Wire Holder Swapping for Faster Wire Population Changeovers
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Solution Overview
Problem
Conventional wire processing devices require high manipulation costs and time for changing wire populations, as wires need to be swapped and reattached to a terminal block, which is inefficient.
Innovation Solution
A wire processing device with a carrying device that holds releasable holding devices, equipped with encoders for data storage and acquisition, allowing for automated identification and processing of wire populations, reducing the need for manual swapping and enabling toolless attachment and detachment of holding devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wires are manually swapped and reattached to a terminal block, then wire population can be changed, but manipulation cost and setup time increase significantly
Solution Approach 1:
The system divides the wire management into separate modular components: wire stores containing individual wires, holding devices that grip multiple wires, and a terminal block. This segmentation allows independent preparation and quick replacement of wire assemblies without manual reattachment of individual wires.
Solution Approach 2:
Wires are pre-organized in wire stores and pre-gripped by holding devices before being brought to the terminal block. The holding devices are prepared in advance with specific wire configurations, enabling rapid changeover by simply replacing pre-prepared assemblies rather than manually assembling wires during setup.
2Adaptability or versatility
If individual wires are manually attached to the terminal block, then wire population can be changed, but manipulation cost increases
Solution Approach 1:
The holding device acts as an intermediary between the wire store and the terminal block. It grips multiple wires simultaneously and presents them as a unified assembly to the terminal block, reducing the complex manual manipulation of individual wires to a simple single-unit replacement operation.
Solution Approach 2:
The holding device creates a standardized interface or 'copy' of the wire assembly that can be universally attached to the terminal block. This standardized holding device interface simplifies the operation to a repeatable, low-cost action that can be performed quickly without specialized manual dexterity for each wire configuration.
3Adaptability or versatility
If manual wire swapping is performed, then wire population can be updated, but setup time is extended
Solution Approach 1:
Wire assemblies are prepared in advance in wire stores with holding devices already gripping the wires in the desired configuration. This preliminary preparation eliminates the time-consuming step of manually assembling and arranging individual wires during the changeover process, enabling rapid replacement of entire wire assemblies.
Solution Approach 2:
The wire management system is segmented into independent, replaceable units (wire stores with holding devices) that can be prepared separately and quickly exchanged at the terminal block. This segmentation transforms a complex multi-step manual process into a simple single-step replacement operation, dramatically increasing changeover speed.
Data Source
AI summary
A wire processing device including a wire processing mechanism for processing a wire, and a wire handling device for transferring the wire to the wire processing mechanism. The wire processing device has a carrying device, and a holding device for holding the at least one wire can be releasably arranged on the carrying device. The wire processing device includes an acquisition device for acquiring data stored on the holding device.