Wire Spinner Mechanism for Cable Untwisting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for untwisting and straightening twisted wires in cables are slow, inefficient, and can damage the wires, failing to effectively separate and straighten them due to 'twist memory' in the wire material.

Innovation Solution

A wire preparation device equipped with a motor and multiple wire spinners, each with a collet sleeve and outer collar, securely holds and rotates the wires to untwist and straighten them, overcoming the limitations of manual methods and ensuring reliable processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual untwisting is used, then the wires can be separated, but the process is slow and does not effectively straighten the wires due to twist memory

Engineering Contradiction:

Improveease of untwistingVSAvoiduntwisting speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual mechanical untwisting with an automated rotational mechanism. A motor drives a spindle that rotates to automatically untwist multiple wires simultaneously, eliminating manual labor while significantly increasing processing speed and effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The device segments wires into individual positions on the spindle, allowing each wire to be independently secured and processed. This segmentation enables simultaneous handling of multiple wires while maintaining control over each individual wire's untwisting process.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the pick method is used, then untwisting can be achieved, but the awl may damage the wires and cannot untwist all types of wires

Engineering Contradiction:

Improveuntwisting capabilityVSAvoidwire damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the sharp awl tool with a controlled rotational mechanical system. The motor-driven spindle uses friction and controlled pressure from clamping mechanisms rather than sharp edges, eliminating wire damage while effectively untwisting various wire types.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The device allows adjustment of rotational speed, torque, and clamping pressure parameters to accommodate different wire types and conditions. This parameter variability enables safe and effective untwisting of diverse wires without causing damage.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If manual separation is used, then wires can be separated from twisted pairs, but the wires are not effectively straightened due to twist memory

Engineering Contradiction:

Improveease of separationVSAvoidwire straightness

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces manual separation with a motorized rotational system that applies controlled twisting forces in the opposite direction. This systematic counter-rotation effectively removes twist memory and straightens wires, achieving precision that manual methods cannot accomplish.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The device applies continuous rotational motion to the wires during the untwisting process, maintaining constant engagement and force application. This continuous action ensures complete removal of twist memory and thorough straightening, unlike intermittent manual operations.

Inventive Principle:

Principle #20Continuity of useful action

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 device efficiently untwists and straightens wires, reducing manual effort and risk of damage, enabling faster and more reliable preparation of cables for termination, while maintaining wire integrity.

Implementation Method 1

The wire spinner is configured to be rotated by the motor relative to the device housing to untwist the one or more wires of the cable that are releasably secured within the collet sleeve

Methodology Applied

Scientific EffectMechanical rotation:

Implementation Method 2

The outer collar in the actuated position forces the collet sleeve to contract radially inward to releasably secure the one or more wires within the channel

Methodology Applied

Scientific EffectRadial contraction:

Data Source

PatentUS11296486B2Wire preparation device

Publication Date: 2022.04.05 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A wire preparation device includes a motor, a device housing coupled to the motor, and a wire spinner held by the device housing. The wire spinner is mechanically connected to the motor via power coupling components. The wire spinner extends to a wire end that protrudes from the device housing. The wire spinner includes a collet sleeve defining a channel configured to receive an end of one or more wires of a cable therein through an opening at the wire end. The wire spinner further includes an outer collar surrounding the collet sleeve and selectively movable relative to the collet sleeve to force the collet sleeve to contract radially inward for releasably securing the one or more wires within the channel. The wire spinner is rotated by the motor relative to the device housing to untwist or straighten the one or more wires secured within the collet sleeve.