Solution Overview
Problem
Existing cable processing devices face challenges in precisely positioning non-stationary bundling heads for twisted wires of varying lengths, as the realignment of twisting heads is force-regulated rather than length-regulated, leading to inaccuracies and inefficiencies, especially when the bundling head is not needed during operations.
Innovation Solution
An apparatus with a feed device, stationary and non-stationary holding devices, and a non-stationary bundling device equipped with a controllable drive and distance measuring system allows for precise positioning of the bundling segment relative to the twisting heads, enabling precise bundling and reducing unnecessary movement of the bundling device's mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the bundling head is mounted and moved together with the twisting head for the leading wire end, then the positioning of the bundling head can be simplified, but the mass of the unit increases and unnecessary movement occurs when bundling is not needed
Solution Approach 1:
The apparatus separates the bundling head from the twisting head, making them independent movable units. The bundling head can be moved along the guiding direction independently on its own support structure, while the twisting head remains stationary. This segmentation allows the bundling head to be positioned only when needed, reducing unnecessary movement and energy consumption.
Solution Approach 2:
The bundling head is designed to be dynamically positionable along the guiding direction through a controllable drive mechanism. This dynamic positioning capability allows the system to move the bundling head only when bundling operations are required, rather than continuously moving a combined unit, thus reducing unnecessary mass movement and energy waste.
2Device complexity
If the bundling head is moved together with the twisting head, then the positioning mechanism is simplified, but energy is wasted moving the bundling device mass during operations where only twisting occurs
Solution Approach 1:
The system divides the processing heads into separate functional units - a stationary twisting head and an independently movable bundling head. This segmentation enables the bundling head to remain stationary during twisting-only operations, eliminating energy waste from moving unnecessary mass, while still allowing easy positioning when bundling is needed.
Solution Approach 2:
The controllable drive mechanism enables the bundling head to autonomously position itself along the guiding direction based on operational requirements. This self-service capability allows the bundling head to move only when needed for bundling operations, rather than being continuously moved with the twisting head, thus reducing energy consumption.
3Ease of manufacture
If force-regulated realignment is used for the twisting head, then the twisting process is simplified, but the precise positioning of the bundling head becomes difficult
Solution Approach 1:
A distance measuring device acts as an intermediary between the bundling head and the wire bundle, providing precise position feedback. This intermediary measurement system enables accurate positioning of the bundling head along the guiding direction, compensating for the limitations of force-regulated realignment and ensuring precise bundling operations.
Solution Approach 2:
The distance measuring device provides continuous feedback on the position of the bundling head relative to the wire bundle. This feedback mechanism allows the control system to adjust the bundling head position with high precision, overcoming the imprecision of force-regulated realignment and enabling accurate bundling operations.
Data Source
AI summary
An apparatus to process a plurality of electrical wires as well as a method that uses the apparatus are indicated. The apparatus includes a feed device, a stationary holding device, a holding device that is non-stationary along a linear guiding direction, a non-stationary bundling device that is separate from the non-stationary holding device and a controller connected to a drive of the non-stationary bundling device. The stationary holding device and/or the non-stationary holding device are configured to twist the respectively held end of the wires; The controller controls the drive in such a way that a distance between a bundling segment of the non-stationary bundling device and the non-stationary holding device assumes a specified or a specifiable distance.