Sequential Wire Marking System with Automatic Counter Reset
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Solution Overview
Problem
Current systems for applying sequential numbering to extruded wire or cable are inefficient, requiring operators to interrupt production and perform complex interface adjustments to change target lengths, leading to waste and production slowdowns.
Innovation Solution
A system with a user-friendly interface on a monitor connected to a computer processing system that allows operators to input target numbers directly, enabling seamless transitions between different segment lengths without stopping production, using a printing device that automatically resets and continues printing on subsequent segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the operator enters a new target length quickly after the previous segment is marked, then production continues without stopping, but the operator requires advanced training and the process is complicated by the non-intuitive program interface
Solution Approach 1:
The system performs automatic functions including self-monitoring of wire length, self-resetting of the counter at target numbers, and self-continuation of printing without requiring operator intervention during the printing process
Solution Approach 2:
The patent replaces the complex mechanical interface interaction with a simplified system where the printer automatically detects wire length through sensing mechanisms and adjusts printing parameters electronically without requiring operator navigation through complex menus
2Adaptability or versatility
If the operator goes through the process of changing the target number, then the sequential numbering can be adjusted to a different target, but the wire that passes through during the adjustment must be scrapped
Solution Approach 1:
The system prepares for target number changes in advance by continuously monitoring wire length and pre-calculating when the next target will be reached, allowing the operator to input new target numbers before the current wire segment is complete
Solution Approach 2:
The system provides continuous feedback to the operator about the current wire length, remaining distance to the next target, and anticipated waste, allowing the operator to make informed decisions about target number changes that minimize scrap
3Manufacturing precision
If the production line is stopped to reprogram the next batch target number, then the target can be changed accurately, but production is dramatically slowed down
Solution Approach 1:
The printing system maintains continuous operation by automatically resetting and continuing to print sequential numbers on subsequent wire segments without requiring production line shutdowns
Solution Approach 2:
The system dynamically adjusts printing parameters and target numbers during continuous operation, allowing the production line to maintain constant speed while the printing system adapts to different segment length requirements
Data Source
AI summary
A process and system for printing sequences of alpha-numeric characters on segments of wire or cable during production. In one embodiment, the process and system comprises printing a sequence of alpha-numeric values onto a first segment of wire up to an input target value. The process and system further comprises printing a sequence of alpha-numeric values onto a second segment of wire up to a second input target value. In one embodiment, the process and system is capable of printing sequences on segments of wire or cable up to variable target values without requiring a shutdown of the production process, and without requiring lag time between printing on subsequent wire or cable segments.