Cable preparation machine having arcing contour blades

A cable preparation machine includes a frame forming a cable cutting zone, the frame having a cable opening along a cable axis at the cable cutting zone receiving an end of a cable. The cable preparation machine includes a pulley assembly rotatably coupled to the frame about the cable axis and a drive assembly operably coupled to the pulley assembly to rotate the pulley assembly about the cable axis. The cable preparation machine includes a blade assembly operably coupled to the pulley assembly and rotated with the pulley assembly about the cable axis. The blade assembly includes a blade having an arcuate cutting edge configured for cutting an insulator from the end of the cable.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to a cable preparation machine.

Cables are used in many applications. Typically, an end of the cable is prepared for termination to a terminal, contact, connector, circuit board or other component by exposing the conductor(s) of the cable. For example, with a coaxial or shielded cable, the cable typically includes a center conductor, an inner insulator, an outer conductor, such as in the form of a foil and a cable braid, and an outer insulator, such as a cable jacket. Cable preparation processes typically involve removal of the various layers of the cable for termination of the conductive layers to the component. For example, the outer insulator is stripped to expose the cable braid, the cable braid is stripped to expose the inner insulator and the inner insulator is stripped to expose the inner conductor.

Conventional cable preparation processes require several different process steps and several different preparation machines to perform all of the preparation steps. For example, the cable is typically inserted into a first machine to remove the outer insulator. The cable is then removed from the first machine and inserted into a second machine to remove the cable braid. The cable is removed from the second machine and then inserted into a third machine, or back into the first machine, to remove the inner insulator. Different steps and different machines are used because different preparation operations on the same cable need different cutting blades and other considerations performed in independent machines. Conventional cable preparation processes are time-consuming and expensive.

Additionally, with some known cable preparation machines, removal of layers may damage other layers of the cable. For example, conventional cable preparation machines utilize a pair of slicing blades movable in opposing directions to slice through the insulators. However, such slicing blades may nick or cut the cable braid or the inner conductor strands as the slicing blades are closed around the cable to slice through the insulator. The damage caused to the cable braid or the inner conductor may be unacceptable to end users. Additionally, the linear slicing blades are designed to cut and remove an insulator having one specific diameter. Separate blades are needed for cutting an inner insulator and an outer insulator or for cutting insulators of different diameter cables.

A need remains for a cable preparation machine capable of removing insulator layers in a cost effective and reliable manner.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a cable preparation machine is provided including a frame forming a cable cutting zone, the frame having a cable opening along a cable axis at the cable cutting zone receiving an end of a cable. The cable preparation machine includes a pulley assembly rotatably coupled to the frame about the cable axis and a drive assembly operably coupled to the pulley assembly to rotate the pulley assembly about the cable axis. The cable preparation machine includes a blade assembly operably coupled to the pulley assembly and rotated with the pulley assembly about the cable axis. The blade assembly includes a blade having an arcuate cutting edge configured for cutting an insulator from the end of the cable.

In another embodiment, a cable preparation machine is provided including a frame forming a cable cutting zone, the frame having a cable opening along a cable axis at the cable cutting zone receiving an end of a cable. The cable preparation machine includes a pulley assembly rotatably coupled to the frame about the cable axis. The pulley assembly includes a front pulley and a rear pulley rotatable relative to the front pulley. The rear pulley has an actuator. The cable preparation machine includes a blade assembly operably coupled to the pulley assembly. The blade assembly has a blade arm pivotably coupled to the front pulley being operably coupled to the actuator of the rear pulley. The actuator pivots the blade arm relative to the front pulley upon relative rotation of the front pulley and the rear pulley. The blade assembly has a blade extending from the blade arm having an arcuate cutting edge configured for cutting an insulator of the cable. The cable preparation machine includes a drive assembly operably coupled to the pulley assembly to rotate the pulley assembly about the cable axis. The drive assembly is operably coupled to the front pulley to rotate the front pulley and is operably coupled to the rear pulley to rotate the rear pulley. The drive assembly is configured to rotate the front and rear pulleys independent of each other to actuate the blade assembly.

In a further embodiment, a cable preparation machine is provided including a frame forming a cable cutting zone, the frame having a cable opening along a cable axis at the cable cutting zone receiving an end of a cable. The cable preparation machine includes a drive assembly having a first drive unit and a second drive unit. The cable preparation machine includes a pulley assembly rotatably coupled to the frame about the cable axis. The pulley assembly includes a front pulley operably coupled to the first drive unit and a rear pulley operably coupled to the second drive unit. The front pulley is rotatable in a forward direction and a reverse direction by the first drive unit. The rear pulley is rotatable in a forward direction and a reverse direction by the second drive unit independent of the rotation of the front pulley. The cable preparation machine includes a blade assembly operably coupled to the pulley assembly having a blade pivotably coupled to the front pulley. The blade has an arcuate cutting edge configured for cutting an insulator of the cable.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates a cable preparation machine100in accordance with an exemplary embodiment. The cable preparation machine100includes a cable cutting device102configured to cut and remove one or more insulators from an end150of a cable104, such as an outer insulator152(for example, a cable jacket) and/or an inner insulator154. The cable cutting device102may be configured to cut and remove a cable braid156from the end150of the cable104. The inner insulator154separates the cable braid156from an inner conductor158of the cable104. The cable braid156provides electrical shielding for the inner conductor158. The inner conductor158may be a solid core wire or a stranded wire. Optionally, the cable preparation machine100may be configured to flare the cable braid156. Optionally, the cable preparation machine100may be configured to fold the cable braid156at the end of the cable104. The cable preparation machine100is able to prepare the end of the cable104without moving the cable104between different machines. For example, the cable cutting device102includes different cutting blades for cutting the insulator(s)152,154and the cable braid156during different cable cutting steps within the cable preparation machine100without removing the cable104from the cable cutting zone of the cable cutting device102. As such, the end of the cable104may be processed and prepared quickly and efficiently using a single machine.

The cable preparation machine100includes a frame110supporting the various components of the cable preparation machine100. The frame110forms a cable cutting zone112where the end of the cable104is processed and prepared. For example, the cable cutting device102is located at the cable cutting zone112. The frame110includes a base114and support members116mounted to the base114. The support members116support various components of the cable preparation machine100. In an exemplary embodiment, the frame110includes a cabinet118housing the cable cutting device102in a chamber120of the cabinet118. The cabinet118surrounds the cable cutting device102to prevent injury to the operator of the cable preparation machine100. The cabinet118includes one or more walls122surrounding the chamber120. Optionally, the cabinet118includes a door124for accessing the chamber120. In an exemplary embodiment, the cabinet118includes a cable opening126through one or more of the walls122to allow the cable104to be loaded into the chamber120to the cable cutting zone112.

In an exemplary embodiment, the cable preparation machine100may include a cable holder130(shown inFIG. 14) that holds the cable104during the cable preparation process. For example, the cable holder130holds the cable104in the cable cutting zone112for removal of the insulator(s)152,154and the cable braid156. Optionally, the cable holder130is movable relative to the frame110to position the cable104in the cable cutting zone112. The cable holder130may be located forward of the cabinet in various embodiments.

In an exemplary embodiment, the cable preparation machine100includes a braid manipulation device132for preparing the end of the cable104, such as for manipulating the cable braid156during cable preparation. The braid manipulation device132may include a mandrel or other component that may be inserted into or into the end of the cable104. The mandrel may be used to flare the cable braid156during processing of the end of the cable104. The mandrel may be used to fold the cable braid156backwards during processing of the end of the cable104. In the illustrated embodiment, the braid manipulation device132is located behind the cabinet118.

Optionally, the cable preparation machine100may include a chute134for discarding the removed slugs of insulator(s)152,154and/or the removed slugs of cable braid156after being cut and removed from the end of the cable104. The chute134transfers the discarded slugs away from the cable cutting zone112.

FIG. 2is a perspective view of a portion of the cable preparation machine100showing the cable cutting device102in accordance with an exemplary embodiment.FIG. 2illustrates a base170and a support wall172of the frame110used to support the cable cutting device102. The support wall172of the frame110includes a cable opening174along a cable axis176at the cable cutting zone112that receives the end150of the cable104(shown inFIG. 1).

The support wall172of the frame110includes drive openings178therethrough between a front180and a rear182of the support wall172. The drive openings178may be located generally on opposite sides of the cable opening174; however, other locations are possible in alternative embodiments, such as above and/or below the cable opening174.

The cable cutting device102includes a pulley assembly200, a drive assembly202and a blade assembly204. The pulley assembly200is rotatably coupled to the support wall172of the frame110about the cable axis176. The pulley assembly200is located forward of the front180of the support wall172. The drive assembly202is operably coupled to the pulley assembly200to rotate the pulley assembly200about the cable axis176. The blade assembly204is operably coupled to the pulley assembly200and is rotated with the pulley assembly200about the cable axis176.

In various embodiments, the blade assembly204is configured for cutting the outer insulator152from the end150of the cable104in one cutting configuration of the cable cutting device102when the cable104is positioned in the cable opening174. Optionally, the blade assembly204is configured for removing the outer insulator slug from the end150of the cable104after being cut, such as by holding the insulator slug in the cable opening174as the cable104is drawn out of the cable opening174until the insulator slug falls off the end of the cable104. In various embodiments, the blade assembly204is configured for cutting the inner insulator154from the end150of the cable104in another cutting configuration of the cable cutting device102when the cable104is positioned in the cable opening174. Optionally, the blade assembly204is configured for removing the inner insulator slug from the end150of the cable104after being cut, such as by holding the insulator slug in the cable opening174as the cable104is drawn out of the cable opening174until the insulator slug falls off the end of the cable104. The cable104may be positioned in the cable opening174for removal of the cable braid156or manipulation of the cable braid156, such as flaring or folding of the cable braid156. The drive assembly202, the pulley assembly200and the blade assembly204are operated differently in the different cutting configurations.

In an exemplary embodiment, the blade assembly204includes multiple cutting blades210disposed about the cable axis176. For example, the blades210may triangulate the cable104within the cable opening174during the cutting operations to ensure that the cable104remains centered within the cable opening174for consistent cutting depth by the blades210. The blades210are configured for cutting the insulators152,154of the cable104. In the illustrated embodiment, the blades210are fixed blades having arcuate cutting edges212at radially inner edges of the blades210for cutting the insulators152,154. For example, the blades210may be sickle shaped. The blades210may be wedge shaped being narrower at the arcuate cutting edges212and wider at the radially outer ends of the blades210opposite the arcuate cutting edges212. The arcuate cutting edges212are concave. The arcuate cutting edges212have a radius of curvature that closely matches a radius of curvature of the cable104. The arcuate cutting edges212may have a radius of curvature that more closely matches the radius of curvature of the outer insulator152, such as in inner diameter of the outer insulator152, or may have a radius of curvature that more closely matches the radius of curvature of the inner insulator154. Optionally, the blade assembly204may include braid blades (not shown) configured for cutting the cable braid156of the cable104.

In an exemplary embodiment, the pulley assembly200includes a front pulley220operably coupled to a first drive unit230of the drive assembly202and a rear pulley222operably coupled to a second drive unit232of the drive assembly202. The front pulley220is forward of the rear pulley222and both pulleys220,222are located forward of the front180of the support wall172of the frame110. The front pulley220is rotatable independent of and relative to the rear pulley222. For example, the first drive unit230may be operated independently of the second drive unit232, and the second drive unit232may be operated independently of the first drive unit230. For example, the first drive unit230may be operated to rotate the front pulley220in a forward direction and in a reverse direction. Similarly, the second drive unit232may be operated to rotate the rear pulley222in a forward direction and in a rearward direction. During operation, the front pulley220may be operated at a different rate than the rear pulley222or may be operated at the same rate as the rear pulley222. In certain operations, the front pulley220and the rear pulley222may be operated in different directions. In certain operations, the front pulley220or the rear pulley222may remain stationary while the other of the front pulley220or the rear pulley222may be operated in a forward direction or a rearward direction. When the front pulley220and the rear pulley222are operated at different speeds and/or in different directions, the pulley assembly200actuates the blade assembly204, such as for opening or closing the blades210around the cable104.

In an exemplary embodiment, the blades210are rotated with the pulley assembly200about the cable axis176to position the blades210relative to the cable104for cutting the cable104. The blades210are positionable at different rotational positions relative to the cable104, such as for cutting at different locations around the cable104. In various embodiments, the blades210may be driven in a radially cutting direction, such as in a chopping action, to cut through the insulators152,154. The blades210may chop inward, deflect back outward (or retract), rotate to a new rotational position, and then again chop inward (any number of times) to cut through the insulators152,154. In other various embodiments, the blades210may be driven in a rotating cutting direction, such as in a slicing action, to cut through the insulators152,154.

In the illustrated embodiment, the first drive unit230of the drive assembly202includes a first drive motor240, a first drive shaft242, a first drive pulley244and a first drive belt246coupled to the front pulley220. The drive motor240is located rearward of the support wall172and the drive pulley244is located forward of the support wall172. The drive shaft242passes through the drive opening178. The drive motor240rotates the drive shaft242, which rotates the drive pulley244. The drive motor240may be rotated in a forward direction or a reverse direction. As the drive pulley244is rotated, the drive belt246rotates the front pulley220. In various embodiments, the drive motor240may be a stepper motor. In other various embodiments, the drive motor240may be a servo motor. Other types of drivers may be used in alternative embodiments, such as a hydraulic driver, a pneumatic driver, or another type of drive unit. The drive system may utilize other intermediary structures other than the drive belt246between the drive pulley244and the front pulley220to transfer rotation of the drive pulley244to rotation of the front pulley220, such as a chain, a gear, and the like. Other types of drive systems may be used in alternative embodiments. For example, the drive pulley244may define a drive gear directly engaging the front pulley220. For example, the drive pulley244may include teeth and the front pulley220may include teeth that mesh with the teeth of the drive pulley244such that the front pulley220is directly driven by the drive pulley244rather than being driven by an intermediary structure.

In the illustrated embodiment, the second drive unit232of the drive assembly202includes a second drive motor250, a second drive shaft252, a second drive pulley254and a second drive belt256coupled to the rear pulley222. The drive motor250is located rearward of the support wall172and the drive pulley254is located forward of the support wall172. The drive shaft252passes through the drive opening178. The drive motor250rotates the drive shaft252, which rotates the drive pulley254. The drive motor250may be rotated in a forward direction or a reverse direction. As the drive pulley254is rotated, the drive belt256rotates the front pulley220. In various embodiments, the drive motor250may be a stepper motor. In other various embodiments, the drive motor250may be a servo motor. Other types of drivers may be used in alternative embodiments, such as a hydraulic driver, a pneumatic driver, or another type of drive unit. The drive system may utilize other intermediary structures other than the drive belt256between the drive pulley254and the rear pulley222to transfer rotation of the drive pulley254to rotation of the rear pulley222, such as a chain, a gear, and the like. Other types of drive systems may be used in alternative embodiments. For example, the drive pulley254may define a drive gear directly engaging the rear pulley222. For example, the drive pulley254may include teeth and the rear pulley222may include teeth that mesh with the teeth of the drive pulley254such that the rear pulley222is directly driven by the drive pulley254rather than being driven by an intermediary structure.

The drive assembly202is operated to rotate the pulley assembly200about the cable axis176. The blades210are rotatable with the pulley assembly200around the cable axis176. The drive assembly202rotates the pulley assembly200in a first drive configuration to actuate the blades210, such as to open or close the blades210relative to the cable104. The first drive configuration is used for cutting the outer insulator152of the cable104. In an exemplary embodiment, when the drive assembly202is operated in the first drive configuration, the blade assembly204is operated in the first cutting configuration to a first cutting depth. The drive assembly202rotates the pulley assembly200in a second drive configuration to actuate the blades210, such as to open or close the braid blades210relative to the cable104, to a second cutting depth. The second drive configuration is used for cutting the inner insulator154of the cable104, such as after the cable braid156is removed from the end of the cable104.

FIG. 3is a front view of the cable cutting device102in accordance with an exemplary embodiment. The pulley assembly200includes a hub260received in the cable opening174of the support wall172. The hub260is hollow and configured to receive the end150of the cable104(shown inFIG. 1). The front pulley220and the rear pulley222are rotatable on the hub260.

The rear pulley222includes actuators262(shown in phantom) extending forward from the rear pulley222into slots264in the front pulley220. The actuators262may be actuator pins in various embodiments. However, other types of actuators may be used in alternative embodiments. The actuators262extend through the front pulley220to engage the blade assembly204. The actuators262actuate the blade assembly204during operation of the cable cutting device102. For example, as the front pulley220rotates relative to the rear pulley222, the actuators262engage the blade assembly204to actuate the blade assembly204. In various embodiments, when the front pulley220rotates faster than the rear pulley222, the blades210are opened and when the rear pulley222rotates faster than the front pulley220, the blades are closed around the cable104. However, when the front and rear pulleys220,222are rotated at the same rate, the blades210are neither opened nor closed, but rather are rotated with the front and rear pulleys220,222.

In an exemplary embodiment, the pulley assembly200has a normal position wherein the front pulley220is rotationally centered with respect to the rear pulley222. The front pulley220may include hard stop pins266extending forward of the front pulley220that engage the blade assembly204to position the blade assembly204in the normal position. The location of the hard stop pins266in the slots264may define the normal position, which may be varied by moving the hard stop pins266within the slots264. In other various embodiments, rather than using hard stop pins266the ends of the slots264may define the hard stops to define the normal position. The pulley assembly200may be operated to advance the blades210from the normal position. For example, relative rotation of the front pulley220with respect to the rear pulley222may cause the blades210to advance inward toward the cable104. The pulley assembly200may be operated to retract the blades210to the normal position. For example, relative rotation of the front pulley220with respect to the rear pulley222may cause the blades210to retract away from the cable104.

The blade assembly204includes blade arms270holding the blades210. The blade arms270are pivotably coupled to the front pulley220of the pulley assembly200. The blade arms270pivot relative to the front pulley220to open or close the corresponding blades210. The blade arm270holds the corresponding blade210for cutting the insulators152,154. In the illustrated embodiment, the blade assembly204includes three blade arms270with each blade arm270holding the corresponding blade210to triangulate the blades210around the cable opening174. Greater or fewer blade arms270may be provided in alternative embodiments.

The blade arms270are pivotably coupled to the front pulley220by an arm pivot pin276. The blade arms270are pivoted relative to the front pulley220of the pulley assembly200to change a cutting depth of the corresponding blade210. For example, the relative movement (for example, angular position) of the front pulley220relative to the rear pulley222determines the amount of pivot of the blade arm270, and thus the location of the blade210relative to the cable opening174to control the cutting depth of the blade210. The cable cutting device102may accommodate cables104of various diameters by changing the cutting depth of the blades210. In an exemplary embodiment, the arm pivot pin276is offset from the actuator262. When the actuator262engages and drives against the blade arm270, the blade arm270is pivoted about the arm pivot pin276to close the blade210for cutting the cable104.

The actuator262causes the blade arm270to pivot when the front pulley220is rotated at a different rate than the rear pulley222. In a first drive configuration, the front pulley220is rotated at a faster rate than the rear pulley222to actuate the blade assembly204. For example, the pulley assembly200may be used to retract (for example, open) the blade210away from the cable104(for example, from a closed position back to the normal position) in the first drive configuration. In a second drive configuration, the rear pulley222is rotated at a faster rate than the front pulley220to actuate the blade assembly204. For example, the pulley assembly200may be used to advance the blade210toward the cable104(for example, from the normal position to a cutting position) for closing the blade210on the cable104for cutting the insulator152or154. In a third drive configuration, the front pulley220and the rear pulley222are rotated at the same rate. In the third drive configuration, the blade arm270remains stationary relative to the front pulley220and thus does not open or close when the front pulley220is rotated at the same speed as the rear pulley222. For example, the blade arm270may be repositioned relative to the cable104as the pulley assembly200is driven in the third drive configuration. In various embodiments, the blade210may be held at a constant cutting depth and rotated with the front pulley220when the front pulley220and the rear pulley222are rotated at the same speed.

In an exemplary embodiment, the actuator262is used to return the blade arm270to the normal position from the advanced position. For example, relative rotation of the rear pulley222relative to the front pulley220returns the blade arms270. However, in alternative embodiments, each blade arm270is coupled to an arm return spring (not shown) that pulls the blade arm270back to the normal position. The arm return spring biases the blade arm270to an open position. As the actuator262is retracted, the arm return spring opens or returns the blade arm270to the normal position against the hard stop pin266. The hard stop pin266holds the blade arm270in the normal position. The arm return spring returns the blade arm270to a position where the blade arm270engages the hard stop pin266, defining the normal position. The blade arm270is unable to open further than the normal position because the blade arm270bottoms out against the hard stop pin266.

In operation, when the rear pulley222is rotated in a first direction (for example, clockwise) relative to the first pulley220, the actuator262presses against the corresponding blade arm270to actuate the blade arm270and close the blade210around the cable104. When the rear pulley222is rotated in an opposite second direction (for example, counterclockwise) relative to the first pulley220, the actuator262moves back toward the normal position in the slot264. The actuator262or the arm return spring returns the blade arm270to the normal position against the hard stop pin266.

In an exemplary embodiment, each blade arm270includes a body280extending between a first side282and a second side284. The body280extends between an inner end286and an outer end288. The first side282faces the hard stop pin266. In the normal position, the first side282abuts against the hard stop pin266. In the illustrated embodiment, the arm pivot pin276is located proximate to the first side282and proximate to the inner end286. Other locations are possible in alternative embodiments. In an exemplary embodiment, the actuator262is received in a pocket in the rear of the blade arm270to cause advancing and retracting movement of the blade arm270as the rear pulley222is moved relative to the front pulley220in the advancing direction or in the retracting direction. However, in alternative embodiments, the actuator262may engage the first side282of the blade arm270, such as proximate to the outer end288, to force advancing movement of the blade arm270. In such embodiments, the return spring may be used to retract the blade arm270. Other actuator locations are possible in alternative embodiments. In the illustrated embodiment, the blade210is mounted to the blade arm270proximate to the second side284at the inner end286. The blade210extends inward from the inner end286. When the blade arm270is pivoted, the cutting edge212of the blade210is closed inward toward the cable opening174to engage and cut the cable104.

In an exemplary embodiment, the drive assembly202includes a position sensor assembly for sensing a rotational position of the pulley assembly200. For example, the position sensor assembly may include a proximity sensor. Other types of position sensors may be used to determine the rotational positions of the front pulley220and/or the rear pulley222. The position sensor assembly may include position sensors fixed to the front pulley220and/or to the rear pulley222. In other various embodiments, the drive motors240,250may be servo motors having internal position sensors for determining rotational positions of the drive units230,232to determine the corresponding rotational positions of the front and rear pulleys220,222.

FIG. 4is a side view of a blade210of the blade assembly204in accordance with an exemplary embodiment.FIG. 5is a perspective view of the blade210in accordance with an exemplary embodiment. The blade210includes a cutting end290and a mounting end292opposite the cutting end290. In an exemplary embodiment, the blade210is manufactured from a metal material, such as tool steel. The blade210may be stamped, formed, milled, molded, die cast, or manufactured by other processes. The blade210is manufactured to have the arcuate cutting edge212at the cutting end290.

The blade210includes an opening294at the mounting end292that receives a fastener or other securing feature to secure the blade210to the blade arm270. In the illustrated embodiment, the mounting end292is rectangular; however, the mounting end292may have other shapes in alternative embodiments.

In the illustrated embodiment, the blade210is sickle shaped at the cutting end290to form the arcuate cutting edge212. The arcuate cutting edge212is concave. The arcuate cutting edge212has a radius of curvature, which may closely match a radius of curvature of the cable104. The cutting end290is wedge shaped being narrower at the cutting edge212and wider at a radially outer end296of the blade210opposite the cutting edge212. The cutting edge212may be thin, such as forming a knife edge configured to cut through the insulators152,154as the blade210is chopped into the insulators152,154in a radial cutting direction. Optionally, a distal edge298of the cutting end290may be wedge shaped, such as defined by side walls297being slanted or angled relative to each other and narrowing from the radially outer end296to the cutting edge212. The distal edge298may form a cutting edge, such as for slicing through the insulators152,154as the blade210is rotated around the cable104in a rotating cutting direction. The distal edge298and the cutting edge212meet at a corner299. The corner299may be pointed in various embodiments. The corner299may be rounded in other various embodiments.

FIG. 6is a front view of a portion of the cable cutting device102in accordance with an exemplary embodiment showing the blades210open relative to the cable104in a non-cutting configuration.FIG. 7is a front view of a portion of the cable cutting device102in accordance with an exemplary embodiment showing the blades210in a first cutting configuration cutting the outer insulator152.FIG. 8is a front view of a portion of the cable cutting device102in accordance with an exemplary embodiment showing the blades210cutting the outer insulator152at a different rotation position than the rotation position illustrated inFIG. 7.FIG. 9is a front view of a portion of the cable cutting device102in accordance with an exemplary embodiment showing the blades210in a second cutting configuration cutting the inner insulator154.

The pulley assembly200is driven from the open configuration (FIG. 6) to the first cutting configuration (FIG. 7orFIG. 8) or the second cutting configuration (FIG. 9) by the drive assembly202(shown inFIG. 2). The rear pulley222is positioned at a different rotational position relative to the front pulley220in each of the illustrated positions. Rotation of the rear pulley222relative to the front pulley220causes actuation of the blade assembly204. For example, the actuator262(shown in phantom inFIG. 7) engages the blade arm270and causes the blade arm270to pivot about the arm pivot pin276as the rear pulley222moves relative to the front pulley220. Movement of the blade arm270causes movement of the blade210attached thereto. The pulley assembly200pivots the blade210about the cable opening174to open and close the blade210relative to the cable104. The blades210are moved to different cutting depths for cutting the outer insulator152and the inner insulator154. The cutting depths may be calibrated and/or programmed into the cable preparation machine100(FIG. 1) based on diameters of the insulators152,154. In an exemplary embodiment, the cable cutting device102is capable of cutting different diameter cables104by changing the cutting depths of the blades210and controlling the rotation of the pulley assembly200during use.

In an exemplary embodiment, the arcuate cutting edges212of the blades210are concave to follow the curvature of the cable104. The radius of curvature of the arcuate cutting edges212may have a radius of curvature that more closely matches the radius of curvature of the outer insulator152than the inner insulator154. In the illustrated embodiment, the lengths of the cutting edges212of the blades210are too short for cutting through the insulator152in a single cutting action. The blades210form an incomplete circle around the insulator152,154leaving gaps between the ends of the cutting edges212. As such, during use, the blades210are moved to a different rotational position (for example, compareFIG. 7andFIG. 8) to cut through the insulator152. In various embodiments, the blades210may be moved approximately 30° between the different cutting positions. Optionally, the blades210may be moved in a rotational cutting direction by rotating the pulley assembly200with the blades210in the closed position, thus causing the blades210to press through the insulator152as the pulley is rotated. However, in other various embodiments, the blades210are moved between the various rotational positions with the blades210in the open position (FIG. 6) and then closed in a radial cutting direction at the different rotational positions, such as in a chopping cutting action. For example, the pulley assembly200may be moved to the first rotational position and then operated to close or chop the blades210into the insulator152to form cuts in the insulator152in the shape of the blades210. Webs of the insulator152material may remain between the cuts, such webs being removed by later, successive cuts. In an exemplary embodiment, the insulator152is pressed or smashed inward in a chopping manner as the blades210are closed in the radial inward cutting direction, rather than cleanly slicing through the insulator152. The chopping or smashing of the material of the insulator152protects the layer interior of the insulator152, such as the cable braid or the foil or the inner conductor. For example, the blades210may not pass entirely through the insulator152to the interior layer, leaving a small amount of the material of the insulator152between the cutting edge212and the metal layer interior of the insulator152. The cutting edges212of the blades210are protected by reducing impact or engagement with metal structures of the cable104.

The blades210may then be opened and the pulley assembly moved to the second rotational position. The pulley assembly200is then operated to again close or chop the blades210into the insulator152at the second rotational position to cut the next section of the insulator152(for example, to cut the webs of material). Such process may be repeated as necessary to cut the entire circumference of the insulator152in multiple chopping cuts. A similar process may be used for cutting the inner insulator154. As such, the drive assembly202is operated to drive the pulley assembly200in a first drive configuration to actuate the blades210to a first depth to cut the outer insulator152. The drive assembly202is operated to drive the pulley assembly200in a second drive configuration to actuate the blades210to a second depth to cut an inner insulator154. The cable preparation machine100has the ability to precisely control cutting dynamics during the cutting process. For example, the cable preparation machine may control rotation direction of the front pulley220, rotation direction of the rear pulley222, rotation rate of the front pulley220, rotation rate of the rear pulley222, closing speed of the blades210, rotation amount of the pulleys220,222, number of rotations of the pulleys220,222, number of chops of the blades210, cutting depth of the blades210. The cable preparation machine may be calibrated, such as using a fixed diameter mandrel or other calibration device.

FIG. 10is a front view of a portion of the cable cutting device102in accordance with an exemplary embodiment showing the blades210used for removing a cut slug300of the outer insulator152.FIG. 11is a front view of a portion of the cable cutting device102in accordance with an exemplary embodiment showing the blades210used for removing a cut slug302of the inner insulator154. After the outer insulator152or the inner insulator154is cut by the blade assembly204, the blade assembly204may be used to remove the cut slugs300or302, respectively. For example, the blades210may be moved to a partially released position, rather than the open position (FIG. 6). In the partially released position, the blades210are at a released and safe distance from the layer beneath the insulator152or154while keeping the blades210engaged with the insulator152or154. As such, the inner layer(s) are able to be pulled outward from the blade assembly204without damaging or scraping along the inner layer(s). For example, the blades210may be released a distance less than a thickness of the insulator152or154such that the cutting edges212of the blades210do not clear the insulator152or154, but rather are configured to engage the insulator152,154. The cable104may then be retracted from the cable opening174(for example, the cable104may be moved relative to the blade assembly204) with the blade assembly204remaining in a fixed position holding the slug300or302. Once the cable104clears the slug300or302, the slug300or302may be discarded, such as by opening the blade assembly204allowing the slug300or302to fall away into the chute134(shown inFIG. 1).

In other various embodiments, the pulley assembly200may be operated to close the blades210around the cut slug300or302in a pinching manner rather than a cutting manner. The cable104may then be retracted from the cable opening174(for example, the cable104may be moved relative to the blade assembly204) with the blade assembly204remaining in a fixed position holding the slug300or302relative to the pulley assembly200as the cable is retracted out of the slug300or302. Once the cable104is pulled out of the slug300or302, the slug300or302may be discarded. In various embodiments, the blade assembly204may be used for removing the slugs300,302without using the blade assembly204to cut the insulators152,154. For example, another type of cutting device may be used, such as a laser cutting device that cuts the insulators152,154and then the blade assembly204is used to remove the cut slugs300,302.

FIG. 12is a side view of the cable cutting device102illustrating the pulley assembly200, a portion of the drive assembly202and the blade assembly204.FIG. 13is a side view of the cable cutting device102illustrating the pulley assembly200, a portion of the drive assembly202and the blade assembly204.FIG. 12shows the second drive pulley254and the second drive belt256operably coupled to the rear pulley222.FIG. 13shows the first drive pulley244and the first drive belt246operably coupled to the front pulley220.FIGS. 12 and 13show the blade arms270of the blade assembly204coupled to the front of the front pulley220. The cable104is illustrated extending into the cable cutting device102.

The drive assembly202is operated to rotate the front pulley220and the rear pulley222to actuate the blade arms270of the blade assembly204in a first drive configuration to actuate the blade assembly204in a first direction for closing the blade assembly204toward the cable104. The drive assembly202is operated to rotate the front pulley220and the rear pulley222to actuate the blade arms270of the blade assembly204in a second direction for opening the blade assembly204away from the cable104. Different cutting operations may be performed by the single cable cutting device102without the need of removing the cable and inserting the cable into a different cable preparation machine. In various embodiments, the drive assembly202is operable in a drive configuration such that the first drive unit230rotates the front pulley220at a faster rate than the second drive unit232rotates the rear pulley222to actuate the blades210away from the insulator152. In other various embodiments, the drive assembly202is operable in a drive configuration such that the second drive unit232rotates the rear pulley222at a faster rate than the first drive unit230rotates the front pulley220to actuate the blades210toward the cable104for cutting the insulator152. In other various embodiments, the drive assembly202is operable in a drive configuration such that the first drive unit230and the second drive unit232rotate the front pulley220and the rear pulley222at a same rate.

FIG. 14is a partial sectional view of a portion of the cable preparation machine100showing the cable cutting device102and the cable holder130. The cable holder130includes a chuck304for holding the cable104. The cable holder130includes a slide306for moving the chuck304toward and away from the cable cutting device102. Once the cable104is secured in the chuck304, the slide306moves the end150of the cable104into the cable opening174at the cable cutting zone112. The cable cutting device102is operated with the cable104remaining in the cable holder130to remove the various layers of the cable104to prepare the end of the cable104. The cable holder130may move the cable104forward and rearward relative to the cable cutting device102as shown by arrow308, such as to remove the slugs300,302(shown inFIGS. 12 and 13). The cable cutting device102is configured to remove a portion of the outer insulator152and a portion of the inner insulator154to expose the inner conductor158and to expose the cable braid156for termination of the cable104to another component. The cable cutting device102is able to remove each of the layers of the cable104without removing the cable104from the cable preparation machine100. A single cable preparation machine100is able to perform multiple processing steps using the cable cutting device102.