Cable Wire Selection Tool for Precise Connector Tip Processing
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Solution Overview
Problem
The manufacturing of electronic connectors requires various processing steps for cable wires, such as insulated jacket cracking, shield trimming, and contact crimping, which are often labor-intensive and prone to errors.
Innovation Solution
An automated method for cable wire processing involves a cable selection tool that moves to contact a set of cable wires, selectively positioning one wire for processing while bending others out of the way, allowing for efficient application of tip processing operations within a defined working region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual processing methods are used for cable wires, then flexibility and adaptability are maintained, but labor intensity increases and error incidence rises
Solution Approach 1:
The processing system is segmented into distinct functional modules: a cable wire holder for positioning, a selection tool for identifying target wires, and processing tools for executing operations. This modular segmentation enables automated processing while keeping each component relatively simple and manageable.
Solution Approach 2:
A selection tool acts as an intermediary between the control system and the cable wires. It physically contacts the wires to identify which ones require processing, translating the automated selection criterion into mechanical action without requiring complex sensing or manipulation systems.
2Productivity
If automated processing is implemented, then productivity increases and defects decrease, but system complexity increases
Solution Approach 1:
The selection function and processing function are merged into a coordinated automated system. The selection tool identifies target wires, and processing tools immediately follow to perform operations, eliminating the need for separate manual inspection and processing steps, thereby improving productivity without proportionally increasing complexity.
Solution Approach 2:
The cable wire holder and selection tool work together in a self-contained manner where the selection tool automatically identifies and positions target wires without requiring external intervention or complex programming, enabling the system to serve itself in the wire selection process.
3Productivity
If multiple cable wires are processed simultaneously, then productivity increases, but selection precision and processing accuracy may deteriorate
Solution Approach 1:
The system segments the set of cable wires into individually addressable units using the cable wire holder, which positions each wire in a distinct location. The selection tool then contacts specific wires based on predetermined criteria, ensuring precise identification and processing of target wires even when multiple wires are present.
Solution Approach 2:
The selection tool applies local contact forces to specific cable wires at specific positions, creating localized selection action. This allows different wires to be treated differently based on their position and characteristics, maintaining precision while enabling batch processing capabilities.
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
A method (200) for automated cable wire processing includes receiving a set of two or more cable wires (304A-C), including at least a first cable wire (304A) positioned at a selection position (414), and a second cable wire (304B) positioned away from the selection position (414). A cable selection tool (306) is automatically moved to contact the set of two or more cable wires (304A-C), such that contact between the cable selection tool (306) and the first cable wire (304A) causes a tip portion (706A) of the first cable wire (304A) to extend into a working region (708), and contact between the cable selection tool (306) and the second cable wire (304B) moves a tip portion (706B) of the second cable wire (304B) outside of the working region (708). One or more tip processing operations are applied to the tip portion (704A) of the first cable wire (304A) within the working region (708).