Cable sorter automat and a method for automatically sorting cables

A cable sorter for a plurality of cables is provided and includes a cable receiving device and a cable assembly device. The cable receiving device includes a plurality of cable receiving grooves, while the cable assembly device includes a cable feeding passageway. The cable feeding passageway is positioned to correspond with the plurality of cable receiving grooves.

FIELD OF THE INVENTION

The invention relates to a cable sorter and, in particular, to a cable sorter for automatically rearranging a plurality of cables of a predefined cable diameter in a predetermined sequence.

BACKGROUND

Sorting and rearranging cables in a predetermined sequence is generally performed manually using basic tools. Manual sorting and rearranging of cables is a time consuming process. Manual sorting is also susceptible to mistakes being made in the cable sequence. Other disadvantages of a manual sorting and rearranging process are the risks of damage to the cables and compromising the purity of the cable with debris during the process. When handling optical fibers, even the smallest impurities or small damages done to the cable, for example by bending of the cable below a tolerable bending radius, can lead to a failure or complete breakdown of the cable function.

SUMMARY

It is an object of the invention to provide a cable sorter for a plurality of cables. The cable sorter includes a cable receiving device and a cable assembly device. The cable receiving device includes a plurality of cable receiving grooves, while the cable assembly device includes a cable feeding passageway. The cable feeding passageway is positioned to correspond with the plurality of cable receiving grooves.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

The structure and function of a cable sorter according to the invention will be described with reference toFIGS. 1 to 4.

With respect toFIG. 1, a cable sorter1according to the invention is shown and includes a revolving cylinder3with a cable receiving device5and a cable assembly device7with a cable feeding passageway9.

The cable receiving device5includes a plurality of cable receiving grooves11. The cable receiving grooves11open up along a radial direction of the revolving cylinder3. Each cable receiving groove11includes a cable receiving passageway13facing away from the rotational axis R and is aligned with a cylinder surface15of the revolving cylinder3. In the shown embodiment, one of the cable receiving grooves11is shown in a transport position18and its cable receiving passageway13is aligned with the cable feeding passageway9.

As shown, the cable receiving grooves11are arranged equally spaced from each other around the cylinder surface15.

As shown inFIG. 1, a portion of each cable17is positioned in the cable feeding passageway9and arranged in the transfer position19. The cable feeding passageway9includes positioning surfaces10and10′ and aligns the cables17in a flat and parallel order.

The cables17that are located in cable receiving grooves11of the cable receiving device5are arranged in a storage position23.

A stationary retention member25is arranged around the revolving cylinder3and effectively covers the cable receiving grooves11. The stationary retention member25secures the cables17inside the cable receiving grooves11during rotational movement of the revolving cylinder3.

The stationary retention member25includes a transfer opening27, which allows the cables17to transfer between the cable assembly device7and the cable receiving grooves11. The stationary retention member25in the shown embodiment is a mechanical bearing for the revolving cylinder3.

A cable transfer member29is also provided to feed the cables17through cable feeding passageway9and into the cable receiving device5. The cable transfer member29urges the cables17from a transfer position19in a direction towards the cable receiving device5.

As shown inFIG. 2, a plurality of cables17are positioned in the cable receiving grooves11around the revolving cylinder3and with the cable transfer member29being located in an extraction position31.

The cable receiving grooves11are aligned parallel to the rotational axis R. The cable sorter1may include two stationary retention members25, as shown. The stationary retention members25are positioned to support and retain the revolving cylinder3during rotational movement the revolving cylinder3.

In the shown embodiment, the cable sorter1further includes cable transfer supports33that are used to support the cable transfer members29. Each cable transfer supports33may be connected to a drive, which may include a motor or an actuator.

As shown inFIG. 2, the cable sorter1may include two cable transfer members29that are spaced apart from each other along a length thereof, which is parallel to the rotational axis R. The cable transfer members29may be protrusions extending from the cable transfer supports33and include a cable support surface34which is formed as a recess in the shown embodiment. The cable support surface34may be aligned with the positioning surface10′ when the cable transfer member29is in the extraction position31.

The two stationary retention members25are spaced apart from each other and are enclosed between the two cable transfer members29. Alternatively, the stationary retention members25can be arranged such that the cable transfer members29are positioned between them.

In the shown embodiment ofFIG. 2, the revolving cylinder3includes two cable transfer passageways35. The cable transfer passageways35are channels that encircle the revolving cylinder3around the rotational axis R. The cable transfer passageways35allow the cable transfer members29to move into the extraction position31, in which the cable transfer members29penetrate the cable transfer passageways35.

In the shown embodiment, the revolving cylinder3further includes an alignment Member37having an alignment surface39to pre-align cables17to maintain an uncoiled alignment of the cables17that are located in cable receiving grooves11.

With reference toFIG. 3, that cable sorter1may further include a housing41that partially surrounds the revolving cylinder3. Additionally, a tolerance section43is provided between the revolving cylinder3and the housing41. The tolerance section43surrounds the revolving cylinder3and provides space for cables17that are in the storage position23to at least partially bend out of the cable receiving grooves11. By allowing the cables17to bend at least partially out of the cable receiving grooves11, damage to the cables17can be prevented. Additionally, the risk of a cable that prevents movement of the revolving cylinder3, by getting stuck between the revolving cylinder3and the housing4, is effectively reduced. The tolerance section43may be enclosed by the stationary retention members25.

With respect toFIG. 4, the cable receiving groove11is a rounded receptacle45in the shown embodiment. The width46of the receptacle45is preferably chosen to be between 110% and 130% of the cable diameter47. The cable receiving passageway13of the cable receiving groove11may be limited by deflection surfaces49. The deflection surfaces49may be formed as flat areas51, as shown. The deflection surfaces49can alternatively be curved.

When the cables17are positioned from the transfer position19into the storage position23, the cables17are urged along a feeding direction53towards the cable receiving device5.

After one cable17has been placed in a cable receiving groove11and is therefore in the storage position23, the cable receiving device5may be moved along a feeding direction55or55′ to place a cable17in the next empty cable receiving groove11in front of the cable feeding passageway9. The deflection surface49effectively push the cables17that are in the transfer position19into the cable feeding passageway9in a direction opposite to the feeding direction53. The deflection surface49applies pressure to the cable17, which is in a deflection position57that is defined as being the position of cable17that is in the transfer position19and being located adjacent to a cable receiving groove11.

The deflection surfaces49each have a width50which is preferably between 50% and 100% of the cable diameter47. A direction of the deflection surface49includes a vector having a component that is parallel to a cylindrical surface15of the cable receiving device5and another component that is perpendicular to the surface15of the cable receiving device5.

The deflection surface49applies pressure onto the cable17when in the deflection position57by a pressure angle α. The pressure angle α is defined as the angle between a contact surface59on a cable surface61and a center line63of the cable feeding passageway9, wherein the contact surface59is located at a contact point65between the cable17and the deflection surface49. The pressure angle α is preferably around 30° in order to avoid cable damage.

During movement of the cable receiving device5in a feeding direction55′, deflection surface49applies pressure on a cable17being in the deflection position57by a pressure angle α′. The pressure angle α′ is defined as the angle between a contact surface59′ on the cable surface61and the center line63of the cable feeding passageway9, wherein the contact surface59′ is located at a contact point65′ of the cable17being in the storage position23and the cable17being the deflection position57.

The deflection surface49applies pressure onto the cable17in the deflection position57by the pressure angle α which is similar to the pressure angle α′, at which a cable17that is in the storage position23applies pressure to the cable17that is at the deflection position57when the cable receiving device5moves along the feeding direction55′.

In the embodiment, the deflection surface49is flat. The angle β between the flat area51and the surface15of the cable receiving device5adjacent to the cable receiving passageway13is preferably chosen to be between 25° and 35°.

The geometry of the deflection surfaces49may vary depending on the cable diameter47and the width46of the receptacle45. The geometry may be adapted in order to form deflection surfaces49which push cables17in a direction towards the cable feeding passageway9.

The cable feeding passageway9may be adapted to force cables17in a flat and parallel manner. The width21of the cable feeding passageway9may be adapted to prevent one cable17to move pass another cable17and to change the sequence. It may be adapted to force the cables in a flat and parallel manner. The width21of the cable feeding passageway9is preferably chosen to be at least 100% and less than 200% of the cable diameter47to keep the cables17in the flat and parallel arrangement. An advantageous width21of the cable feeding passageway9may be 120% of the cable diameter47.

The cable sorter1may include a cable sensor (not shown), which is directed onto cables17, with the cables17being located in a cable feeding passageway9or in the cable receiving device. The cable sensor is adapted to detect a cable identification characteristic and to transmit a cable sequence signal to a control module. A cable sensor may detect and recognize the individual cables of a plurality of cables17in order to determine the actual cable sequence prior or after the sorting and rearranging process.

The control module may include a comparator (not shown), which is adapted to compare the cable sequence signal to a predefined target sequence, and wherein the control module is operatively connected to a drive, moving at least one of the cable receiving device5and the cable transfer member29. The control module may be fed with a desired target sequence of the cables.17The comparator may compare the actual cable sequence with the target sequence and may, if the actual sequence differs from the target sequence, operate the drive and control the sorting and rearranging process.

Now with reference toFIGS. 5 to 9 and 10 to 14, process steps for sorting cables17using a cable sorter1according to the invention will be described.

As shown inFIGS. 5 to 9, a transfer process wherein cables17are loaded into a cable sorter1according to the invention is illustrated. In order to keep a clear presentation of the process steps, reference signs of elements which do not differ in the figures are not shown inFIGS. 5 through 9.

FIG. 5shows cables17loaded into the cable feeding passageway9in a transfer position19. At least one cable transfer member29keeps the cables17located inside the cable feeding passageway9and may be adapted to urge the cables17together. The cable transfer member29may be spring loaded to bias and apply pressure onto the cables17along the feeding direction53.

The cable receiving device5, which is formed as a revolving cylinder3, is not yet in a position in which a cable receiving groove11is in a transport position18and aligned to the cable feeding passageway9. In this process step, the cable sequence may be detected by a cable sensor in order to determine the actual cable sequence.

The cable assembly device may include an insertion opening67, adapted to facilitate the easy insertion of cables17into the cable feeding passageway9.

As shown inFIG. 6, the revolving cylinder3rotates around the rotational axis R in the feeding direction55. The revolving cylinder3has been rotated until one cable receiving groove11is aligned to the cable feeding passageway9, being in the transport position18. The cable receiving groove11is now ready to receive a cable17from the cable feeding passageway9. The cable17that is located closest to the revolving cylinder3, but not received in a cable receiving groove11, is in the deflection position57.

With respect toFIG. 7, the cable sorter1is shown after the cable transfer member29has moved along the feeding direction53for a distance substantially equal to the diameter47of one cable17. The cable17that was in the deflection position57has been moved into the cable receiving groove11, being now in the storage position23.

FIG. 8shows the cable sorter1after the revolving cylinder3has been rotated partially in the feeding direction55, transporting the cable17that is in the storage position23along the feeding direction55and, at the same time, moving an empty cable receiving groove11in a direction towards the cable feeding passageway9. For the cables17that are in the transfer position19, the process steps shown in theFIGS. 5 to 8are now repeated until all cables17have been inserted into cable receiving grooves11, the cables17then being in the storage position23.

FIG. 9shows the situation when all cables17are received in the cable receiving grooves11and the cable feeding passageway9is empty. The cable transfer member29has moved along the feeding direction53until it aligns with the cylinder surface15, closing the cable feeding passageway9to prevent cables17from accidentally moving into the cable feeding passageway9. The cable transfer member29is now located at a closing position71.

FIGS. 10-14schematically shows the process of transferring cables17from the cable receiving device5into a cable feeding passageway9.

FIG. 10resembles the situation ofFIG. 9. The cables17are received in the cable receiving grooves11in the cable receiving device5and the cable transfer member29is located at the closing position71.

FIG. 11shows the first step of an extracting process. According to a predetermined cable sequence, the revolving cylinder3may rotate in any of the feeding directions55or55′ to align a first cable17that is to be extracted according to the desired cable sequence to the cable feeding passageway9.

FIG. 12presents the situation when the predetermined cable17that is to be transferred from the cable receiving device5into the cable feeding passageway9is aligned in front of the cable feeding passageway9, which means that the cable receiving groove11that is carrying the cable17is in the transport position18. The cable transfer member29may now be moved out of the closing position71, opening the cable receiving groove11to the cable feeding passageway9.

FIG. 13shows the cable transfer member29after being moved into the extraction position31, in which the cable17is located between the cable feeding passageway9and the cable transfer member29. The cable transfer member29may have been moved around the cable17being in the storage position23.

FIG. 14shows the situation after the cable transfer member29has been urged along the extracting direction73back into the closing position71. During movement along the extracting direction73, the cable transfer member29has transferred the cable17out of the cable receiving groove11into the cable feeding passageway9.

The cable transfer member29will subsequently remain in the closing position71while the revolving cylinder3rotates in one of the feeding directions55or55′ in order to move the next predetermined cable17to the cable feeding passageway9. Subsequently, the process steps shown inFIGS. 10 to 14will be repeated until all predetermined cables17are extracted from the cable receiving device5into the cable feeding passageway9.

It should be appreciated for those skilled in this art that the above embodiments are intended to be illustrative, and can be improved by those skilled in the art. The structures described in the various embodiments may be freely combined without a confliction of the structure or principle.

Although exemplary embodiments of the present disclosure are described in detail with reference to the attached drawings, the embodiments disclosed in the drawings are intended to be illustrative to the preferable embodiments of the present disclosure and should not be construed as a limitation to the present disclosure.

Although several exemplary embodiments of the overall concept of the present closure have been shown and described, it would be appreciated by those skilled in the art that various changes or modifications may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents.

It should be noted that the word “comprising” or “including” does not exclude the presence of elements or steps other than those listed in a claim, unless such exclusion is explicitly stated. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements, unless such exclusion is explicitly stated. Further, the reference signs should not be construed as a limitation to the protection scope of the disclosure.