CABLE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is being filed on November 13, 2017 as a PCT International Patent Application and claims the benefit of Chinese Patent Application No. 201611001833.5, filed on November 14, 2016, and claims the benefit of Chinese Patent Application No. 201710040360.8, filed on January 18, 2017, the disclosures of which are incorporated herein by reference in their entireties.

TECHNICAL FIELD

[0002] This disclosure relates to a system and method for automatically cutting and coiling a length of cable. In particular, this disclosure relates to systems and methods to coil a length of fiberoptic cable.

BACKGROUND

[0003] Cable, especially fiberoptic cable, is expensive. It is important to provide exact lengths of cable to the field, and to avoid waste. Manual methods of coiling cable are labor intensive and can result in mistakes or material waste. Improvements are desirable.

SUMMARY

[0004] Systems and methods for automatically cutting and coiling a length of cable are provided to improve the prior art.

[0005] In a first aspect, a system for automatically cutting and coiling a length of cable includes a cutting machine constructed to pull cable from a decoiler and cut the cable to a predetermined length; a first robot positioned to grasp the cable; a turntable including first and second clamps and an adjustable mandrel; and a support unit positioned to guide the cable between the cutting machine and the turntable. The first clamp is positioned to releasably hold a first end of the cable positioned therein by the first robot. The mandrel is constructed to rotate about a spindle and coil the cable on the mandrel. The second clamp is positioned to releasably hold a second end of the cable positioned therein by the first robot after the mandrel coils the cable and the cutting machine cuts the cable. The support unit is constmcted and arranged to vertically move to adjust the cable as the cable is coiled on the mandrel.

[0006] In preferred systems, there is a laser arrangement to detect the position of the first end of the cable when positioned in the first clamp and to detect the position of the second end of the cable when positioned in the second clamp.

[0007] Preferably, the laser arrangement includes a first laser detector at the first clamp and a second laser detector at the second clamp.

[0008] In preferred systems, the mandrel is expandable and retractable.

[0009] In one or more embodiments, the system further includes a second robot constructed and arranged to pick the coiled cable from the turntable and move the coiled cable to a conveyer.

[0010] In many systems, the second robot is constructed and arranged to tie wrap the coiled cable.

[0011] In preferred implementations, the system further includes a plurality of decoilers to feed cable to the cutting machine.

[0012] Preferably, the support unit includes a plurality of rollers that grip the cable and allow the cable to pass longitudinally therealong in a direction of the cable as the cable runs from the cutting machine to the turntable.

[0013] In example embodiments, the system can further comprise a labeling machine positioned downstream of the cutting machine and constructed to place identification on the cable.

[0014] In one or more embodiments, the labeling machine is constructed to either label or laser print an identification on each of the first end and the second end of the cable.

[0015] In example embodiments, the cable that is coiled comprises fiberoptic cable.

[0016] In another aspect, a method for automatically cutting and coiling a length of cable is provided. The method includes pulling cable from a first decoiler; automatically grasping the cable using a first robot and releasably fixing a first end of the cable; coiling the cable; vertically adjusting the cable as the cable is coiled; cutting the cable to a predetermined length; and automatically grasping a second end of the cable using the first robot and releasably fixing the second end of the cable.

[0017] In example methods, the step of coiling the cable includes coiling the cable about an adjustable mandrel.

[0018] Preferably, the step of vertically adjusting the cable includes using a support unit to guide the cable and move the cable vertically to ensure that the cable does not overlap itself.

[0019] In example methods, the step of reliably fixing a first end of the cable includes using a laser detector to check the position of the first end of the cable, and readjusting the first robot if the laser detector does not detect the first end of the cable.

[0020] In example methods, the step of releasably fixing the second end of the cable includes using a laser detector to check the position of the second end of the cable, and readjusting the first robot if the laser detector does not detect the second end of the cable.

[0021] In example methods, after the step of fixing the second end of the cable, there is a step of using a second robot to pick the coiled cable and move the coiled cable to a conveyer.

[0022] In example methods, the step of using the second robot further includes tie- wrapping the coiled cable.

[0023] In example methods, the step of using the second robot further includes decreasing a diameter in the adjustable mandrel when the second robot picks the coiled cable.

[0024] Preferably, the method further includes using a labeling machine to place an identification on the cable.

[0025] In example methods, the step of placing identification on the cable includes using a label or laser printer to put an identification on each of the first end and second end of the cable.

[0026] Preferably, the method includes, when the first decoiler is empty of cable, automatically feeding cable from another decoiler. [0027] In example methods, the step of pulling cable from a first decoiler includes pulling fiberoptic cable from the first decoiler.

[0028] A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which are incorporated herein and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

[0030] FIG. 1 is a perspective view of an embodiment of a cut and coiled length of cable produced by the system and methods of this disclosure;

[0031] FIG. 2 is a perspective view of a spool of cable before being processed by the system and methods of this disclosure;

[0032] FIG. 3 is a top schematic, top plan view of one embodiment of a system for automatically cutting and coiling a length of cable, in accordance with principles of this disclosure;

[0033] FIG. 4 is a schematic top plan view of a portion of the system shown in FIG. 3;

[0034] FIG. 5 is a schematic, perspective view of a part of the system of FIGS. 1 and 2;

[0035] FIG. 6 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process;

[0036] FIG. 7 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process;

[0037] FIG. 8 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process; [0038] FIG. 9 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process;

[0039] FIG. 10 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process;

[0040] FIG. 11 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process;

[0041] FIG. 12 is a schematic, perspective view of the system of FIGS. 3 and 4 and showing another step of the process;

[0042] FIG. 13 is a flow chart showing an embodiment of a method for automatically cutting and coiling a length of cable; and

[0043] FIG. 14 is a continuation of the flow chart of FIG. 13.

DETAILED DESCRIPTION

[0044] FIG. 1 illustrates a perspective view of coiled cable 20 that is made by the system and methods of this disclosure. The cable 20 can be many types of cable, but the system and methods herein are particularly useful for fiberoptic cable. The coiled cable 20 should be produced at a precise length to avoid problems in the field and to avoid waste. The coiled cable 20 is typically later processed to put connectors on each free end, and can be used as patch cords, etc. In FIG. 1, the coiled cable 20 is secured in its coiled shape with tie wrap 22 to maintain the coiled cable 20 in its coiled shape.

[0045] Typically, before the cable results in the coiled cable 20 of FIG. 1, it is supplied in the form of spools 24 (FIG. 2) with cable 26 wound around the spool 24. The cable 26 can then be unwound or decoiled from the spool 24 as part of the system and process.

[0046] FIG. 3 is a top plan view of one embodiment of a system 30 for automatically cutting and coiling the cable 26 to result in coiled cable 20. The system 30 includes at least one decoiler 32. In this embodiment, a plurality of decoilers 32 are shown. The decoilers 32 can be in the form of spools 24 as shown in FIG. 2. The decoilers 32 feed a length of the cable 26 to the rest of the system 30. [0047] In FIG. 3, there are four decoilers shown at 32a, 32b, 32c, and 32d. There can be more or fewer decoilers 32. To keep availability high, it is preferred to start the next coil automatically fed to a remainder of the system 30 after the end of the previous coil. For example, if the first decoiler used is from 32a, when the decoiler from 32a is out of cable, cable from the decoiler 32b can be accessed. It is preferred that this is automatic, but it is possible that this will be a manual process.

[0048] The system 30 further includes a cutting machine 34. The cutting machine 34 pulls the cable 26 from the decoiler 32. The cutting machine 34 also measures the length of cable and cuts it during the method. The measuring and cutting is performed with a degree of precision to avoid product waste.

[0049] The system 30 includes a first robot 36. The first robot 36 is positioned to grasp the cable 26 after it leaves the cutting machine 34. The robot 36 can be in many different forms, but it is preferred that the robot 36 have six axes of motion. The first robot 36 performs other functions, as described further below.

[0050] The system 30 further includes a turntable 38. The turntable 38 will coil the cable 26 into the desired shape of the coiled cable 20. The turntable 38 includes a first clamp 40 and second clamp 42. The first and second clamps 40, 42 are for holding the cable 26. Preferably, the clamps 40, 42 hold an end of the cable 26.

[0051] The first clamp 40 is positioned to releasably hold a first end 44 (FIG. 6) of the cable 26 positioned therein by the first robot 36. The first robot 36 brings the cable 26 from the cutting machine 34 preferably at the same speed that the cutting machine 34 is operating. The first robot 36 places the first end 44 of the cable 26 in the first clamp 40, and the first clamp 40 is closed to secure the cable 26 in place.

[0052] A laser arrangement 46 is preferably used to detect the position of the first end 44 of the cable 26 when positioned in the first clamp 40. The laser arrangement 46 can be in the form of a first laser detector 48 positioned adjacent to the first clamp 40. If the first laser detector 48 does not detect the first end 44 of the cable, the first robot 36 will be readjusted to correct this problem. In preferred arrangements, it can be important to have the position of the first end 44 precisely placed to control the resulting length of the cable. In those situations, the laser detector 48 is helpful in helping to locate the end 44 within the preferred tolerance, such within a millimeter. [0053] The turntable 38 further includes a mandrel 50. The mandrel 50 is constructed to rotate about a spindle (central axis) and coil the cable 26 on the mandrel 50. The turntable 38 is controlled by the first robot 36 and may include a servo motor to start rotation of the turntable 38.

[0054] Preferably, the mandrel 50 is automatically expandable and retractable. The diameter of the mandrel 50 can be adjusted based on the size of the coil desired. In addition, the mandrel 50 can have the diameter decreased when the cable that is coiled on the turntable 38 is moved from the turntable 38 to the downstream process. This is described further below.

[0055] The second clamp 42 on the turntable 38 is positioned to releasably hold a second end 52 (FIG. 9) of the cable 26. The second end 52 is positioned in the second clamp 42 by the first robot 36 after the mandrel 50 coils the cable 26 and the cutting machine 34 cuts the cable 26. In example methods, the cable 26 is pulled into the cutting machine 34, the first robot 36 grabs the cable 26 from the cutting machine 34 and places the cable 26 into the first clamp 40, where the first clamp 40 secures the first end 44. The turntable 38 then rotates the cable 26 about the mandrel 50. The cable 26 is then cut by the cutting machine 34, and the first robot 36 picks the second end 52 of the cable 26 and positions it into the second clamp 42.

[0056] The laser arrangement 46 can be used to detect the position of the second end 52 of the cable 26 when positioned in the second clamp 42. The laser arrangement 46 can include a second laser detector 54 positioned adjacent to the second clamp 42. If the second laser detector 54 does not detect the second end 52 of the cable 26, the first robot 36 is adjusted to correct for this deficiency. In preferred arrangements, it can be important to have the position of the second end 52 precisely placed to control the position of the end 52 the cable. In those situations, the laser detector 54 is helpful in helping to locate the end 52 within the preferred tolerance, such within a millimeter.

[0057] The system 30 further includes a support unit 56. The support unit 56 is positioned to guide the cable 26 between the cutting machine 34 and the turntable 38. The support unit 56 is constructed and arranged to vertically move to adjust the cable 26 as the cable 26 is coiled on the mandrel 50. For example, the support unit 56 will vertically move upwardly while the cable 26 is being wound or coiled about the mandrel 50 to ensure that the cable 26 is coiled against the mandrel 50 and not coiled in radial overlap against itself. At the end of each coiling step, the support unit 56 moves vertically downwardly in position for the next cable winding process.

[0058] Many embodiments are possible, and in the one shown, the support unit 56 includes a plurality of opposing rollers 58 that guide and grip the cable 26 to allow the cable 26 to pass longitudinally therealong in a direction of the cable 26 as the cable 26 runs from the cutting machine 34 to the turntable 38. In FIGS. 6-12, four rollers 58 are shown, with two opposing pairs adjacent to each other in the process direction.

[0059] The system 30 further includes a second robot 60. The second robot 60 is constructed and arranged to pick the coiled cable 20 from the turntable 38 and move the coiled cable 20 to a conveyer 62. See FIG. 10. In FIG. 10, the second robot 60 is shown having grasping fingers 64 which pick up the coiled cable 20 along the outside diameter. The mandrel 50 can be adjusted so that the diameter of the mandrel 50 becomes smaller to allow for easier picking and transport of the coiled cable 20 from the mandrel 50 to the conveyer 62 by the second robot 60. FIG. 11 shows the coiled cable 20 being held by the fingers 64 of the second robot 60 just as the coiled cable 20 was lifted from the mandrel 50. FIG. 12 shows the coiled cable 20 moved onto the conveyer 62 by the second robot 60. The second robot 60 can then fix the coiled cable 20 by applying tie wrap 22 to the coiled cable 20. In some embodiments, the length of the cable and the positions of the ends 44 and 52 are important to both avoid waste and to allow for automated handling of the coiled cable 20 downstream. In such arrangements, the second robot 60 includes the fingers 64 to carefully retain the shape of the coiled cable, and the tie wrap 22 is used to secure the coiled cable 20 in its final desired shape, so that it may be processed with automated equipment downstream. These arrangements held to control the shape and length of the coiled cable within the desired tolerance, such as within a millimeter. In other arrangements, the preciseness of the length or tolerance is not important, and can vary.

[0060] The system 30 further includes a labeling machine 66. The labeling machine 66, in this embodiment, is positioned downstream of the cutting machine 34 and is constructed to place an identification on the cable 26. In preferred systems 30, the labeling machine 66 will either label or laser print an identification on each of the first end 44 and the second end 52 of the cable 26. In the example shown, the identification is placed on the first end 44 of the cable 26 prior to coiling and prior to being picked by the first robot 36. The second end 52 is identified by the labeling machine 66 after coiling but before being picked by the first robot 36 and placed in the second clamp 42. Alternatives are possible for when and how labeling occurs.

[0061] FIGS. 13 and 14 depict a method 70 that can be practiced to cut and coil the cable 26 and result in the coiled cable 20. The method includes pulling cable 26 from first decoiler 32a. This is shown at step 72, in which the next length of cable is pulled from the buffer. The buffer here is typically one of the spools 24 / decoilers 32.

[0062] The method 70 includes automatically grasping the cable 26 using the first robot 36 and releasably fixing the first end 44 of the cable 26. This can include, as shown at step 74, feeding the cable through the cutting machine 34 to the support unit 56. At step 76, the first robot 36 goes to a pick position at the support unit 56. At step 78, the first robot 36 is motion controlled to control the support unit 56 and control the cable feed. At step 80, the first robot 36 picks the first end 44 of the cable 26 and places it in the first clamp 40 on the turntable 38.

[0063] In preferred methods, the first laser detector 48 will look for the first end 44 of the cable, as shown at step 82. If the laser does not see the first end 44 of the cable 26, then the path of the first robot 36 is readjusted for proper placement in the first clamp 40. This is shown at step 84. After step 84, the first laser detector 48 again looks for the first end 44 of the cable 26. If it is not seen, the step 84 is repeated, and this loop is repeated until the first laser detector 48 does see the first end 44 of the cable 26.

[0064] After the first laser detector 48 sees the first end 44 of the cable 26, the first clamp 40 clamps the first end 44. The mandrel 50 is adjusted to the desired diameter of the coiled cable. This is shown at step 84.

[0065] The method 70 further includes the step of coiling the cable. At step 86, this is done by turning the turntable 38, controlled by the first robot 36.

[0066] The method 70 further includes a step of vertically adjusting the cable 26 as the cable 26 is coiled. This step is also shown at step 86 as the support unit 56 raises and lowers to allow for proper coiling. Proper coiling includes ensuring that the cable 26 does not overlap itself. Rather, subsequent loops of the coil are vertically on top of the previous loop in an axial direction, and not in a radial direction.

[0067] The method 70 further includes the step of cutting the cable 26 to a predetermined length. This is shown at step 88. The cable cutting machine 34, after measuring the cable 26 to the predetermined length will cut the cable to the predetermined length.

[0068] At step 90, the support unit 56 pulls the second end 52 of the cable for the first robot 36 to pick.

[0069] The method 70 further includes the step of automatically grasping the second end 52 of the cable 26 using the first robot 36 and releasably fixing the second end 52 of the cable 26. At step 92, the first robot 36 goes to the picking position at the support unit 56. Step 92 can be performed during the steps of cutting the cable 88 and having the support unit pull the second end 52 at step 90. At step 94, the first robot 36 picks the second end 52 and places it in the second clamp 42 on the turntable 38.

[0070] After the second end 52 is placed in the second clamp 42, the second laser detector 54 looks for the end of the cable at step 96. If the second laser detector 54 does not see the end of the cable, then the path of the first robot 36 is readjusted for proper placement in the second clamp 42. This step of readjusting is shown at step 98. After readjusting, the step 96 of the second laser detector 54 looking for the end of the cable is repeated. Again, if the end is not seen, the step 98 of readjusting the path of the first robot is repeated. This loop is continued until the second laser detector 54 sees the end of the cable 26.

[0071] At step 100, the second end 52 is clamped by the second clamp 42. The first robot 36 leaves the area, and the second robot 60 enters the area for pickup.

[0072] At step 102, the second robot 60 brings the coiled cable 20 from the turntable 38 to the conveyer 62. There, the second robot 60 tie wraps the coiled cable 20.

[0073] After step 102, the process is started over again for the next length of cable.

[0074] The step of coiling the cable 26 includes coiling the cable 26 about the mandrel 50, which is adjustable. The mandrel 50 can be adjusted for the desired diameter of the coiled cable. The diameter of the mandrel can also be adjusted during the step of the second robot 60 picking the coiled cable 20 from the mandrel 50. Specifically, the diameter of the mandrel is made smaller to allow for easier pick-up and movement by the second robot 60.

[0075] The method 70 can further include the step of using the labeling machine 66 to place an identification on the cable 26. This step can include using a label or laser printer to put an identification on each of the first end 44 and second end 52 of the cable 26.

[0076] The method 70 can further include, when the first decoiler 32a is empty of cable, automatically feeding cable from another decoiler, such as decoiler 32b. The step of pulling cable from the first decoiler 32a can include pulling fiber optic cable from the first decoiler 32a.

[0077] The method 70 can have a cycle time of under 30 seconds, and often under 25 seconds, such as about 20 seconds. Using robot control results in accurate cable lengths and avoids waste. The method 70 can result in cost savings, in that robots perform the functions instead of humans.

[0078] The above represents example principles. Many embodiments can be made using these principles.