EP4216378A1 - Cable alignment device and method for aligning assembled cable ends of two cables of a cable strand with correct position during rotation and arrangement for fitting connector housings with cable ends to the cable alignment device - Google Patents

Abstract

A dual cable alignment device (10) for aligning assembled cable ends of two cables (3, 4) of a twisted cable strand (2) in the correct rotational position, the cable alignment device (10) comprises two clamping jaws (7, 8) and one arranged between the clamping jaws (7, 8). center bar (9). Each of the two clamping jaws (7, 8) which can be moved towards one another in the closing direction (s) can clamp a cable (3, 4) between the central web (9) and the clamping jaws (7, 8). The clamping jaws (7, 8) are also designed to be movable laterally past the central web (9) in order to change the rotational position by rolling the cable (3, 4) clamped between them. The clamping jaws (7, 8) can be moved laterally independently of one another by means of their own lateral drives (16, 17), which ensures that each cable (3, 4) can be precisely and reliably brought into the desired rotational position.

Description

The invention relates to a cable alignment device for aligning assembled cable ends of two cables of a cable harness in the correct rotational position. Furthermore, the invention relates to an arrangement for handling cables and for equipping plug housings with cable ends that have been aligned by means of such a cable alignment device, and a method for aligning assembled cable ends in the correct rotational position.

Wiring harnesses, such as those used in automobiles or airplanes, consist of several cables that are fitted with connector housings at their ready-made cable ends. For this purpose, the previously assembled, i.e. cut to length, stripped and provided with contact elements (e.g. crimp contacts) cable ends are inserted into chambers or receptacles of the connector housing. As a rule, the cables of a cable harness with the cable ends to be assembled are available individually and are also inserted individually into the chambers of the connector housing with corresponding mechanical devices. Recently, cable harnesses consisting of two or more cables are also being used to an increasing extent, primarily twisted cables, for which there is also a need to equip the free, in particular untwisted and possibly stretched cable ends of the cable harness. Twisted cables such as so-called UTP cables (UTP: Unshielded Twisted Pair) offer greater protection against electrical and magnetic interference than untwisted pairs of wires and are characterized by particularly good signal transmission qualities. In addition to twisted cables, however, untwisted cables from cable strands or other multi-cable systems can also be used in which the cables are merely arranged next to one another and combined in a composite.

For the automatic assembly of connector housings with cable strands consisting of two

Corresponding mechanical devices known to those skilled in the art as cable assembly stations are used for cables. The two contact elements must be in the correct rotational position (angular position around the longitudinal axis of the cable) so that they can fit and be inserted into cells of a connector housing, which makes the automatic assembly of connector housings with cables challenging. In order to be able to exploit the advantages of UTP cables, the untwisted areas of the cable ends should be kept as short as possible. Aligning such short cable ends of the twisted cable strand in the correct rotational position is particularly demanding.

A cable alignment device for the rotationally correct alignment of assembled cable ends of two cables of a twisted cable harness is known from EP 3 301 768 A1 known. With this cable alignment device, the cable ends can be rotated by means of a rotary gripping device which acts on the cable strand at the twisted cable area. An optical detection device for determining the rotational position of the cable checks the alignment of the contact elements. Such an optical detection device was already in the EP 1 304 773 A1 described. The cable alignment device according to EP 3 301 768 A1 also has cable grippers arranged one behind the other in the longitudinal direction of the longitudinal axis on the section of the untwisted cable end. The cable grippers are set up to fix only one cable at the cable end and to guide the cable end of the other cable. If one cable end is in the correct rotational position by turning the cable strand on the twisted cable area, it is fixed by the responsible cable gripper, while the other cable end is only guided by the cable gripper. As soon as both contact elements are correctly oriented, the actual assembly process can begin. As can be seen, the orientation process of this cable alignment device takes place in several work steps.

It is therefore an object of the present invention to avoid the disadvantages of the known and in particular to create an improved cable alignment device for aligning assembled cable ends of two cables of a twisted cable strand in the correct rotational position, which can be operated particularly efficiently.

This object is achieved according to the invention with a cable alignment device for rotationally correct alignment of assembled cable ends of two cables, in particular a twisted cable harness with the features of claim 1. For the sake of simplicity, this cable alignment device is also referred to below as a dual cable alignment device. The dual cable alignment device comprises two clamping jaws and a central bar arranged between the clamping jaws, with one cable each being able to be clamped between the central bar and one of the clamping jaws. To create a closed position, the clamping jaws can be two clamping jaws that can be moved towards one another in the closing direction. In the closed position, the respective cable is clamped between the clamping jaws and the middle bar. In the closed position, the two cables preferably run approximately axially parallel with respect to their cable ends. In order to change the rotational position, at least one of the and preferably both clamping jaws is designed to be able to be moved laterally past the central web, so that the respective rotational position of the cable can be changed by rolling when driving past. In the present case, lateral means a directional statement that runs on the one hand transversely and preferably at right angles to the longitudinal axis of the cable alignment device and on the other hand transversely and preferably at right angles to the closing direction. If the cable extends along a longitudinal axis, the cable clamped between the clamping jaws and the central web rotates about its longitudinal cable axis. In other words, the movement of the engaging means (clamping jaws, central web) past one another causes a rolling movement of the cable clamped between them. In particular, round cables, ie cables with a more or less circular outer contour, allow such rolling.

With the dual cable alignment device, assembled cable ends can be aligned quickly and efficiently. In particular, it is possible with this dual cable alignment device to align both cables or cable ends simultaneously, which significantly shortens the process time for the rotationally correct alignment. The contact elements attached to the cable ends can thus be brought into the correct rotational position easily and precisely. This also creates the basis for the cable ends with the contact elements being able to be easily inserted into the cells of a connector housing. The rotational position mentioned can be determined by an angle around the longitudinal axis of the cable. The angle indicates by how much the cable would have to be rotated around its longitudinal axis from the actual position in order to reach its target position.

When the cable, which extends along the longitudinal axis in the closed position, is held in a clamping manner between the central bar and one of the clamping jaws, the lateral displacement process can begin. If both assembled cable ends are to be aligned, both clamping jaws can be moved at the same time. However, other modes of operation are also conceivable. Thus, only one of the clamping jaws can be moved at first and only after the relevant first cable end has reached the correct rotational position is the other clamping jaw moved to adjust the second cable end. It is also conceivable that only one of the clamping jaws is moved in the lateral direction. For example, when one of the assembled cable ends specifies a reference position to which the cable end of the other cable is aligned.

For closing, i.e. for creating the closed position, and preferably also for opening the clamping jaws, the dual cable alignment device can have at least one feed drive. If only one feed drive is used, the clamping jaws can be geared to one another in such a way that both clamping jaws can be moved with the feed drive. However, it is advantageous if a separate feed drive is provided for each clamping jaw. This design even allows cables of different thicknesses to be processed. The respective feed drive can, for example, be designed pneumatically or electromechanically.

The two clamping jaws are preferably positioned one above the other or next to each other in relation to the longitudinal axis, at least in an initial or open position and after the closing process has been completed, i.e. in the closed position before lateral movement. The clamping jaws positioned in this way are consequently arranged overlapping or covering one another, seen in the viewing direction of the closing direction.

The central web can be arranged in a fixed manner in the cable alignment device at least temporarily, in particular at least during the lateral movement for changing the rotational position.

A separate lateral drive can be provided for the at least one laterally displaceable clamping jaw, whereby the clamping jaws have their own drives are independently laterally movable. The respective lateral drive can be controlled individually. Two lateral drives are preferably provided, one individually controllable lateral drive being assigned to each clamping jaw. This ensures that each cable is brought into the desired rotational position precisely and reliably. The lateral drive can have a threaded rod drive. Furthermore, linear guides can be provided for the precise guidance of the clamping jaws for the lateral movement.

An advantageous dual cable alignment device results when the clamping jaws and the central web each have clamping surfaces running parallel to one another. The clamping surfaces can be flat. Profiled clamping surfaces can be provided to ensure a reliable rolling movement during lateral movement. These clamping surfaces can be provided with a profiling preferably formed by grooves or grooves.

The grooves or grooves of the profiling can form a pattern with a large number of parallel lines. Two sets of parallel lines crossing each other to form a diamond-shaped pattern are also conceivable.

The grooves or grooves of the profiling can be arranged running transversely to the longitudinal axis and preferably running diagonally on the clamping surfaces. It can be particularly preferable if the grooves or grooves assigned to the respective clamping jaws are oriented transversely and preferably at right angles to the grooves or grooves assigned to the central web.

To form advantageous clamping surfaces, the clamping jaws and the central web can have coatings of an elastomer to increase friction. Means of attack coated in this way can also ensure slip-free rolling of a cable whose outer sheath is smooth and difficult to handle. Alternatively, the clamping jaws and the central web, particularly if they are made of metallic materials, can be roughened in the area of the clamping surfaces to increase friction.

The middle web can taper towards the rear end Have inlet section. The rear end is the end that faces the twisted area of the cable harness. The tapering entry section specifies an entry geometry for the two cables of the cable ends. At the rear, this inlet section adjoins a clamping section that includes the clamping surfaces. The inlet section can be formed, for example, by bevels in the central web. The two cables of the cable ends can lie against the bevels and form a kind of cable triangle.

For greater variability of the cable alignment device, it can be advantageous if the central web can be exchanged, and preferably can be exchanged automatically.

A further embodiment relates to a cable alignment device in which the central web has web segments which are separated from one another in a step-like manner for the selective specification of different clamping surfaces. The clamping surfaces of the individual web segments can be spaced at different distances from one another. This means that different cables can be processed with the same device. This central web is thus formed as a column which is stepped in relation to the web axis. The central web with the web segments separated from one another in a step-like manner can be moved in steps by means of an adjusting device between the clamping jaws, depending on the selected step.

At least one clamping segment of the central web can have grooves or grooves to form a profile on the contact surfaces. The grooves or grooves of the middle bar can interact with corresponding grooves or grooves of the clamping jaws in such a way that during a lateral movement the clamping jaws and the middle bar can be partially interlocked and the next larger step does not impede the movement of the clamping jaw.

The clamping jaws and/or the central web can be equipped with sensors for determining the torsional moment applied to the clamped cable, as a result of which torsion of the cable can be determined in a simple manner and undesired torsion can be prevented. Such sensors are particularly helpful when handling very thin cables, since such cables must not be twisted too much. Force sensors are preferably used as sensors, which in the lateral direction (z-direction) measure.

Furthermore, the dual cable alignment device can include a detection device for determining the respective rotational position of the assembled cable ends. The detection device can preferably be an optical detection device.

The rotational positions of the cable ends are preferably determined at least before the start of the alignment process. Based on the knowledge of the actual condition, it can be calculated to what extent the cable has to be rotated. The distance required for the lateral movement can be calculated by taking the cable diameter into account. After the first setting, the lateral method preferably checks whether the rotational position has actually been assumed to be in the desired position. Otherwise, the readjustment process must be repeated again. Alternatively, it is also conceivable that the rotational position is monitored permanently or at least during the entire alignment process. A cable end monitored in this way allows control without prior calculation of the required travel path, during which the clamping jaw is continuously moved laterally and the travel process is stopped when the correct rotational position is present.

For example, the optical detection device can include a camera. Alternatively, the optical detection device can be or include a scanning unit or an image acquisition module with at least one line sensor. The assembled cable ends are preferably introduced into the image acquisition module before the start of the alignment process.

A further aspect of the invention relates to an arrangement for handling cables with a cable alignment device for aligning assembled cable ends of two cables of a twisted cable strand in the correct rotational position, in particular the dual cable alignment device described above and with an assembly gripping unit with two individually controllable cable grippers for grasping the assembled cable ends of the cables aligned in the correct rotational position and for feeding the assembled cable ends to connector housings. The assembly can take place in a connector housing with two cells, for example. However, two connector housings are also conceivable, into which the respective cable ends are plugged.

The two clamping jaws and the middle bar of the dual cable alignment device can optionally also be used for assembly, in that the two clamping jaws and the middle bar assume the functions of cable grippers. This can be done, for example, in that the central web is designed to be divisible or consists of two parts and that the web halves or parts separated by division can each work together with the associated clamping jaws to create individual gripping units in such a way that they can each be moved more or less individually for the assembly process to connector housings.

The invention then relates to a method for aligning assembled cable ends of two cables of a particularly twisted cable strand in the correct rotational position, preferably using the cable alignment device described above. The method is characterized in that each of the cables is clamped between gripping means, and that the clamped cables are set in motion by the gripping means moving past one another, thereby changing the rotational position of the assembled cable ends of the cables and thus aligning the respective assembled cable end. The engaging means are preferably the clamping jaws mentioned at the outset and the central web.

In one embodiment, the engagement means are moved past one another until the desired rotational position of the respective assembled cable end is reached. It is advantageous if only one of the means of attack is moved per cable and the other means of attack is stationary or remains stationary. The latter means of engagement can be formed by a common component which is arranged centrally between two means of engagement which can be moved laterally.

The rotational position of the assembled cable ends can be monitored using an optical detection device that uses a shadow image of the contact elements to detect the position. The shadow image is preferably generated from the shadow width or shadow contour of the contact elements and the angle of rotation of a scanning unit of the optical detection device.

A particularly advantageous method results when the rotational position of the assembled cable ends is monitored by means of the optical detection device, which uses a shadow image of the two contact elements of the cable ends to determine the position, with the determination of the rotational position of the assembled cable ends being excluded from the examination of the area of the shadow image in which an overlap of the shadow contours of the two contact elements occurs.

Furthermore, it can be advantageous if the assembled cable ends are pre-aligned and only then is the rotational position of the assembled cable ends determined for the first time by means of the optical detection device. The process time for carrying out the alignment process can thus be further shortened. An operator can carry out the pre-alignment manually, for example.

The cable rolling movements caused by the means of attack driving past each other can lead to the cable ends being further apart. This aspect can be useful. For example, the cable ends, which are now farther apart, can be gripped more easily by cable grippers. The cable ends can be approximately at the same height in the closed position or at the beginning of the alignment process. The assembled cable ends can have different heights during or after the alignment process. The fully aligned, assembled cable ends can be gripped by cable grippers at different heights and brought to the desired location, e.g. in the cells of a connector housing, for assembly.

Figur 1

eine perspektivische Darstellung einer erfindungsgemässen dualen Kabelausrichteinrichtung zum rotationslagerichtigen Ausrichten von konfektionierten Kabelenden zweier Kabel eines verdrillten Kabelstrangs mit einem Mittelsteg und zwei Klemmbacken in einer Schliessstellung,

Figur 2

eine perspektivische Darstellung des verdrillten Kabelstrangs mit ausgerichteten konfektionierten Kabelenden,

Figur 3a-3c

jeweils einzelne Arbeitsschritte entsprechende Darstellungen einer erfindungsgemässen dualen Kabelausrichteinrichtung in schematisierten Vorderansichten,

Figur 4a-c

perspektivische Darstellungen der dualen Kabelausrichteinrichtung von Figur 1 während einzelnen Arbeitsschritten,

Figur 5

die duale Kabelausrichteinrichtung aus Figur 1 in einer Seitenansicht mit fertig ausgerichteten konfektionierten Kabelenden,

Figur 6

die duale Kabelausrichteinrichtung in der Draufsicht,

Figur 7

eine perspektivische Darstellung einer dualen Kabelausrichteinrichtung mit einer optischen Detektionseinrichtung zum Ermitteln der Rotationslagen der konfektionierten Kabelenden,

Figur 8

eine perspektivische Darstellung einer Anordnung mit der dualen Kabelausrichteinrichtung und der optischen Detektionseinrichtung gemäss Figur 7 sowie mir einer Bestückungsgreifeinheit mit zwei Kabelgreifern,

Figur 9

eine Seitenansicht einer Anordnung mit der dualen Kabelausrichteinrichtung und der Bestückungsgreifeinheit mit zwei Kabelgreifern,

Figur 10

eine perspektivische Darstellung der Anordnung gemäss Figur 9,

Figur 11

eine perspektivische Darstellung eines Mittelstegs und zweier Klemmbacken für die duale Kabelausrichteinrichtung gemäss einem weiteren Ausführungsbeispiel,

Figur 12

der Mittelsteg und die Klemmbacken in einer Draufsicht,

Figur 13

eine perspektivische Darstellung eines Mittelstegs und zweier Klemmbacken für die duale Kabelausrichteinrichtung gemäss einem weiteren Ausführungsbeispiel,

Figur 14

der Mittelsteg und die Klemmbacken in einer Draufsicht,

Figur 15

eine perspektivische Darstellung eines als gestufte Säule ausgeformten Mittelstegs und zweier Klemmbacken für eine weitere duale Kabelausrichteinrichtung,

Figur 16

der als gestufte Säule ausgeformte Mittelsteg und die Klemmbacken in einer Draufsicht,

Figur 17

eine Variante eines Klemmbackens für die duale Kabelausrichteinrichtung,

Figur 18

eine alternative Ausführung des Klemmbackens von Figur 17,

Figur 19

schematisierte Vorderansichten der dualen Kabelausrichteinrichtung in verschiedenen Stellungen,

Figur 20

eine Kraft/Weg-Kurve,

Figur 21

eine alternative Kraft/Weg-Kurve,

Figur 22

eine vereinfachte Darstellung einer Prüfsituation zum Ermitteln der Rotationslage von konfektionierten Kabelenden mit Schattenbild,

Figur 23a/b

eine vereinfachte Darstellung der Prüfsituation mit Schattenbild, wenn ein Kontaktteil gedreht wird, und

Figur 24

eine vereinfachte Darstellung einer Prüfsituation mit Schattenbild gemäss einer bevorzugten Ausführungsform mit vorausgerichteten Kontaktelementen

Further individual features and advantages of the invention result from the following description of exemplary embodiments and from the drawings. Show it:

figure 1

a perspective view of a dual cable alignment device according to the invention for the rotationally correct alignment of assembled cable ends of two cables of a twisted cable strand with a central web and two clamping jaws in a closed position,

figure 2

a perspective view of the twisted cable harness with aligned cable ends,

Figure 3a-3c

representations of a dual cable alignment device according to the invention in schematic front views corresponding to individual work steps,

Figure 4a-c

Perspective views of the dual cable alignment device of FIG figure 1 during individual work steps,

figure 5

the dual cable alignment device figure 1 in a side view with fully aligned cable ends,

figure 6

the dual cable alignment device in top view,

figure 7

a perspective view of a dual cable alignment device with an optical detection device for determining the rotational positions of the assembled cable ends,

figure 8

a perspective view of an arrangement with the dual cable alignment device and the optical detection device according to FIG figure 7 as well as an assembly gripping unit with two cable grippers,

figure 9

a side view of an arrangement with the dual cable alignment device and the assembly gripper unit with two cable grippers,

figure 10

a perspective view of the arrangement according to figure 9 ,

figure 11

a perspective view of a central bar and two clamping jaws for the dual cable alignment device according to a further embodiment,

figure 12

the middle bar and the clamping jaws in a plan view,

figure 13

a perspective view of a central bar and two clamping jaws for the dual cable alignment device according to a further embodiment,

figure 14

the middle bar and the clamping jaws in a plan view,

figure 15

a perspective view of a central web shaped as a stepped column and two clamping jaws for a further dual cable alignment device,

figure 16

the middle bar shaped as a stepped column and the clamping jaws in a plan view,

figure 17

a variant of a clamping jaw for the dual cable alignment device,

figure 18

an alternative version of the jaws of figure 17 ,

figure 19

Schematic front views of the dual cable alignment device in different positions,

figure 20

a force/displacement curve,

figure 21

an alternative force/displacement curve,

figure 22

a simplified representation of a test situation to determine the rotational position of assembled cable ends with a silhouette,

Figure 23a/b

a simplified representation of the test situation with a shadow when a contact part is rotated, and

figure 24

a simplified representation of a test situation with a shadow according to a preferred embodiment with pre-aligned contact elements

figure 1 shows a cable alignment device 10 for aligning cable ends of two cables 3, 4 of a twisted cable strand 2 extending along a longitudinal axis L in the correct rotational position. For the sake of simplicity, the term “dual cable alignment device” is therefore also used below for the cable alignment device 10 handling two cables 3, 4. The respective cable is usually an electrical cable containing, for example, a solid conductor made of copper or steel or wire strands and insulation as a sheath for the conductors.

This in figure 1 The Cartesian coordinate system shown serves as an aid to understanding the directions and the main movements of the components of the dual cable alignment device 10. The dual cable alignment device 10 comprises two clamping jaws 7 and 8, which can be moved transversely to the longitudinal axis L, in opposite directions between an initial or open position and a closed position in the y direction. The longitudinal axis L also corresponds to the direction in which the respective cable longitudinal axes of the cable ends of the cables 3, 4 run. The closing movement to create the closed position is indicated by arrows s. The dual cable alignment device 10 further includes a central web 9 arranged between the clamping jaws 7, 8 1 In the closed position shown, the two cables 3, 4 running approximately axially parallel are held in place by the cable alignment device 10. In each case, a cable 3, 4 is held in a clamping manner between the central web 9 and one of the clamping jaws 7, 8.

The cable alignment device 10 shown here is used in particular with regard to a subsequent assembly of connector housings with ready-made cable ends. At the respective stripped cable ends of the twisted cable strand 2, crimp contacts are present as contact elements 5, 6, for example.

How out figure 1 can be removed, the assembled cable ends of the cables 3, 4 are not rectified and oriented obliquely relative to the vertical and horizontal. Be rotationally aligned with the dual cable alignment device 10 described in detail below. figure 2 shows a cable harness 2 with such aligned finished cable ends of the cables 3, 4, wherein the cable ends with the contact elements 5, 6, however, lie on a common horizontal plane.

at in figure 2 shown twisted cable harness 2 is a so-called UTP cable. At the free ends of the cables 3, 4 are contact elements 5, 6 with rectangular or rhombic cross-section outer contours attached. However, the contact elements 5, 6 could also have other non-round cross-sectional shapes. Round contact elements usually do not require their rotational position to be adjusted. Grommets 35 are also attached to the ends of the cables 3, 4 by way of example. Of course, grommets can also be dispensed with if required. The twisted area of the cable harness 2 is denoted by 13 . The front side of the short untwisted area with the assembled cable ends of the cables 3, 4 adjoins this twisted area 13. Areas of the cables 3, 4 are designated by 14, 15, in which areas the clamping jaws 7, 8 and the central web 9 act on the respective cable. However, the dual cable alignment device 10 can also be used to process untwisted cable strands composed of two cables.

The basic structure and operation of the dual cable alignment device 10 is from the Figures 3a to 3c removable. figure 3 a shows the dual cable aligner 10 in a home position. In this position, the cable ends of the cable harness can be inserted into the dual cable aligner 10 . One cable 3, 4 each is then located between one of the clamping jaws 7, 8 and the centrally arranged central web 9. The two clamping jaws 7, 8 are then moved toward one another by means of feed drives (not shown here). The corresponding closing directions or movements are indicated with arrows s1 and s2. To close the clamping jaws 7, 8, it is advantageous to provide two feed drives so that each clamping jaw 7, 8 can be fed in individually. This also has the advantage that cables of different thicknesses can also be processed if necessary. Figure 3b shows the situation after delivery. In the closed position, the cables 3, 4 are held in a clamping manner between the central web 9 and one of the clamping jaws 7, 8.

After the closed position has been created, the assembled cable ends of the cables 3, 4 are generally not yet in the correct rotational position. The corresponding misalignments are in Figure 3b with angles α ₁ and α ₂ indicated. For alignment, the clamping jaws 7, 8 are now moved in the lateral direction, while the middle bar 9 remains stationary. The corresponding lateral movement of the clamping jaws 7, 8 is indicated by arrows _w1 and _w2 . In the case shown here, the clamping jaws 7, 8 perform an opposite but not coupled movement. Depending on the misalignment and the desired target position, movements in the same direction are also conceivable. Under certain circumstances, only one of the clamping jaws 7, 8 is moved.

The clamping jaws 7, 8 and the central web 9 each have clamping surfaces 20, 21, 22, 23 running parallel to one another. The clamping surfaces 20, 21, 22, 23 are, for example, designed to be planar in the present case. By driving past each other the attack means 7, 9; 8, 9, the clamped cables 3, 4 are set in a cable rolling motion. In order to enable the cable rolling movement, the cables have an outer contour that is approximately circular in cross section and is predetermined, for example, by the cable sheath. The opposing clamping surfaces 20, 22; 21, 23 each specify a type of track on which the cables can roll off. The cable 3 rolls down when the clamping jaw 7 is moved laterally in the w ₁ direction. The cable 4 rolls up when the clamping jaw 8 is moved laterally in the w ₂ direction. After the lateral procedure, the in Figure 3c shown situation in which the misalignments of the assembled cable ends of the cables 3, 4 are corrected. As can be seen, the cables 3, 4 are no longer at the same height. As a result of the cable rolling movements, the cables 3, 4 are moved up or down.

The lateral displacement path by which the respective clamping jaws 7, 8 must be moved up or down essentially depends on the angle α1, α2. These angles can be detected by means of detection devices for determining the rotational position of the cables. Such detection devices are explained in detail below. The cable diameter is often already known and does not necessarily have to be specifically recorded. Based on the knowledge of the actual state, as based on the angle value α ₁ , α ₂ , including the cable diameter, it can be calculated to what extent the cable must be rotated and consequently how large the travel path required for this must be.

The Figures 4a to 4c show the dual cable aligner 10 of FIG figure 1 in the same positions analogous to Figures 3a-3c . In figure 1 and in the Figures 4a to 4c are also the respective drives for moving the individual components recognizable. Infeed drives for closing and opening the clamping jaws 7, 8 are denoted by 18, 19. The infeed drive 18, which is designed pneumatically or electromechanically, for example, moves the clamping jaw 7 in the s ₁ direction for infeed, the infeed drive 19 moves the clamping jaw 8 in the s ₂ direction for infeed ( Figure 4a ). The two clamping jaws 7, 8 are designed to change the rotational position of the assembled cable ends of the cables 3, 4 by means of lateral drives 16, 17 on the central web 9 laterally mobile past. Each clamping jaw 7, 8 is assigned its own individually controllable lateral drive 16, 17 for the lateral movement. The clamping jaws 7, 8 can be moved independently of one another in the w ₁ or w ₂ direction by means of their own drives 16, 17. It can thus be ensured that each cable 3, 4 is brought into the desired rotational position precisely and reliably. The lateral drives 16, 17 are embodied as threaded rod drives with threaded rods 36 in the present example. Other linear drives such as those with linear motors can also be used for the lateral drives 16, 17. Pneumatic or hydraulic lateral drives are also conceivable.

The clamping jaws 7, 8 and the central web 9 have flat clamping surfaces for loading the cables 3, 4. In order to increase the friction, the clamping jaws 7, 8 and the central web 9 can have coatings made of an elastomer, so that advantageous clamping surfaces are created which allow the cables 3, 4 to roll without slipping. As an alternative to coating, it is also conceivable to roughen the clamping jaws 7, 8 made of metallic materials and the central web 9 in the area of their clamping surfaces, which can also increase the friction for optimal cable rolling movements.

Further structural details of the dual cable alignment device 10 can be found in FIGS Figures 5 and 6 be removed.

To check whether the assembled cable ends of the cables 3, 4 are in the correct rotational position after the alignment process, the in figure 7 Optical detection device 11 shown can be used. With this optical detection device 11, however, the actual states of the cable ends, ie the misalignments essentially characterized by the angles α1, α2 at the start of the alignment process (cf. Figure 3b ) be determined. The optical Detection device 11 includes an image acquisition module with a scanning unit with line sensors. The optical detection device 11 also has a test head 40, which is cylindrical here by way of example, which contains the line sensors and which can be rotated about its axis in a manner known per se. For this purpose, for example, an image acquisition module can be used, as is already known from FIG EP 1 304 773 A1 has become known. With regard to details on the structure and the basic mode of operation, reference is made to this document. The present optical detection device 11 differs from the known detection device primarily in that it is particularly well suited for detecting assembled cable ends of two cables. This aspect will be discussed below in particular with reference to figures 23 up to 25 still received in detail.

After the angular position has been set by moving the clamping jaws 7, 8 laterally, the rotational position of the assembled cable end is checked for each cable 3, 4 using the optical detection device 11 to determine whether the target position has actually been assumed. Otherwise, the readjustment process must be repeated again.

How out figure 7 can be seen, the cable alignment device 10 is equipped with linear guides 37, which ensure lateral linear movements with high precision.

After completion of the alignment process, in which the assembled cable ends of the two cables 3, 4 were aligned in the correct rotational position by means of the dual cable alignment device 10 described above and the correct rotational position of the assembled cable ends was determined or checked by means of the optical detection device 11, the next work step can be the actual assembly. For assembly, the assembled cable ends of the cables 3, 4 are grasped by an assembly gripping unit 12 and guided to connector housings (not shown), which are figure 8 is shown. In this case, the contact elements 5, 6 are plugged into cells of a connector housing, for example.

In the present case, the dual cable alignment device 10 is therefore a component of an arrangement for handling cables, which is denoted by 1 and which, for the sake of simplicity, is referred to below as the “assembly arrangement”. The placement arrangement 1 comprises the dual cable alignment device 10, the optical detection device 11 and the pick and place unit 12.

The pick-and-place gripping unit 12 has two cable grippers 30, 31 for gripping the assembled cable ends of the cables 3, 4 and for feeding the assembled cable ends, which are aligned in the correct rotational position, to the connector housings. Each of the cable grippers 30, 31 can be controlled individually and can be moved in the x, y and z directions. The fact that the cable grippers 30, 31 can be moved independently of one another by means of corresponding actuators ensures that the cables, which are generally at different heights after the alignment process, can be gripped. A third gripper 32 is also provided for strain relief of the cable harness 2 during loading.

Further details of the pick-and-place gripping unit 12 for the pick-and-place assembly 1 are shown in FIGS figures 9 and 10 removable. So are about in figure 9 the directions of movement of actuators are indicated by double arrows, with which the cable grippers 30, 31 can be moved. By means of actuators designated 50, the cable grippers 30, 31 can be moved up and down in the z-direction in order to be able to grasp the cables 3, 4 lying at different heights. Actuators 49; Actuators 51 are used to move the cable grippers 30, 31 in the y-direction figure 9 Actuators 48 for opening and closing the cable grippers 30, 31 can be seen.

The cable grippers 30, 31 grasp the cables 3, 4 in front of the components (jaws 7, 8, central web 9) acting on the cable. Since these components 7, 8, 9 act on a comparatively large cable section - with respect to the cable longitudinal axis L - for the cable rolling movements, the cable grippers 30, 31 have only little space for grasping the cables 3, 4. Therefore, each of the cable grippers 30, 31 has cranked front parts 33, which connect the respective gripper jaws 38 of the cable grippers with the gripper supports 39. The cranked cable grippers 30, 31 are also very popular figure 10 recognizable.

To ensure a reliable rolling movement of the cable during the lateral process, the two clamping jaws 7, 8 and the central web 9 can be profiled Clamping surfaces are provided. Clamping surfaces with such profiles formed by grooves or grooves are in the Figures 11 to 16 shown. In the embodiment according to Figures 11 and 12 the grooves of the profiles run in the z-direction, ie at right angles to the longitudinal axis L of the cable alignment device 10. The profile is formed by grooves running parallel to one another. The grooves of the clamping surface 20 of the clamping jaw 7 are denoted by 24; the grooves of the clamping surface 22 of the central web are denoted by 34 . The clamping surfaces 21 and 23 assigned to the other cable are designed in the same way. As can be seen, the grooves 24, 35 of the clamping surfaces 20 and 22 lying opposite one another cover one another—seen in the y-direction. This arrangement is particularly good in figure 12 recognizable. Like subsequent figure 16 relating to a further exemplary embodiment, the grooves can also be arranged offset from one another in the cable alignment device 10 .

In the figure 11 shown jaws 7, 8 are designed as one-piece components. The components, which are preferably made of metallic materials, consist of jaws containing the clamping surfaces 20 or 21, connecting arms 28 and connecting parts 29, the connecting parts 29 forming spindle nuts for the previously mentioned threaded rod drives.

From the Figures 11 and 12 It can then be seen that the central web 9 has a tapering inlet section 25 which adjoins the clamping surfaces 22 , 23 and which faces the twisted region 13 of the cable harness 2 . The inlet section 25 is formed by bevels that create a favorable inlet geometry.

An alternative embodiment of the profiling show the Figures 13, 14 . The profiles of the clamping surfaces 20, 21, 22, 23 of the two clamping jaws 7, 8 and the central web 9 also run transversely to the longitudinal axis L, as in the previous embodiment, but here diagonally. How figure 13 shows, the diagonally running grooves 24 of the clamping jaw 7 are oriented at right angles to the grooves 34 associated with the central web 9 . The same applies to the clamping jaws 8 . Here, too, the grooves of the clamping jaw 8 are oriented at right angles to the grooves associated with the central web.

The Figures 15 and 16 relate to another arrangement with jaws 7, 8 and Center bar 9 for the cable alignment device 10. The center bar 9 has step-like separate bar segments for optionally specifying different clamping surfaces 22, 23; 22', 23';22",23" on. The central web 9 is formed as a stepped column with respect to a web axis running in the z-direction. The clamping surfaces 22, 23 of the first web segment, the clamping surfaces 22', 23' of the second web segment and the clamping surfaces 22", 23" of the third web segment are obviously spaced apart by different distances. With such an arrangement, cables of different thicknesses can be aligned in the correct rotational position. The central web 9 can be moved between the clamping jaws 7, 8 by means of a drive, not shown here. The moving in and out movement of the central web 9 would take place in the direction of the z-axis. In figure 15 are the clamping jaws 7, 8 at the height of the first bar segment of the middle bar 9. In order to get to the next larger step or the next but one step, the middle bar 9 must be shifted by a corresponding distance in the z-direction. The clamping segment of the middle bar 9 has grooves 34 which interact with corresponding grooves 24 of the clamping jaws 7, 8 in such a way that during an alignment process for aligning the assembled cable ends in the correct rotational position, the clamping jaws 7, 8 and the middle bar 9 can be retracted partially interlocking during a lateral movement, so that the next larger step does not impede the movement of the clamping jaws 7, 8.

The Figures 17 and 18 show a clamping jaw 8, which is provided with sensors for determining the torsional moment applied to the cable. Of course, the second clamping jaw is normally designed in the same way.

Thanks to such sensors, excessive torsion of the cable in the closed position during the lateral displacement process for changing the rotational position and thus undesired twisting of the cable can be prevented. In the embodiment according to figure 17 strain gauges arranged on an upper side and an underside of the connecting arm 28 are arranged as sensors. A recess is provided in the connecting arm 28 in order to make the deformation easier to recognize for the strain gauges and thus to be able to precisely measure the force in the z-direction. From this force, the torsion of the cable during alignment can be deduced. In the alternative embodiment according to figure 18 the connecting arm 28 has integrated pressure sensors 27 . The two-piece running jaws 8 consists of the connecting arm 28 with the jaws formed thereon for specifying the clamping surface 21 and from the connecting part 29. The deformation of the gripper jaw 8 in the z-direction can alternatively be determined, for example, via an actual/target comparison of the clamping surfaces of the outer jaws. The position of the clamping surface is measured in the Z direction and compared with the target position.

It may be that the measured deformation or force only allows a direct conclusion about the torsion of the cable end to a limited extent. The insulation can be deformed by clamping the cable, which leads to a flexing of the insulation when the clamping jaws are moved in the z-direction. In addition to the torsional moment of the cable, the flexing resistance can also act against the force of the clamping jaw (force in the z-direction). Such phenomena and how to counteract them are Figures 19a to 19d shown, this being explained here using the example of the cable 3 on the left in the figures.

In Figure 19a are the jaws 7, 8 in the closed position in which the jaws 7 touches the cable 3. If the clamping jaw 7 is now moved further in the direction of the arrow s, there is a deformation of the insulation of the cable sheath of the cable 3 ( Figure 19b ). When the clamping jaw 7 is moved laterally in the direction of the arrow w, the cable 3 is set in a rolling motion, during which flexing occurs. How Figure 19c shows, despite the flexing, the cable can be brought into the correct rotational position.

Another way provides that the clamping jaw 7 is moved briefly in the opposite direction. This countermovement is in Figure 19d indicated by the arrow r. Since the flexing resistance always acts in the opposite direction to the direction of movement, the flexing resistance can be eliminated by moving back briefly. The retraction of the clamping jaw serves to isolate the torsional moment of the cable from the flexing resistance. This results in a process according to Figures 19a, 19b, 19c and 19d . If a threshold value for the force in the z-direction is exceeded ( Figure 19c ), the return movement ( Figure 19d ) triggered. After retracting, the movement in the w-direction (cf. Figure 19c ) be continued. There can be a very small area where only the torsional moment of the cable 3 acts. But what you can always see is a clear drop in the amount of force (i.e. a drop in F) and, with continued return, a um curve offset by twice the amount of flexing resistance.

The resistance from flexing can be quantified in two ways. On the one hand, the offset of the force/displacement curve can be considered. Such a force/displacement curve is in figure 20 shown. Since the theoretical force/displacement curve of the cable (dash-dotted line) goes through the zero point, the offset is largely attributable to the flexing resistance. This essentially corresponds to the process according to the Figures 19a, 19b and 19c . A force/displacement curve for the process according to Figures 19a, 19b, 19c and 19d shows figure 21 . The outward journey is represented by a solid line and the return journey by the dashed line.

The rotational position of the assembled cable ends is monitored by means of an optical detection device 11, which uses a silhouette of the two contact elements 5, 6 of the cable ends 14, 15 to detect the position. In figure 22 a test situation with a shadow is shown as an example. The optical detection device 11 comprises a light curtain 11 and a line sensor 42 lying opposite it. The assembled cable ends of the two cables are located between them, with the present contact elements 5 and 6 being shown in simplified form as almost rectangular cross-sectional areas. In the present embodiment, the contact elements 5 and 6 have a diamond-shaped outer contour; In other words, the cross sections of the contact elements 5 and 6 are drawn as parallelograms. The parallelograms are evidently not perpendicular to the light curtain, which is close to a real situation where the cable ends may be slightly tilted. The optical detection device 11 can be rotated about an axis of rotation which extends in the direction of the x-axis. The line sensor 42 takes an image after each rotation of the optical detection device 11, whereby the in figure 22 composite silhouette shown is created. The axis of the silhouette labeled ω corresponds to the angle of rotation of the optical detection device 11.

The method for aligning assembled cable ends of two cables of the UTP cable in the correct rotational position can, for example, proceed as follows: The finished UTP cable is introduced into the cable alignment device 10 and the cables are clamped at the untwisted cable ends by the clamping jaws 7, 8 in the manner described above (closed position). For strain relief, the twisted area of the cable are kept at a certain distance from the arrangement with the clamping jaws 7, 8 and the central web 9. Thereafter, the optical detection device 11 is moved into a test position (cf. previous 7 ). There, the optical detection device 11 rotates the test head 40 around the contact elements 5, 6 and checks the rotational position of the contact elements. The probe 40 has the light curtain 41 and the associated line sensor 42 to generate shadow images of the contact elements 5.6. While the test head 40 rotates around the contact elements 5, 6, the captured shadow images are recorded. The shadowed edges of the contact elements illuminated in this way are denoted by 44 .

In a manner known per se, the shadow contour is examined for local minima 45 in order to determine the rotational position of the contact elements 5, 6. However, since there are now two contact elements 5, 6, the two shadow contours 43 overlap when the probe 40 rotates about the contact elements 5, 6. According to a starting position, however, the shadow edges can be assigned to the contact elements 5, 6. The area of expected overlap is excluded from the investigation. So that rotation angle range of the test head 40 in which it is expected that the contact elements 5, 6 are on top of each other (from the point of view of the line sensor). This overlap area is in figure 22 labeled 46.

If the contact elements 5, 6 run approximately parallel to the axis of rotation of the probe 40 and have a rectangular cross section in the cutting plane of the light curtain 41, then the minima 45 of a contact part 5, 6 are offset from one another by 90°. In this ideal situation, the local minima are repeated after 180°. Therefore, the entire 360° range does not necessarily have to be searched for the minima. If the contact elements 5, 6 with a rectangular cross section run at a small angle (e.g. 5°) to the axis of rotation of the test head 40, the detected cross section may be slightly distorted into a parallelogram if the tilting axis runs diagonally.

As long as the minima 45 do not move too far away from 90°, this case can be intercepted by the tolerance range of the cable alignment device 10. If the cross-section of the rectangular contact element is strongly distorted into a parallelogram, the current rotational position can also be calculated. The following The assembly process could possibly be made more difficult by a bent cable tip and the previous machining process therefore shows an error. Therefore, an error message is often preferred.

If there are problems in detecting the minima 45, the affected contact element 5, 6 can be rotated by the cable alignment device by a small amount and the test head 40 scans the new shadow contour. The shape of the shadow contour of the rotated contact element 5, 6 has changed and has been displaced along the angular axis of the shadow diagram. This is in the figures 23 and 24 shown. If a minimum 45 was in the area of the overlap, it would now step out of it.

In order to shorten the test time, it is also conceivable for the test head 40 to contain a second light curtain (not shown) with an associated line sensor, with this second light curtain being positioned offset by 90° to the first light curtain.

After the test, the cable alignment device 10 rotates the cable ends into the desired angular position. At the end of the alignment process, the contact elements 5, 6 can be rotated differently relative to one another, depending on the slots provided.

After completing the alignment in the correct rotational position, the assembly gripping unit 12 comprising two individually controllable cable grippers 30, 31 grips the cable ends at their respective z-positions and the optical detection device is moved away from the test position. Before or during departure, the contact elements 5, 6 are scanned in order to determine the positions of the tips of the contact elements in a known manner. Thereafter, the cable grippers 30, 31 insert the contact elements 5, 6 into the slots or cells provided on the connector housing, with the assembly process being adapted to the positions of the tips.

In a further preferred embodiment of the alignment process, the contact elements can be fed to the cable alignment device 10 in a prealigned manner. Thanks to this measure, the angular range through which the cable alignment device 10 must be able to rotate the contact elements 5, 6 can be reduced to ±20°. Also the examination area of the probe 40 can be reduced since--as is shown in FIG. 25--with pre-aligned contact elements 5, 6 a local minimum 45 per contact part is sufficient to determine the rotational position. Prealigned in this way, contact elements 5, 6 with an asymmetrical cross section can also be processed well.

Claims (15)

Cable alignment device (10) for aligning, in the correct rotational position, assembled cable ends of two cables (3, 4) of an in particular twisted cable strand (2), the cable alignment device (10) comprising: two clamping jaws (7, 8) and a central bar (9) arranged between the clamping jaws (7, 8), one cable (3, 4) each being able to be clamped between the central bar (9) and one of the clamping jaws (7, 8), and at least one of the and preferably both clamping jaws (7, 8) being designed such that it can be moved laterally past the central web (9) in order to change the rotational position. Cable alignment device (10) according to Claim 1, characterized in that a separate lateral drive (16, 17) is provided for the at least one laterally displaceable clamping jaw (7, 8). Cable alignment device (10) according to Claim 1 or 2, characterized in that the clamping jaws (7, 8) and the central web (9) each have clamping surfaces (20, 21, 22, 23) running parallel to one another, the clamping surfaces (20, 21, 22, 23) preferably being profiled and the clamping surfaces (20, 21, 22, 23) particularly preferably each having a 24, 34) formed profiling are provided. Cable alignment device (10) according to one of Claims 1 to 3, characterized in that the clamping jaws (7, 8) and the middle bar (9) consist of metallic materials which are roughened in the area of the clamping surfaces (20, 21, 22, 23) or that the clamping jaws (7, 8) and the middle bar (9) are coated in the area of the clamping surfaces (20, 21, 22, 23). Cable alignment device (10) according to one of Claims 1 to 4, characterized in that the central web (9) has a tapering inlet section (25) adjoining a clamping section comprising clamping surfaces (22, 23). Cable alignment device (10) according to one of Claims 1 to 5, characterized in that the central web (9) has web segments which are separated from one another in steps for optionally specifying different clamping surfaces (22, 23, 22', 23', 22", 23"). Cable alignment device (10) according to Claim 6, characterized in that at least one clamping segment of the middle bar (9) has grooves or grooves (34', 34"), which interact with corresponding grooves or grooves (24', 24") of the clamping jaws (7, 8) in such a way that, in the event of a lateral movement, the clamping jaws (7, 8) and the middle bar (9) can be retracted, partially interlocking. Cable alignment device (10) according to one of Claims 1 to 7, characterized in that the clamping jaws (7, 8) and/or the central web (9) are equipped with sensors (26, 27) for determining the torsional moment applied to the clamped cable (3, 4). Cable alignment device (10) according to one of Claims 1 to 8, characterized in that it further comprises a preferably optical detection device (11) for determining the respective rotational position of the cables (3, 4). Arrangement (1) for handling cables with a cable alignment device (10) for aligning assembled cable ends of two cables (3, 4) in the correct rotational position of an in particular twisted cable strand (2), in particular a cable alignment device (10) according to one of Claims 1 to 8 and an assembly gripping unit (12) with two individually controllable cable grippers (30, 31) for gripping and feeding to connector housings or to cells of a connector housing of the rotation correctly aligned ready-made cable ends (14, 15) of the cables (3, 4). Method for aligning assembled cable ends of two cables (3, 4) in the correct rotational position, in particular a twisted cable strand (2), preferably using the cable alignment device (10) according to one of Claims 1 to 9 and optionally for equipping plug housings (20) with Ready-made cable ends of two cables (8, 9) of the in particular twisted cable strand, characterized in that : - each of the cables (3, 4) is pinched between engagement means (7, 8, 9), and - the clamped cables (3, 4) are caused to roll by the action means (7, 8, 9) moving past one another, as a result of which the rotational position of the assembled cable ends of the cables (3, 4) is changed and the respective assembled cable end (14, 15) is aligned. Method according to Claim 11, characterized in that only one of the means of engagement (7, 8) is moved for each cable (3, 4) and the other means of engagement (9) remains stationary. Method according to Claim 11 or 12, characterized in that the rotational position of the assembled cable ends is monitored by means of an optical detection device (11) which uses a silhouette of the two contact elements (5, 6) of the cable ends (14, 15) for position detection, with the determination of the rotational position of the assembled cable ends (14, 15) excluding from the examination the area of the silhouette in which an overlapping of the shadow contours of the two contact elements (5, 6) occurs. Method according to one of Claims 11 to 13, characterized in that the assembled cable ends (14, 15) are pre-aligned and only then is the rotational position of the assembled cable ends (14, 15) determined by means of the preferably optical detection device (11). Method according to one of Claims 11 to 14, characterized in that the ready-made cable ends (14, 15) assume different heights during or after the alignment process and that the completely aligned ready-made cable ends (14, 15) are each gripped by cable grippers (30, 31) at the different heights and brought to the desired location for assembly.

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