Wire Twisting Guide Mandrel Layout for Consistent Lay Length
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Solution Overview
Problem
Existing devices for twisting individual wires into cable bundles face issues with guide mandrels interfering with wires and requiring separate actuators, leading to unpredictable lay lengths and additional vertical space requirements.
Innovation Solution
A device with individual twisting units and a guide device that includes a guide pin and movement/locking elements, allowing the guide mandrel to be pivoted into the twisting axis without separate actuators, maintaining consistent lay length and reducing vertical space needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a guide mandrel is used to separate individual wires during twisting, then the lay length can be standardized, but the guide mandrel may interfere with the individual wires and requires separate actuators
Solution Approach 1:
The patent combines the guide mandrel function with the twisting unit structure itself. The twisting unit is designed to perform both the twisting action and the wire separation function through its inherent structural elements, eliminating the need for separate guide mandrels and their associated actuators. This integration resolves the contradiction by maintaining lay length consistency while reducing device complexity.
Solution Approach 2:
The patent extracts the guide mandrel as a separate movable component that can be repositioned or removed. The guide mandrel is designed to be movable along the twisting axis, allowing it to be positioned only when needed for lay length control and retracted or removed when not needed, thus avoiding interference with wires while maintaining precision when required.
2Manufacturing precision
If the guide mandrel is positioned before twisting begins, then wire separation is achieved, but vertical space is required for mandrel positioning
Solution Approach 1:
The patent transitions the guide mandrel positioning from a vertical dimension to a horizontal or longitudinal dimension along the twisting axis. By moving the mandrel along the axis of twisting rather than requiring vertical displacement, the solution achieves wire separation while minimizing vertical space requirements, effectively resolving the spatial contradiction.
Solution Approach 2:
The guide mandrel is designed to be nested within or integrated into the twisting unit structure. The mandrel can be retracted into the twisting unit body when not in use, eliminating the need for external vertical space. This nesting approach allows the mandrel to be present during twisting for precision control while occupying minimal space when retracted.
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 enables efficient twisting of wires with consistent lay length and reduced vertical space requirements, improving the quality and efficiency of cable bundle formation.
Implementation Method 1
The actuation takes place against a prestressing force of a spring element
Data Source
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Figure 5~7
AI summary
A device (100) and a method for twisting individual conductors (11, 12) around a twisting axis (V) to form a conductor bundle (10) along an extension axis (A) are provided. The device (100) comprises spaced-apart individual rotary units (41, 42) for separately holding conductor ends (15, 16) at one end of the individual conductors (11, 12), a twisting unit (30) for holding and twisting conductor ends at the other end of the individual conductors (11, 12), and a guide device (35) to which a guide mandrel (360) is attached for at least partially separating the individual conductors 11, 12 during a twisting process by means of the twisting unit in a region where there is a transition from an untwisted region to a twisted region.The guide device (35) further comprises a movement element (355) for moving the guide mandrel (360) from a starting position into a moved position in which the guide mandrel is moved into the twisting axis (V); and a locking element (353) for holding the guide mandrel (360) in the position moved out of the twisting axis (V).