Process for recognising and/or connecting wires of a cable

Abstract

 A separating device of the wires (3a, 3b) without sheaths of a cable (2) consists of a wedge-shaped push rod (12) located near the end of the cable (2); the push rod (12) moves from a first to a second position and vice versa; when the push rod (12) is found in the first position the wires (3a, 3b) are not separated; vice versa, when the push rod (12) is found in the second position the wires (3a, 3b) without sheaths are separated for examining their physical characteristics.

Description

[0001] The present invention relates to a process for recognising electric wires forming a first cable in order to weld, connect, grip said wires to corresponding wires forming a second cable, or to printed circuits, connectors, terminals etc.
The invention further relates to systems and/or apparatuses used for carry out the process.

[0002] In general, a cable is an electric line consisting of more wires covered by insulating material in the entire development, and housed inside protecting coating.
In the denomination of electric cable are comprised all types of cables, wires, cords, conductors and leads used in the electric systems and equipments of telecommunication.
A cable comprises a sheath or circular protecting or continuous coating applied on the wires; these consist of a metal conductor coated by an insulator suitable for standing to the voltage; the insulator is also used for obtaining the cores; therefore, a core is a wire coated by an insulator, when it is a part of a cable.

PRIOR ART

[0003] To connect in serie or in parallel two or more cables to terminals, printed circuits, connectors, clamps, etc., it is necessary to connect the wires of the cables suitable for feeding the same utilising system; for this reason each wire is recognised for an own colour or other physical features which make it evident.
At the moment the recognition of the colour or other features typical of each wire is carried out at sight or with apparatuses for inspection (tester or the like) by means of which the operators recognise the wires to be welded, connected, jointed, etc.

[0004] The disadvantage of the usual recognising methods consists of being manual; therefore, there depends on the experience and goodwill of the operator.

AIMS AND FEATURES OF THE INVENTION

[0005] The main purpose of the present invention is to obviate these disadvantages. The invention, as claimed, solves the problem of defining a process for recognising and/or connecting electric wires of a cable.
A second purpose of the present invention is to create systems and/or apparatuses for carry out the process.

PHASES AND FEATURES OF THE PROCESS

[0006] The process consists of the following phases which constitute a working cycle:

A - Removing phase in which the sheath of the cable to be connected, welded or gripped is removed from its end;

B - Recognising phase, in which the physical features of the single wires are recognised;

C - Connection phase in which the wires having physical features similar to other wires, terminals, printed circuits, connectors, clamps, etc. are connected.

PARTICULARITY OF THE PHASES

[0007] Each phase is carried out according to particular protocols which can be replied for each working cycle in order to obtain end-items with controlled quality.

[0008] The phase A is carried out by means of a separating device capable of separating the electric wires belonging to a first cable to begin the subsequent recognising phase B; in fact, before the phase A the sheaths of the electric wires, which are at an end of said cable, are removed and separated to each other so that it is possible to separately recognise each wire of the cable.

[0009] The phase B is carried out by maintaining the separating device in the position of separation of the electric wires and by examining at least one physical feature of each wire of the cable by means of a device suitable for the exam; during the phase B, the wire having the required physical feature is disposed in a sequence suitable for the welding, connection or gripping, forming the subsequent phase C, the last of the working cycle.

[0010] Preferably, the examined physical feature is the colour of the insulating coating of each wire; an other physical feature characterising each wire is the inductance which can be quantified by means of a tester during the phase B.

MAIN FEATURES OF THE APPARATUSES USED DURING THE PROCESS FOR RECOGNISING AND WELDING

[0011] The apparatuses for carrying out the process according to the present invention comprise:

a separating device capable of separating the wires belonging to a first cable for starting the subsequent recognising phase B;

sensors of the physical features of the single wires;

a central control unit connected to the sensors; the central control unit controlling at least one device capable of displacing or maintaining fixed the wires separated by the separating device according to the values of the signals of the sensors to arrange the wires in a sequence suitable for the welding, connection or gripping, considering the reference sequence of the wires of the cable.

[0012] A device for the connection of the cables capable of displacing the end of each wire, until it is moved into the position suitable for the welding, connection or gripping.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Further advantages, details and salient features of the invention will be outlined in the following description of preferred embodiments of the system as in the present invention, with reference to the accompanying drawings:

Fig.1 represents schematically a side view of a first embodiment of a separating device before having separated the wires of the cable;

Fig.2 schematically represents a front view of the device of Fig.1 with a vice used for rotating the cable;

Fig.3 represents schematically a side view of the device of Fig.1 which has separated the wires of the cable;

Fig.4 represents schematically a side view of a second embodiment of a separating device before having separated the wires of the cable;

Fig.5 represents schematically a side view of the device of Fig.4 which has separated the wires of the cable:

Fig.6 represents schematically a perspective of a device for welding the cables;

Fig.7 represents schematically a side view of a third embodiment of the separating device before having separated the wires of the cable;

Fig.8 represents schematically a front view of the third embodiment of the device in condition of Fig.7;

Fig.9 shows schematically a front view of the third embodiment of the separating device which squashes the wires of the cable to separate them;

Fig.10 is a schematic side view of the device in condition of Fig.9;

Fig.11 shows a front view of the device which already squashed the separated wires, arranged out-of-order;

Fig.12 shows a cable with the wires arranged in order;

Fig.13 shows a mechanism capable of arranging in order the wires of a cable;

Figs 14, 15 and 16 demonstrate how it is possible to arrange in order the wires of a cable initially arranged out-of-order;

Figs 17 to 23 show an embodiment of a wedge-shaped push rod used for separating the ends of the wires and tools allowing the deformation of said wires;

Fig.24 shows a fourth embodiment of the separating device before having separated the wires of the cable;

Fig.25 shows the separating device after having separated the wires of the cable.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0014] The device shown in Figures 1 to 3 is used for separating the wires without the sheath of a cable.
This device essentially consists of a self-centring vice 1 supporting an end of a cable 2; from the end a plurality of wires 3a, 3b protrudes, the wires 3a, 3b being coated by coloured insulating material; the vice 1 consists of three wheels 4, 5, 6 adhering to the external surface of the end of the cable 2 for loading it with a torsional stress. The wheels 4, 5, 6 are rotated by a motor 7 feed by a source of electric energy 8 and controlled by a central control unit 9; a plurality of emitters 10 is provided each emitting a beam of polychrome light towards a respective wire 3a, 3b; the mirrored light presenting the colour of the coating of the wire 3a, 3b comes back towards the sender 10 (used as receiver) connected to the central control unit 9 through an amplifier 11 of the signal of the sender - receiver 10.

[0015] Each sender 10 is sensitive only to a colour so that it changes the level its signal when receives the mirrored light of said colour; therefore, each sender 10 sends to the central control unit 9, through the amplifier 11, an electric signal the first level of which shows that the mirrored light has the colour to which the sender 10 is sensitive, while the second level shows that the mirrored light has not the colour to which the sender 10 is sensitive, respectively.

[0016] A wedge-shaped push rod 12 is near the end of the cable 2; the push rod 12 is supported, for example, by a sliding guide (not shown) to move from the position of Fig.1 to the position of Fig.3 et vice versa.

[0017] When the push rod 12 is found in the position of Fig.1 the wires 3a, 3b are not separated; vice versa, when the push rod 12 is found in the position of Fig.3 opens the wires 3a, 3b without sheath allowing that each sender 10 to send its own beam of light towards the wire to which it is faced; if the mirrored light of the coating of the wire 3a (3b) has the colour to which the sender 10 (functioning as receiver) is sensitive, the first level of the signal of the sender 10 enables the central control unit 9 to maintain the motor 7 still, so that the wire 3a (3b) remains in the original sequence.
On the contrary, if the mirrored light of the coating of the wire 3a (3b) has not the colour to which the sender 10 (functioning as receiver) is sensitive, the second level of the signal of the sender 10 enables the central control unit 9 to set at work the motor 7 until the wires 3a, 3b are disposed in the sequence suitable for welding, connection or gripping, considering the reference sequence A, B, C, D of the wires of the cable 2.

[0018] The device shown in Figures 4, 5 is identical to that of previous Figures except for the fact that the recognising sensor consists of a sensor 14 of a electrical characteristic of the wires (impudence, tension, current, frequency and the like).
When the push rod 12 is found in position of Fig.4 the wires 3a, 3b are not separated; vice versa, when the configuration of Fig.5 is reached the wires 3a, 3b coming out from the cable 2 are separated by the push rod 12 to allow that each sensor 14 to contact the metal of a wire; if the sensor 14 in contact with the wire 3a measures that the value of the examined electrical characteristic is suitable for the cable, the connection to the printed circuit, the connector, the terminal and the like, to which the wire 3a has to be connected, the central control unit 9 receives from the sensor 14 a signal the first level of which enables it to maintain the motor 7 still so that the wire 3a is maintained in the original sequence.

[0019] On the contrary, if the sensor 14 measures that the value is not suitable, the central control unit 9 receives from the sensor 14 the signal at the second level enabling it to set at work the motor 7 until the wires 3a, 3b (and the other not shown) are moved into the sequence suitable for the welding, connection or gripping, considering the reference sequence A, B, C, D of the cable 2.

[0020] Fig.6 represents schematically a perspective of a welding device comprising a supporting structure 15 for two actuators 16, 17 manoeuvred by a central control unit (not shown).
The actuators 16, 17 are specular; therefore, the description of the components and functions of the first actuator 16, is also sufficient for the components and functions of the second actuator 17.
The actuator 16 (17) consists of a bracket 18 (19) rotating around a pin 20 (21) supported by the structure 15 (or by the structure, not shown, specular to the structure 15); a cursor 22 (23) slides in the horizontal part of the bracket 18 (19) supporting the cursor 22 (23) and grips a wire 3a (3b).
Devices are provided controlled by the central control unit to rotate the bracket 18 (19) around the pin 20 (21) and to slide the cursor 22 (23) in the horizontal part of the bracket 18 (19); these devices are known, therefore they are not shown.

[0021] By means of these movements it is possible to move the end of the wires 3a, 3b, in order to reach the position suitable for the welding of said end with one of the bump contact of the printed circuit 24; the displacement take easily place by translating the cursor 22 (23) and rotating the bracket 18 (19) until the end of the wire 3a has reached the bump contact 43 of the printed circuit 24 to which the wire has to be connected.
Therefore, the combination of both movements allows the displacement of the ends of the wires 3a, (3b) which easily reach the position suitable for the welding with the relevant bump contacts of the printed circuit 24.
Figs 7, 8 represent schematically a third embodiment of the separating device before having squashed an end of a cable 2; the wires A, C, B, D come out from the cable 2 being placed in a erroneous sequence. A vice 25 consists of a fixed structure 26; the wires A, C, B, D of the cable 2 and a movable structure 28 rest on a lower jaw 27 of the fixed structure 26, the jaw 27 sliding on a supporting structure 29 so that the upper jaw 30 can squash the wires A, C, B, D resting on the lower jaw 27 to separate them in a common plane.
Figs 9, 10 show the separating device of Figs 7, 8 squashing the end of the cable 2 with both jaws 27, 30 of the vice 25 in contact. Four sensors 10, each fitted with an amplifier 11, are connected to a central control unit 31.
To move in the right sequence A, B, C, D the wires founding in the erroneous sequence A, C, B, D the jaws 27, 30 of the vice 25 are separated after having squashed and separated the wires by means of the vice 25 (Fig.11).

[0022] For this purpose, each wire 3a, 3b, 3c, 3d is firmly supported by a pincer 32, each pincer presenting an elongated body 33, a supporting basis 34 and a clamping zone 35 for a wire A, B, C, D. (Fig.13)
The supporting basis 34 of each pincer is housed in a panel 36 presenting four parallel guides 37, 38, 39, 40 and two guides 41, 42 perpendicular to the previous. All guides are coplanar allowing the displacement of the supporting basis 34 of the pincers 32.
The numbers concerning the pincers 32 were replaced with the letters of the relevant wires located in erroneous sequence A, C, B, D to better understand the functioning of the panel 36 in Figs 14, 15, 16.
If the receiver 10 of each wire connected to the central control unit 31 recognises that the colours of the coatings of the wires A, B, C, D (or other physical characteristics, as specified above) are not in the right sequence, the central control unit 31 enables four actuators (not shown) to move the basis 34 of the relevant pincers 32 until the wires A, C, B, D are disposed in the sequence A, B, C, D, suitable for the welding, connection or gripping.
For this purpose, the central control unit 31 recognises, in every instant, the positions of the basis 34 relevant to the wires A, C, B, D to avoid impacts during the movement towards the right sequence.
In Fig.14 the basis 34 in panel 36 are disposed in erroneous sequence A, C, B, D; that is demonstrated by the fact that said sequence is shown in the lower part of the panel 36 illustrating the initial situation.

[0023] In this case the central control unit 31 recognises the erroneous position of the wire C and, considering this information, enables the actuator of the base relevant to the wire C to move it in the guide 38 until the guide 41 is reached.
The central control unit 31 stops the actuator of the base relevant to the wire C in the guide 41, since said unit is informed that the guides 37, 39, 40 are engaged by other basis, and cannot be covered. Therefore, the central control unit 31, by recognising the erroneous position of the wire B, enables the actuator of the base of the wire B to move said base in the guide 39 to reach the guide 42, but not the guide 41 since the unit is informed that the last is engaged by the base of the wire C.
At the end of this first serie of movements, the basis of the wires B, C are found in the positions of Fig.14 and replayed in the subsequent Fig.15.
The subsequent movements imposed by the central control unit 31 comply with said logic consisting in acting so that the basis of the pincers of the wires displace only in the free guides until the sequence A, B, C, D, suitable for the welding, connection or gripping (Fig.16), is reached.
The wedge-shaped push rod 12 shown in Figs 17 to 21 presents four longitudinal grooves 44, 45, 46, 47 each capable of housing the end of a relevant wire to maintain the adherence of the wires to the push rod 12 after the recognising phase; in addition, a vice 48 is provided gripping the wires on the longitudinal groves 44, 45, 46, 47 to increase the adherence and opportunely form the wires.

[0024] The vice 48 (Figs 18 to 23) comprises two jaws 49, 50 which wind the body of the wedge-shaped push rod 12 and grip the wires on the longitudinal groves 44, 45, 46, 47 and two levers 51, 52, respectively, integral with the jaws 49, 50 and articulated around a pin 53. Both jaws 49, 50 are shaped to adhere to the external surface of the wedge-shaped push rod 12 when both levers 51, 52 are gripped by opposite stresses F1, F2; when both levers 51, 52 are separated the wedge-shaped push rod 12 is free.
The vice 48 is gripped on the push rod 12 before the recognising phase and open again after the same phase.

[0025] Figs 22, 23 show both jaws set free by the wedge-shaped push rod 12.
Figs 24, 25 show a fourth embodiment of the separating device being very similar to that of Figs 7 to 11. A fixed structure 54 supports a lower jaw 55, on which the end of the cable 2 leans. A movable structure 56 slides with respect to the fixed structure 54 in directions E1, E2 and supports a upper jaw 57.
The jaws 55, 57 present inclined planes allowing to squash the wires of the cable 2 to separate them in a common plane.

Claims

1. Process for recognising and/or connecting electric wires in a cable comprising the following phases:

A - removing phase of the end of the coating of the cable to be connected, welded or gripped;

B - recognising phase of the physical characteristics of the single wires;

C - connection phase of the wires having physical characteristics similar to other wires, terminals, printed circuits, connectors, clamps and the like.

2. Process as in claim 1, characterised by the fact that the physical characteristic examined during the phase B is the colour of the insulating coating of each wire.

3. Process as in claim 1, characterised by the fact that the physic characteristic examined during the phase B is an electrical characteristic of each wire.

4. Process as in claim 3, characterised by the fact that the electrical characteristic is the impedance of each wire.

5. Apparatuses to carry out the process as in one of the previous claims, characterised by the fact that they comprise:

a separating device (12,25) capable of separating the electric wires (3a, 3b) belonging to a first cable (2) to begin the subsequent recognising phase B;

sensors (10,14) of the physical characteristics of the single wires;

a central control unit (9) connected to the sensors (10,14); the central control unit (9) controlling at least a device (1,7,32) capable of moving or maintaining the wires (3a, 3b) fixed, after their separation by means of the separating device (12,25), according to the values of the signals of the sensors (10,14) to place the wires (3a, 3b) in a sequence suitable for the welding, connection or gripping, considering the reference sequence (A, B, C, D) of the wires of the cable (2);

a device to connecting the cables, said device being capable of displacing the end of each wire (3a, 3b) until to place it in the position (43) suitable for its welding, connection or gripping.

6. Apparatuses as in claim 5, in which the separating device is characterised by a wedge-shaped push rod (12) located near the end of the cable (2); the push rod (12) being supported by a sliding guide to move from a first position to a second position and vice versa; when the push rod (12) is found in the first position the wires (3a, 3b) are not separated; vice versa, when the push rod (12) is found in the second position the wires (3a, 3b) without sheath are separated for examining their physical characteristics.

7. Apparatuses as in claim 5 in which the separating device is characterised by a vice (25) consisting of a fixed structure (26), on the lower jaw (27) of which the wires (A, C, B, D) of the cable (2) lean and a movable structure (28) sliding on a supporting structure (29) in order to allow to its upper jaw (30) to squash the wires (A, C, B, D) leaning on the lower jaw (27) to separate them in a common plane.

8. Apparatuses as in claim 5 wherein the central control unit (9) controls a motor (7) feed by a source of electric energy (8) and mechanically connected to a self-centring vice (1) supporting an end of a cable (2); the vice (1) loading with a torsional stress the end of the cable (2); if one of the sensors (10,14) sends to the central control unit (9) a signal, the level of which shows that the physical characteristic of the cable (3a, 3b) has the value of the characteristic to which the sensor (10,14) is sensitive, the central control unit (9) is enabled to maintain the motor (7) fixed, so that the wire (3a, 3b) remains in the original position; if, on the contrary, the signal of said sensor (10,14) has a level indicating that the physical characteristic of the cable (3a, 3b) dies not present the value of the characteristic to which the sensor (10,14) is sensitive, the central control unit (9) is enabled by said signal to move the motor (7) until the wires (3a, 3b) are disposed in the sequence suitable for the welding, connecting or gripping, considering the reference sequence (A, B, C, D) of the wires of the cable 2.

9. Apparatuses as in claim 5 wherein the central control unit (31) controls a plurality of pincers (32), each supporting a wire (3a, 3b, 3c, 3d); the leaning base (34) of each pincer (32) being housed in a panel (36) presenting a plurality of parallel guides (37,38,39,40) and two guides (41,42) perpendicular to the previous (37,38,39,40); if one of the sensors (10,14) recognises from the physical characteristics of the wires (A, B, C, D) that these are not found in the right sequence, the central control unit (31) enables the actuators used for moving the pincers (32) to move the basis (34) until the wires (A, C, B, D) are not located in the sequence (A, B, C, D), suitable for the welding, connection or gripping.

10. Apparatuses as in claim 5 wherein the welding device comprises a supporting structure (15) for two actuators (16,17) manoeuvred by a central control unit; each actuator (16,17) consisting of a bracket (18,19) rotating around a pin (20,21) supported by the structure (15); a cursor (22,23) sliding in the horizontal part of the bracket (18,19) supports it, and grips a wire (3a, 3b); devices are provided controlled by the central control unit to rotate the bracket (18,19) around the pin (20,21) and to slide the cursor (22,23) in the horizontal part of the bracket (18,19), in order to move the end of the wires (3a, 3b) until the reaching of the position suitable for their welding with one of the bump contacts (43) of the printed circuit (24); the displacement taking place with the simple translation of the cursor (22,23) and rotation of the bracket (18,19) until the end of the wire (3a) has reached the bump contact (43) of the printed circuit (24) to which it must be connected.

Drawing