Laser wire processing device

A wire guide and a laser wire-processing device that includes a wire guide are provided. The laser wire-processing device includes a housing and an aperture in a side of the housing, wherein the aperture defines a longitudinal axis that is substantially perpendicular to the aperture. The laser wire-processing device also includes a backstop arranged in the housing and aligned with the longitudinal axis, the backstop defining a wire-contact surface in a facing relationship with the aperture. The laser wire-processing device also includes a wire guide arranged in the housing to manipulate a wire inserted through the aperture into a desired position relative to the longitudinal axis between the aperture and the backstop. The laser wire-processing device also includes a laser operable to direct a laser beam toward an insulation layer of the wire. The wire guide could be a tube arranged in the device or a backstop guide.

BACKGROUND

Lasers can be used for cutting an insulation layer of a conductive wire such that a portion of the insulation can be subsequently removed to expose the conductor. Wire is typically wound around a spool and is unwound from the spool as needed. In some instances, the unspooled wire exhibits a “memory” effect, wherein wire curvature is maintained after the wire is unspooled. Such curvature of the wire can make it difficult to center a free end of the wire with respect to cutting laser(s) in a laser wire-processing device. As a result of the wire end being off center relative to the cutting laser(s), the insulation layer may not be cut completely and/or at least a portion of the insulation layer may be cut inadvertently.

SUMMARY

According to one aspect, a laser wire-processing device comprises a housing and an aperture in a side of the housing. A longitudinal axis extends through and is substantially perpendicular to the aperture. The laser wire-processing device further comprises a backstop arranged in the housing and aligned with the longitudinal axis. The backstop defines a wire-contact surface in a facing relationship with the aperture. The laser wire-processing device further comprises a wire guide arranged in the housing to manipulate a wire inserted through the aperture into a desired cutting position along and relative to the longitudinal axis between the aperture and the backstop. The laser wire-processing device further comprises a laser operable to direct at least one laser beam toward an insulation layer of the wire while in the desired cutting position.

According to one aspect, a method for processing a wire with an insulation layer comprises arranging a wire guide, comprising a tube, in an aperture of a laser wire-processing device. The tube forms a passageway, and the passageway and the aperture define a longitudinal axis. The method also includes inserting the wire into the wire guide. The method also includes operating at least one laser beam in the laser wire-processing device to cut the insulation layer around a periphery of the wire at a location along the longitudinal axis. The method also includes removing the wire from the laser wire-processing device.

According to one aspect, a method of preparing a wire to strip an insulation layer of the wire comprises inserting an end of the wire through an aperture in a laser wire-processing device housing a backstop. The backstop comprises a backstop guide having an inclined surface that tapers from a diametrically larger opening to a diametrically smaller opening while moving in a direction away from the aperture along a longitudinal axis that extends between the aperture and the backstop. The method also comprises urging the end of the wire toward the longitudinal axis as the wire moves along the inclined surface from the diametrically larger opening to the diametrically smaller opening. The method also comprises gripping the end of the wire with the backstop guide. The method also comprises applying tension to the wire. The method also includes operating a laser in the laser wire-processing device to cut the insulation layer around a periphery of the wire. The method also comprises releasing the end of the wire from the backstop guide. The method also comprises removing the wire from the laser wire-processing device.

According to one aspect, a wire guide comprises a tube configured for insertion into a laser wire-processing device. The tube forms a passageway that defines a longitudinal symmetry axis. The passageway is configured to receive a wire therethrough. The wire guide also comprises a first centering member arranged in the passageway of the tube at a first location along the longitudinal axis, wherein the first centering member urges the wire in the passageway toward the longitudinal axis of the passageway.

DETAILED DESCRIPTION

In the following, reference is made to aspects presented in this disclosure. However, the scope of the present disclosure is not limited to specific described aspects. Instead, any combination of the following features and elements, whether related to different aspects or not, is contemplated to implement and practice contemplated aspects. Furthermore, although aspects disclosed herein may achieve advantages over other possible solutions or over the prior art, whether or not a particular advantage is achieved by a given aspect is not limiting of the scope of the present disclosure. Thus, the following aspects, features, and advantages are merely illustrative and are not considered elements or limitations of the appended claims except where explicitly recited in a claim(s). Likewise, reference to “the invention” or “the disclosure” shall not be construed as a generalization of any inventive subject matter disclosed herein and shall not be considered to be an element or limitation of the appended claims except where explicitly recited in a claim(s).

In aspects described herein, a laser wire-processing device includes a wire guide that enables an operator to correctly position a curved or bent wire exhibiting a “memory” effect” within the laser wire-processing device. In operation, the wire guide properly aligns the wire to laser(s) cutter in the laser wire-processing device such that the insulation layer is completely severed without cutting the electrical conductor. The wire guide may be implemented using various aspects. For example, in one aspect, the wire guide is implemented as a tube that is inserted into the laser wire-processing device and extends along a longitudinal axis that defines a centerline for the laser(s) of the laser wire-processing device. The tube has sufficient stiffness to urge the curved wire passing therethrough toward alignment with the longitudinal axis. In another aspect, the wire guide includes a centering member installed therein. In a still further aspect, the wire guide is implemented as backstop guides arranged on a backstop in the laser wire-processing device that urge an end of the wire into alignment. Thereafter, in at least one aspect, the backstop guides can be clamped to grip the wire therebetween. Thereafter, tension can be applied to the curved wire to straighten the wire along the longitudinal axis.

FIG. 1Ais a cross-sectional side view of a laser wire-processing device200for cutting an insulation layer122of a wire120. The insulation layer122surrounds a conductor124within the wire120. In use, a portion of the insulation layer122is removed (i.e., “stripped”) to expose the conductor124such that the wire120may be electrically connected to another electrical device, such as a socket. In the exemplary aspect, the laser wire-processing device200includes a housing202with an aperture204sized to receive the wire120and, in some aspects, a wire guide240therethrough. The aperture204is centered on a longitudinal axis222that intersects a cutting region where the insulation layer122is cut. A laser250is provided in the laser wire-processing device200that is operable to generate one or more laser beams110for cutting the insulation layer122of the wire120in the cutting region.

The laser wire-processing device200includes a turret212and beam steering devices214in the housing202that direct the laser beams110toward the wire120. The turret212enables rotation of the beam steering devices214about the longitudinal axis222(indicated by arrows A) such that the laser beams110can cut the insulation layer122circumferentially around a periphery125of the wire120. The beam steering devices214guide, steer, and/or direct the laser beam110toward a particular location along the longitudinal axis222. To that end, the beam steering devices214could include at least one of mirrors, prisms, and fiber optics that guide, steer, and/or direct the laser beam110toward the particular location. In the aspect illustrated inFIG. 1A, the turret212includes two beam steering devices214arranged 180° apart. Each beam steering device214emits a laser beam110such that the turret212and the two beam steering devices214rotate 180° (or slightly more to ensure overlap) about the longitudinal axis222to cut through an entire outer periphery125of the insulation layer122of the wire120. In various other aspects, the turret212could include one beam steering device214or three or more beam steering devices214. In aspects in which the turret212includes a single beam steering device214, the turret212would rotate 360° (or slightly more to ensure overlap) about the longitudinal axis222to cut through the entire outer periphery125of the insulation layer122of the wire120. In other aspects, the laser beams110are stationary and the wire120can be rotated in one or more of the directions indicated by arrow A such that a periphery125of the wire120is exposed to the laser beams110.

The laser wire-processing device200includes a backstop206A arranged in the housing202. The backstop206A includes a wire-contact surface208A in a facing relationship with the aperture204. An end128of the wire120abuts the wire-contact surface208A of the backstop206A such that the wire-contact surface208A prevents further movement of the wire120into the laser wire-processing device200. The wire-contact surface208A may be provisioned with a feature such as a detent or other texturing to assist in preventing the wire from sliding on the wire-contact surface208A. The backstop206A can be moved in the directions of arrows B toward or away from the aperture204and also relative to the turret212and beam steering devices214. Accordingly, moving the backstop206A toward the aperture204decreases a length of the insulation layer122to be cut from the wire120by the laser beam110. Conversely, moving the backstop206A away from the aperture204increases a length of the insulation layer122to be cut from the wire120by the laser beam110. Accordingly, the backstop206A is adjustable to enable an operator to select a length of the insulation layer122to be removed from the wire120. In various aspects, the length selected may be between approximately 1.25 inches (3.18 cm) and approximately 5.0 inches (12.7 cm).

In the exemplary aspect illustrated inFIG. 1A, the laser wire-processing device200includes a wire guide240. In the aspect illustrated inFIG. 1A, the wire guide240is implemented as a hollow tube230that has a passageway formed therethrough, where the passageway is sized to receive the wire120. The tube230is disposed between the aperture204and the wire-contact surface208A of the backstop206A along the longitudinal axis222. The tube230has suitable stiffness such that the wire120is maintained in a substantially linear shape along the length of the tube230, i.e. the distance between the aperture204and the wire-contact surface208A of the backstop206A. The tube230defines a longitudinal symmetry axis223. The longitudinal symmetry axis223is an axis about which the tube230is symmetric or about which the tube230has a repeating shape or profile. For example, in aspects in which the tube230has a circular cross-sectional profile, the tube230is symmetric at all points about the longitudinal symmetry axis223. As another example, in aspects in which the tube230has a pentagonal cross-sectional profile, the tube230repeats a profile five times about the longitudinal symmetry axis. When the wire120is inserted into the tube230, the tube230urges the wire120into alignment with the longitudinal symmetry axis223. When the tube230is inserted into the laser wire-processing device200, the aperture204aligns the longitudinal symmetry axis223with the longitudinal axis222of the laser wire-processing device200such that the axes222and223are substantially coaxial. As a result of the substantially coaxial alignment between the longitudinal symmetry axis223of the tube230with the longitudinal axis222of the laser wire-processing device200, the wire120inserted in the tube230is substantially aligned with the longitudinal axis222of the laser wire-processing device200.

In various aspects, the wire guide240may be provisioned with a variety of tubes230each having different sized diameters to accommodate wires of different diameters. In one aspect, and as discussed in greater detail below with reference toFIGS. 4A-4C, a tube230is selected to have a passageway with an inner diameter that is slightly larger than an outside diameter of the wire120to be processed. By selecting from among tubes230in such a manner, the wire120may be kept as close to the longitudinal axis222as possible.

In various aspects, the laser wire-processing device200also includes a funnel220disposed in front of the aperture204. The funnel220has a frustoconical interior surface221that has a diametrically enlarged opening at a front end and tapers to a diametrically narrower opening at a backend that is adjacent to the aperture204. When the tube230is used in the laser wire-processing device200, as shown inFIG. 1, the funnel220facilitates insertion of the tube230into the aperture204. Optionally, when the tube230is not used, the funnel220is sized to facilitate insertion of the wire120into the aperture204.

In operation, a tube230of the appropriate diameter is selected according to the diameter of the wire to be cut. The tube230is then inserted through the aperture204of the housing202along the longitudinal axis222until an end232of the tube230contacts the wire-contact surface208A of the backstop206A. The wire120is then inserted through the passageway in the tube230. Alternatively, the wire120is inserted into the tube230first, and then the tube230with the wire120therein is inserted through the aperture204. In either case, the funnel220will assist in guiding the tube230and wire120into registration with the aperture204.

As noted above, the backstop206A is capable of bidirectional movement along the longitudinal axis222in order to position the wire120according to the desired length of insulation layer122to be cut. Accordingly, the tube230and the wire120therein are slidably disposed in the aperture204. Thus, as the backstop206A moves toward the aperture204, the tube230is pushed out of the aperture204by the wire-contact surface208A of the backstop206A, and the wire120(with the end128abutting the backstop206A) is also pushed out of the aperture204. Likewise, as the backstop206A moves away from the aperture204, the tube230can be pushed in (or drawn in) to the aperture204, and the wire120can also be pushed (or drawn) into the aperture204, to remain in contact with the wire-contact surface208A of the backstop206A. Alternatively, the backstop206A may be moved into the desired position before the tube230and wire120are inserted into the housing202.

FIG. 1Billustrates an aspect of the laser wire-processing device200in which the tube230is inserted through the aperture204such that the end232of the tube230is positioned proximate to but not in the path of the laser beam(s)110. As discussed above, the tube230maintains the wire120in a substantially linear shape along the length of the tube230and in alignment with the longitudinal axis222of the laser wire-processing device200. In operation, when the end232of the tube230is positioned proximate to the laser beam(s)110, then the location of the wire120to be cut, slightly extending from the end232of the tube230, is substantially aligned with the longitudinal axis222. In the aspect disclosed inFIG. 1B, the backstop206could be eliminated. A length of wire to be cut could be determined based on a length of wire inserted through the aperture. For example, suppose that the tube230has a length of 4 inches (10.16 cm) and the laser beam(s) is(are) positioned 0.05 inches (0.13 cm) past the end232of the tube230. If 1 inch (2.54 cm) of the insulation layer122is to be removed from the wire120, then a total of 5.05 inches (12.83 cm) of wire would be inserted through the aperture204. If 2 inches (5.08 cm) of the insulation layer122is to be removed from the wire120, then a total of 6.05 inches (15.37 cm) of wire would be inserted through the aperture204. Such linear calculations are possible because the tube230maintains the wire120in a substantially linear shape between the aperture204and the end232of the tube230.

FIG. 2is a cross-sectional side view of a laser wire-processing device200illustrating a variation of the laser wire-processing device200illustrated inFIG. 1A, according to one aspect, in which the backstop206B is sized and shaped as a post to fit within the tube230. Accordingly, where the tube230has a cylindrical passageway, the post-shaped backstop206B has a corresponding cylindrical cross-section such that a wire-contact surface208B of the backstop206B in a facing relationship with the aperture204fits within tube230. In such aspects, at least the wire-contact surface208B of the backstop206B can translate into and out of the tube230in the direction of arrows B. In this arrangement, the tube230can be stationary with respect to the aperture204and the wire120, while the length of the insulation to be cut is determined by the axial movement of the backstop206B. That is, the wire120can be placed into the desired cutting position by moving the backstop206B toward or away from the aperture204along the longitudinal axis222, while the tube230remains stationary.

FIGS. 3A and 3Bare cross-sectional side views of a laser wire-processing device200illustrating a variation of the laser wire-processing device200illustrated inFIG. 1A, in which a pair of clamps404and410are configured to grip the tube230or the wire120in aspects in which the tube230is not used. To this end, the laser wire-processing device200is provisioned with clamps404and410. A first provision of clamps410is arranged on the wire-contact surface208A of the backstop206A that faces the aperture204and a second provision of clamps404is arranged proximate to the aperture204within the housing202. The clamps404,410are actuatable between an unclamped position (shown inFIG. 3A) and a clamped position (shown inFIG. 3B). In the unclamped position, the clamps404,410form a diametrically larger opening relative to the clamped position. In at least one aspect, the clamps404and410are connected to actuators920that move the clamps404and410between the clamped and unclamped positions. For example, the actuators920could be solenoids or pneumatic pistons. In at least one aspect, clamps404and410are connected to biasing members930, such as springs or elastomeric members, which bias the clamps404and410into either the clamped positions or unclamped positions. In at least one aspect, the clamps404,410are connected to both the actuators920and the biasing members930. In such an arrangement, the biasing members930would urge the clamps404,410into one configuration (either clamped or unclamped) and the actuators920would overcome the bias of the biasing members930to urge the clamps404,410into the other configuration.

In one aspect (illustrated byFIGS. 3A and 3B), the tube230may be positioned in a spaced-apart manner such that the end232of the tube230is not in contact with the wire-contact surface208A of the backstop206A with the wire120extending through the tube230with an end128of the wire120in contact with the wire-contact surface208A of the backstop206A. In such an aspect, the clamps410arranged on the wire-contact surface208A of the backstop206A may only grip the end128of the wire120when moved to the clamped position shown inFIG. 3B. The clamps404arranged proximate to the aperture204grip the tube230and the wire120therein. The tube230may be flexible such that the clamps404can deform the tube230to apply a gripping force to the wire120within the tube230(as illustrated inFIG. 3B). In another aspect, both the tube230and the end128of the wire120may be positioned in contact with the wire-contact surface208A of the backstop406such that the clamps410arranged on the wire-contact surface208A of the backstop206A may grip both the tube230and the wire120therein.

In operation, the clamps404,410can be manipulated into the unclamped position by appropriate operation of the actuators920and biasing members930. In the unclamped position, the clamps404,410form an opening sufficiently large to receive the tube230and wire120. Accordingly, the tube230and the wire120can be inserted through the aperture204and brought into contact with the backstop406. The clamps404,410can then be moved in the direction of arrows C into the clamped position (indicated by reference numerals404′ and410′ inFIG. 3B) such that the tube230and the wire120are held in place along the longitudinal axis222. In at least one aspect, the clamps410arranged on the backstop206A are moved to the clamped position shown inFIG. 3Bbefore the clamps404proximal to the aperture204. In this way, tension may be applied to the wire120to render the wire taut and thereby aligned with the longitudinal axis222. Thereafter, while the tension in the wire120is being maintained, the clamps404proximal to the aperture204are moved to the clamped position, shown inFIG. 3B, such that the wire120between the clamps404and410is maintained in a taut state that is aligned with the longitudinal axis222.

FIGS. 4A-4Care cross-sectional side views of a wire guide240implemented as three different tubes230having different sizes that could be used with differently-sized wires (i.e., wires having different exterior dimensions).FIG. 4Aillustrates a first tube230A with an exterior surface502A and an interior surface504A. A dimension (e.g., a diameter) of the exterior surface502A is D1and a dimension of the interior surface504A is d1. The passageway503A through the tube230A also has a dimension of d1.FIG. 4Billustrates a second tube230B with an exterior surface502B and an interior surface504B. A dimension of the exterior surface502B is D2and a dimension of the interior surface504B is dz. The passageway503B through the tube230B also has a dimension of dz. The dimensions D2and d2of the second tube230B are larger than the dimensions D1and d1, respectively, of the first tube230A.FIG. 4Cillustrates a third tube230C with an exterior surface502C and an interior surface504C. A dimension of the exterior surface502C is D3and a dimension of the interior surface504C is d3. The passageway503C through the tube230C also has a dimension of d3. The dimensions D3and d3of the third tube230C are larger than the dimensions D2and d2, respectively, of the second tube230B. The tubes230A,230B, and230C are merely illustrative of tubes that could be included in a wire processing kit. The tubes230A,230B, and230C are configured for selective insertion into the aperture204for use with wires (e.g., the wire120) having different exterior dimensions. In various aspects, such a wire processing kit could include more or fewer than the three illustrated tubes230A,230B, and230C. In use, an operator of the laser wire-processing device (e.g., a worker or a machine) would select a tube with the smallest passageway dimension that is larger than an outer periphery of a wire to have a portion of its insulation layer122severed by the laser wire-processing device200. With reference toFIGS. 1 and 2, the user would insert a funnel220with an interior dimension equal to or slightly larger than a dimension of the exterior surface of the selected tube. Thereafter, the selected tube in funnel220would be inserted into the aperture204of the laser wire-processing device to process the wire.

In various aspects, the tubes230A,230B, and230C can optionally include centering members514, which are discussed in greater detail below with reference toFIGS. 5A-D,6A,6B, and7A-F. The various centering members514are arranged in the passageway503of the respective tube and urge a wire in the passageway toward the longitudinal symmetry axis223.

In various aspects, the tube230of the wire guide240inserted through the aperture204of the laser wire-processing device200can include centering members514arranged in the passageway503to urge the wire120into alignment with the longitudinal symmetry axis223and therefore into alignment with the longitudinal axis222of the laser wire-processing device when the tube230is disposed in the aperture204such that the longitudinal symmetry axis223of the tube230is aligned in a substantially coaxial manner with the longitudinal axis222of the laser wire-processing device200.

FIG. 5Ais a cross-sectional side view of a wire guide according to one aspect that includes a plurality of centering members514A;FIG. 5Bis a cross-sectional side view of the wire guide ofFIG. 5Aillustrating a wire inserted in the wire guide and maintained in position via the plurality of centering members514A. Referring toFIG. 5A, as discussed above, the tube230includes the exterior surface502and the interior surface504, wherein the interior surface504forms the passageway503. In this aspect, the tube230includes a plurality of centering members514A that are installed at various locations within the tube230. In this aspect, the centering members514A extend from the interior surface504toward the longitudinal symmetry axis223at one or more locations along the longitudinal symmetry axis223. The centering members514A are depicted inFIG. 5Ain a relaxed state and define an opening519therethrough. For example,FIG. 5Aillustrates a first centering member514A extending from the interior surface504of the tube230at a first location516along the longitudinal symmetry axis223, a second centering member514A extending from the interior surface504at a second location518along the longitudinal symmetry axis223, a third centering member514A extending from the interior surface504at a third location520along the longitudinal symmetry axis223, and a fourth centering member514A extending from the interior surface504at a fourth location522along the longitudinal symmetry axis223. The tube230includes three regions: a first end portion508, a second end portion512, and a middle portion510between the first and second end portions508and512. The middle portion510defines a laser cutting region511of the tube230. The tube230is insertable through the aperture204of the housing202such that the laser beam110impinges on the tube230in the laser cutting region511defined by the middle portion510. The locations516,518,520, and522of the centering members514A along the longitudinal symmetry axis223are in the first end portion508and the second end portion512such that the centering members514A are not impinged upon by the laser beam110.

FIG. 5Billustrates the tube230ofFIG. 5Awith the wire120inserted through the passageway503therein. As illustrated, the centering members514A are deflected to a flexed state to accommodate the wire120, but will return to the un-deflected state (i.e., the relaxed state) illustrated inFIG. 5Awhen the wire120is removed. Stated differently, the centering members514A are resilient and biased toward the position illustrated inFIG. 5A. The opening519in the relaxed state (shown inFIG. 5A) is smaller than the opening519′ in the in the flexed state to accommodate the wire120therethrough. In one aspect, the centering members514A are made of a plastic material or a silicone polymer material that is flexible. As a result, when the wire120is inserted through the passageway503in the tube230, the deflected centering members514A exert a biasing force on the wire120that urges the wire toward alignment with the longitudinal symmetry axis223. As discussed above, when the tube230is inserted into the aperture204of the laser wire-processing device200, the longitudinal symmetry axis223is aligned in a substantially coaxial manner with the longitudinal axis222of the laser wire-processing device200. As a result, the wire120in the tube230is also aligned with the longitudinal axis222of the laser wire-processing device200.

FIG. 5Cillustrates an end view of an exemplary centering member514A that may be installed in the tube230shown inFIGS. 5A and 5B. In the exemplary aspect shown inFIG. 5C, the centering member514A includes six compliant fronds515arranged around the interior surface504of the tube230. For clarity, one of the compliant fronds515is illustrated in solid line and the remaining five compliant fronds515are illustrated in broken line. In various aspects, the tube230could include more or fewer than the illustrated six compliant fronds515at the locations516,518,520, and522along the longitudinal symmetry axis223. In one aspect, the compliant fronds515are individually attached to the interior surface504of the passageway503. In another aspect, the plurality of compliant fronds515extends from a unitary member517(e.g., a ring) arranged around the interior surface504of the passageway503. In one aspect, the unitary member517with attached fronds515can be inserted into the tube230and attached to the interior surface504of the passageway503with an adhesive. In certain aspects, the unitary member517and fronds515are made of the same material, such as a plastic or silicone polymer. The compliant fronds515are illustrated as having a guitar pick or tear drop shape. In various aspects, the compliant fronds515could have other shapes, such as circular shapes, oval shapes, lozenge shapes, or elliptical shapes. InFIG. 4C, adjacent compliant fronds515overlap toward the center of the passageway503, and include gaps530between adjacent compliant fronds515along the interior surface504. The gaps530provide an airflow path in the event suction is applied through the tube230via the aperture204in a wire laser-processing device200to remove any sort, smoke, or other particulates resulting from the laser beam110cutting through the insulation layer122of the wire120.

FIG. 5Dillustrates an end view of another exemplary centering member514B that may be installed in the tube230shown inFIGS. 5A and 5B. In the exemplary aspect shown inFIG. 5D, the centering member514B includes compliant fronds552that are smaller than the compliant fronds515illustrated inFIG. 4C. Additionally, the arrangement shown inFIG. 5Dincludes five compliant fronds552arranged around the interior surface504of the tube230. In this aspect, the compliant fronds552do not overlap due, at least in part, to the reduced size. Thus, the compliant fronds552include gaps554between adjacent compliant fronds552along the interior surface504and also gaps between adjacent compliant fronds552all the way to the center of the passageway503. In one aspect, the compliant fronds552are individually attached to the interior surface504of the passageway503. In another aspect, the plurality of compliant fronds552extends from a unitary member517arranged around the interior surface504of the passageway503.

A wire guide240that comprises the tube230illustrated inFIGS. 5A-5Dis suitable for use in any of the laser wire-processing devices200shown inFIGS. 1, 2, 3A, 3B, and4A-4C.

FIG. 6A-6Bare a cross-sectional side view and end view of the tube230of the wire guide240with different centering members514C, according to another aspect, arranged around the interior surface504of the tube230. In this aspect, the centering members514C include leaf springs602arranged around the interior surface504at the first end portion508and the second end portion512that push against a wire120inserted through the passageway503to urge the wire120toward alignment with the longitudinal symmetry axis223. The leaf springs include ends606aand606battached to the interior surface504of the passageway such that middle portions604of the leaf springs602and to extend from the interior surface504of the passageway503toward the longitudinal symmetry axis223. When a wire120is inserted through the passageway503, the wire can push the middle portions604toward the interior surface504of the tube230. The leaf springs602, in turn, exert a spring force on the wire that urges the wire toward alignment with the longitudinal symmetry axis223.FIG. 6Billustrates seven leaf springs602arranged around the interior surface504of the tube230in various aspects, a tube230could include more or fewer than seven leaf springs six and two arranged around the interior surface504.

A wire guide240that comprises the tube230illustrated inFIGS. 6A and 6Bis suitable for use in any of the laser wire-processing devices200shown inFIGS. 1, 2, 3A, 3B, and4A-4C.

FIGS. 7A-7Dare cross-sectional side views and end views of the tube230of the wire guide240with another centering member514D, according to another aspect, arranged around the interior surface504of the tube230. In this aspect, the centering members514D include elastomeric grommets700arranged around the interior surface504that inflate to urge a wire120inserted through the passageway503toward alignment with the longitudinal symmetry axis223. The tube230includes first apertures560and second apertures562arranged toward the second end portion512of the tube230. The first apertures560are in communication with an interior volume706of the elastomeric grommets700. The second apertures562are in communication with the passageway503through the tube230. As illustrated inFIG. 7A, when a wire120is inserted through the tube230, the wire120may not be aligned with the longitudinal symmetry axis223of the tube230.FIG. 7Cillustrates a relatively large passageway503between the elastomeric grommets700through which the wire120can pass. After the tube230and the wire120are inserted into a laser wire-processing device, a vacuum system is coupled in flow communication with the aperture204of the laser wire-processing device200. The vacuum system is then activated such that air is pulled through the passageway503in the tube230in the direction of arrows D. The moving air in the passageway503reduces the air pressure in the passageway503according to the Venturi effect. Air in the interior volumes706of the elastomeric grommets700is stationary and therefore remains at atmospheric pressure. As a result, referring toFIGS. 7B and 7D, the elastomeric grommets700expand (i.e., the interior volumes of the elastomeric grommets700increase, as indicated by reference numeral706′) toward the longitudinal symmetry axis223to effectively narrow the diameter of the passageway503, thereby urging the wire120into alignment with the longitudinal symmetry axis223(i.e., in the direction of arrow E) and therefore into alignment with the longitudinal axis222of the laser wire-processing device200.FIG. 7Dillustrates a resultant relatively smaller passageway503′ between the expanded elastomeric grommets700. In at least one aspect, in addition to aligning the wire120with the longitudinal symmetry axis223, the expanded elastomeric grommets700′ can also provide a gripping or clamping force on the wire120such that tension can be applied to the wire120(in a direction out of the aperture204) to further straighten the wire120.

FIGS. 7E and 7Fare end views of another centering member514E in which the multiple elastomeric grommets700illustrated inFIGS. 7C and 7Dare replaced with a unitary elastomeric grommet750arranged around a periphery of the interior surface504of the passageway503.FIG. 7Eillustrates the grommet750in an unexpanded state toward the longitudinal symmetry axis223(i.e., an interior volume752of the unitary elastomeric grommet750is relatively small) such that the passageway503through the tube230is relatively large, which can enable the wire120to easily be inserted through the passageway503.FIG. 7Fillustrates the grommet750in an expanded state (indicated by the reference numerals750′ and752′) such that the passageway503is smaller. As the passageway503gets smaller, the wire120passing therethrough is urged toward the center of the tube230and alignment with the longitudinal symmetry axis223. Additionally, as the unitary elastomeric grommet750expands to the shape shown inFIG. 7F, the unitary elastomeric grommet750′ could squeeze or clamp the wire120, further holding the wire120in place in the tube230.

In addition to expanding the elastomeric grommets700and750, the vacuum can also displace debris and air from within the tube230. The at least one laser beam110severing the insulation layer124of the wire120can generate smoke particles and heat. The vacuum can displace or otherwise remove any smoke particles from the tube230.

Additionally, the movement of air through the tube230caused by the vacuum can cool a portion of the wire120heated by the at least one laser beam110.FIGS. 8A and 8Billustrate two possible arrangements to couple a vacuum system225that can provide such movement of air to the tube230.FIG. 8Ais a cross-sectional side view of a tube230that includes a port227that is in communication with the passageway503. The port227could be a pipe or other tube arranged on the tube230. The vacuum system225is coupled to the port227. For example, the vacuum system225could be coupled to the port227via flexible tubing. In operation, when the vacuum system225is activated, the vacuum system225draws air from the passageway503of the tube230through the port227in the direction indicated by arrow D.

FIG. 8Bis a cross-sectional side view of a tube230in which a vacuum probe229is inserted into the passageway503alongside the wire120. A passageway through the vacuum probe229is in communication with the vacuum system225. In operation, when the vacuum system225is activated, the vacuum system225draws air from the passageway of the tube230through the vacuum probe229in the direction of arrow D.

In various aspects, positive pressure (instead of a vacuum) could be used to displace debris and air from within the tube230and/or within the housing202of the laser wire-processing device200. For example, the laser wire-processing device200could be provisioned with a fan or a pump in the housing202that draws air into the housing202, resulting in an increased air pressure in the housing202. The high-pressure air in the housing flows out through the aperture204, carrying any debris within the housing202.

FIG. 9Ais a cross-sectional side view of another variation of the tube230of the wire guide240illustrated inFIGS. 1, 2, 3A, 3B, 4A-4C, 5A-5D, 6A, 6B, and 7A-7F, according to one aspect, in which the tube is made of an opaque material, such as metal or plastic, or is coated in an opaque material that the laser beam110cannot pass through and the tube230includes a window806through which the laser beam110can reach the wire120in the passageway503. In various aspects, the opaque material has a low emissivity such that portions of the laser beam(s)110that impinge upon the opaque material are substantially absorbed rather than reflected. In one aspect, the window806comprises an opening in the tube230. In another aspect, the window806comprises a portion of the tube230that does not include an opaque coating. In this aspect, the tube230rotates in the direction of arrows A about the longitudinal axis222of the laser wire-processing device such that the window806remains aligned with a laser beam110as the laser beam110rotates about the longitudinal axis222to cut the insulation layer122of the wire120. In aspects in which the laser wire-processing device includes more than one laser beam110, the tube230could include multiple windows806. For example, in aspects in which the laser wire-processing device200includes two laser beams110in the laser wire-processing device200, the tube230includes two windows806on opposing sides of the tube230. The tube230could be connected to the backstop206and/or the turret212to facilitate rotation. In various other aspects, the wire120could rotate within the tube230relative to the laser beams110. As a result, the tube230and laser beams110would be stationary.

FIG. 9Bis a cross-sectional side view of a variation of the tube230illustrated inFIG. 9A, in which the tube230includes the centering members514A arranged in the passageway503. Alternatively, the tube230illustrated inFIG. 9Bcould include the other centering members514B,514C,514D, or514E depicted inFIGS. 5-7and discussed above.

As shown inFIGS. 9A and 9B, the laser access window806is arranged in the middle portions510of the tube230. In various other aspects, the laser access window806could be arranged in the first end portion508or the second end portion512. For example, in one aspect, the laser access window806could extend from an end of the tube230and through the second end portion512to the middle portion510.

A wire guide240that comprises the tube230illustrated inFIG. 8is suitable for use in any of the laser wire-processing devices200shown inFIGS. 1, 2, 3A, and 3B.

As discussed above, in certain aspects, clamps are added to the laser wire-processing device along the longitudinal axis. The clamps can grip a wire inserted into the laser wire-processing device. Thereafter, tension can be applied to the curved wire to straighten the wire along the longitudinal axis.

FIG. 10A-10Bare cross-sectional side views of an aspect of a laser wire-processing device200, wherein the wire guide240comprises one or more backstop guides908arranged on a backstop902of the laser wire-processing device200to urge the end128of the wire120into alignment with the longitudinal axis222. The backstop guide(s)908are arranged on a surface904of the backstop902facing the aperture204. The backstop guides908urge an end of the wire120inserted through the aperture204toward an intersection of the longitudinal axis222with the surface904of the backstop902. In the aspect illustrated inFIGS. 10A-10B, the backstop guides908comprise inclined surfaces909extending toward the aperture204from the backstop902. The inclined surfaces909extend further toward the aperture204at greater distance from the longitudinal axis222. In the event a curved or bent wire120is inserted through the aperture204, the end128of the wire120will encounter one of the inclined surfaces909of the backstop guides908. The inclined surfaces909will urge the end128of the wire120toward the longitudinal axis222. The backstop guides908extend sufficiently far away from the longitudinal axis222such that a bent or curved wire will impinge upon an inclined surface909. In one aspect, the backstop guides908form an opening905therebetween, and the inclined surfaces909urge the end of the wire120toward and into the opening905.

As shown inFIG. 10B, after the end of the wire120has been urged into the opening905, the backstop guides908can be moved in the direction indicated by arrows C to a closed position (indicated by reference numerals908′) such that the opening905′ has a smaller dimension than the opening905shown inFIG. 10A, thereby securing the end128of the wire120in alignment with the longitudinal axis222. Thereafter, tension can be applied to a portion of the wire120extending out of the aperture204such that the wire120within the housing202is taut and straight along the longitudinal axis222. Thereafter, second clamps404arranged proximal to the aperture204in the housing202can be moved from an unclamped position (illustrated inFIG. 10A) to a clamped position (illustrated inFIG. 10Band indicated by reference numerals404′) to clamp the wire120and maintain the portion of the wire120between the backstop guides908and clamps404′ in tension and alignment with the longitudinal axis222.

FIGS. 10C and 10Dare cross-sectional side views of a variation of the laser wire-processing device200shown inFIGS. 10A and 10B, in which the wire guide240includes the backstop guides908and the tube230, discussed above with reference toFIGS. 1-9. The tube230could be squeezed by the backstop guides908and the clamps404to hold both the tube230and the wire120in place and in alignment with the longitudinal axis222.

FIG. 11is a block diagram illustrating at least some possible combinations of the various components described above with reference toFIGS. 1, 2, 3A, 3B, 4A-4C, 5A-5D, 6A, 6B, 7A-7F, 8A, 8B, 9A, 9B, and 10A-10D. A laser wire-processing device200includes a housing202and an aperture204arrange in the housing202to receive a wire120. The laser wire-processing device200also includes a laser250that outputs a laser beam110to cut an insulation layer122of the wire120.

The laser wire-processing device200also includes a wire guide240that directs or urges the wire120into alignment with the longitudinal axis222of the laser wire-processing device200such that the insulation layer122of the wire120can be properly cut by the laser beam110.

In certain aspects, the wire guide240comprises a tube230. The tube230can be sized such that a passageway formed therein is slightly larger than an outer diameter of the wire.FIGS. 4A-4Cillustrate three exemplary tubes230having different interior passageway dimensions, and one of the tubes230with the smallest interior passageway dimension that is larger than an exterior diameter of the wire can be selected. In various aspects, the tube230can include a first centering member514arranged within the interior passageway at a first location along a longitudinal symmetry axis223of the tube230. In addition, in various aspects, the tube230can include a second centering member514arranged within the interior passageway at a second location along the longitudinal symmetry axis223. The centering member(s) urge the wire120toward the longitudinal symmetry axis223of the tube230, which is aligned with the longitudinal axis222of the laser wire-processing device200. The centering member(s) could comprise compliant fronds514A or514B arranged within the passageway, leaf springs514C arranged within the passageway, and/or elastomeric grommets514D or514E arranged within the passageway.

In various aspects, the tube230can be transparent or opaque, and the first and second centering members514can be included in both the transparent and the opaque tubes230. As used herein, the terms transparent and opaque are with respect to a wavelength (or wavelengths) of light of the laser beam110. The tube230is transparent if the laser beam110passes through the tube230. The tube230is opaque if the laser beam110does not pass through the tube230. In at least one aspect, such as aspects in which the tube230is opaque, the tube230can include a laser-access window806through which the laser beam110can impinge upon the wire120. In at least one aspect, the tube230can be rigid. In at least one other aspect, the tube230can be resilient and/or compliant. The first and second centering members514can be included in both the rigid tubes230and the resilient/compliant tubes230.

The laser wire-processing device200includes a backstop206arranged therein that the wire120abuts, and the backstop206is movable relative to the laser beam110to adjust a length of the insulation layer122to be severed from the wire120. In one aspect, the backstop206A includes a wire-contact surface208A facing the aperture204that has a surface area larger than a cross-sectional area of the tube230. In certain aspects, the wire-contact surface208A includes backstop clamps410that can clamp an end of a wire and/or an end of the tube230. In other aspects, the backstop206B includes a wire-contact surface208B that fits within the passageway503in the tube230.

In various aspects, the wire guide240comprises backstop guides908arranged on a backstop902. In at least one aspect, the backstop guides908include inclined surfaces909that urge an end128of a wire120toward a location on the backstop902aligned with the aperture204. In at least one aspect, the backstop guides908define a gap905therebetween that the end of the wire120fits into. In at least one aspect, the backstop guides908are movable to clamp the wire120between them. In such aspects, the backstop guides908could be connected to an actuator920to move the inclined surface(s) between a clamped position and an unclamped position. In at least one aspect, the backstop guides908can be connected to a biasing member930, such as a spring or an elastomeric member, which biases the backstop guides908in a clamped position. In at least one aspect, the backstop guides908could be connected to both the actuator920and the biasing member930such that the actuator920moves the backstop guides908from a biased, clamped position or from a biased, unclamped position.

In at least one aspect, the laser wire-processing device200can also include a gripping clamp404arranged proximal to the aperture204that can grip a portion of the wire120proximal to the aperture204. In particular, the gripping clamps404are most advantageous when used in combination with aspects that include the backstop clamps410on the backstop206or in combination with aspects that include the backstop guides908on the backstop902.

In the aspects described herein, a wire that may have residual curvature after on spooling may be quickly inserted into a laser wire-processing device200in an aligned manner such that the laser wire-processing device200will cleanly sever an insulation layer122of the wire120.FIGS. 12A and 12Bare side views of the end of the wire120and a processed wire120′, respectively. The processed wire120′ includes a gap126in the insulation layer122caused by the laser beam(s)110burning, melting, and/or ablating the insulation layer122. As shown inFIG. 12B, the insulation layer122′ toward the end128of the processed wire120′ has been completely severed from the insulation layer122on the remainder of the processed wire120′. In various circumstances, the insulation layer122′ at the end128of the processed wire120′ may not be completely severed in the gap126, but a sufficient amount of material of the insulation layer122in the gap126may be removed such that remaining insulation layer122material in the gap126can be mechanically severed (e.g., by the insulation layer122′ at the end128of the processed wire120′ being pulled off the conductor124).

The descriptions of the various aspects have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the aspects disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described aspects. The terminology used herein was chosen to best explain the principles of the aspects, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the aspects disclosed herein.

While the foregoing is directed to certain aspects, other and further aspects may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.