Integrated Wire Cable Twisting and Taping Apparatus
Solution Overview
Problem
The existing process of manufacturing twisted pair wire harnesses requires two separate machines, leading to in-process inventory, damage risks, and inefficiencies in applying conductive and insulative tapes, as well as potential tangling of the drain wire, which can result in product failure.
Innovation Solution
A single machine apparatus that secures and twists wire pairs, applies tapes, and includes an electrical continuity tester, using clamps and servo motors to synchronize the twisting and wrapping of wires, tapes, and drain wires, eliminating the need for separate machines and reducing handling-induced damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate machines are used to manufacture twisted pair wire harnesses, then the twisting function can be performed, but in-process inventory is created that requires storage space and is subject to loss or damage
Solution Approach 1:
The patent combines the twisting machine and dual taper machine into a single integrated apparatus. The twisting mechanism (first and second clamps that rotate relative to each other) and taping mechanism (conductive tape and insulative tape application) are merged into one device, eliminating the need for separate machines and reducing in-process inventory handling
Solution Approach 2:
The integrated apparatus performs multiple functions simultaneously: it twists the wire pair, applies conductive tape, applies insulative tape, and tests electrical continuity all in one device. This multi-functional design eliminates the need for sequential processing on separate machines
2Extent of automation
If the dual taper machine uses feed wheels to pull the wires through the machine, then the taping process can be automated, but the pressure of the feed wheels can damage the twisted wire pair
Solution Approach 1:
The patent removes the feed wheels entirely from the design. Instead of using mechanical feed wheels to pull wires through the machine, the apparatus uses a clamp-based system where the first and second clamps secure and manipulate the wire ends, eliminating the damaging pressure contact points while maintaining automated taping capability
3Ease of manufacture
If the drain wire is fed into the dual taper machine from a spool, then the drain wire can be incorporated, but the drain wire can tangle and become wrapped around the wire pair causing product failure
Solution Approach 1:
The patent secures the drain wire to the twisted wire pair at the beginning of the process using the clamps before the taping operation. By establishing proper positioning and securing the drain wire in advance, the system prevents tangling and wrapping issues that would occur during subsequent processing
4Manufacturing precision
If separate machines are used for twisting and taping, then each machine can be optimized for its specific function, but it is difficult to attach the conductive tape and insulative tape to the twisted pair
Solution Approach 1:
The patent integrates the twisting and taping functions in one apparatus, allowing the tape application mechanism to be positioned and operated in close proximity to the twisting mechanism. This enables immediate attachment of conductive and insulative tapes to the twisted pair while the wires are held in position by the clamps, eliminating the handling and positioning difficulties of separate machines
Data Source
AI summary
A single machine configured to manufacture a wire cable assembly including an twisted wire pair and a drain wire having a conductive tape and an insulative tape spirally wrapped about said wire pair. The machine includes a first clamp that secures an end of the wire pair and a second clamp that secures the other end of the wire pair. The second clamp rotates while the first clamp is fixed thereby twisting the wires of the wire pair one about the other. The second clamp can also rotate synchronously with the first clamp thereby rotating the wire pair without twisting. The machine also has a tape reel configured to move parallel to the clamps as they rotate, wrapping tape around the wire pair. The apparatus can be configured to apply the tapes simultaneously to electromagnetically shield and insulate the cable assembly. A method of operating the apparatus is also provided.