Wire Stripping Notch Formation Using Capacitance Contact Detection

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Solution Overview

Problem

Conventional devices for forming notches in coated electric wires, particularly thick wires and those wound around bobbins, face accuracy issues due to accumulated tolerances and potential deformation or misalignment, leading to inconsistent notch depths and insufficient stripping.

Innovation Solution

A device with cutting mechanisms and a rotation mechanism that includes electrically conductive cutter blades and a contact detecting section using variable capacitance to accurately position the cutter blades for precise notch formation, ensuring consistent notch depth across the wire circumference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the V-shaped cutter blades are moved toward the electric wire axis to clamp the coated electric wire so that the V-shaped cutter blades intrude into it to a notch depth corresponding to the determined target positions, then the notch can be formed to a specified depth, but the accuracy for movement of the V-shaped cutter blades is low due to accumulated tolerance from core radius and coating material thickness

Engineering Contradiction:

Improvenotch depth accuracyVSAvoidtarget position accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical measurement system (using electric wire axis as reference with calculated target positions) with an electrical field-based detection system. The contact detecting section uses electrical contact between the cutter blade and the conductor to precisely determine when the cutter blade reaches the correct depth, eliminating accumulated mechanical tolerances from core radius and coating thickness measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the contact detecting section continuously monitors the position of the cutter blade relative to the conductor and provides real-time feedback to the drive mechanism. When electrical contact is detected, the system automatically stops the cutting motion, ensuring precise notch depth control without relying on pre-calculated target positions.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If the pair of V-shaped cutter blades are rotated around the electric wire axis to form the notch, then the notch can be formed around the wire circumference, but the notch depth varies in different regions due to deformation and misalignment of the coated electric wire

Engineering Contradiction:

Improvecircumferential notch formationVSAvoidnotch depth consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent enables the cutter blade to self-adjust its depth for each position around the wire circumference. As the cutter blade rotates and contacts the deformed wire surface, the contact detecting section automatically detects the exact depth required at each point by sensing electrical contact with the conductor, allowing the system to adapt to local variations in wire geometry without manual intervention.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent transitions from a static, pre-determined cutting depth approach to a dynamic, real-time depth adjustment system. The cutter blade's penetration depth is continuously adjusted during rotation based on real-time feedback from the contact detecting section, allowing the system to accommodate deformations and misalignments of the coated electric wire.

Inventive Principle:

Principle #15Dynamics

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 solution improves the accuracy of notch formation by detecting contact with the outermost conductor and adjusting the cutter blade position, reducing the impact of tolerances and deformation, resulting in consistent notch depth and effective stripping.

Implementation Method 1

a contact detecting section configured to detect a contact between an outermost conductor and the cutter blade based on a variable capacitance between the outermost conductor and the cutter blade

Methodology Applied

Scientific EffectVariable capacitance: Capacitance

Data Source

PatentUS20250007259A1Device and method for forming a notch for stripping

Publication Date: 2025.01.02 YAZAKI CORP

AI summary

A device for forming a notch for stripping includes a cutting mechanism which includes an electrically conductive cutter blade; a contact detecting section for detecting contact between an outermost conductor of the coated electric wire and the cutter blade based on a variable capacitance between the outermost conductor and the cutter blade; and a movement mechanism for adjusting a position of the cutter blade and thus positioning the cutter blade to a position corresponding to a specified notch depth for forming the notch, upon detecting the contact between the cutter blade and the outermost conductor by the contact detecting section during movement of the cutter blade.