Peripheral system for automated cable bundling solutions

A system includes a tool for installing a cable material around a set of elongate members. The tool includes a housing; a cartridge detachably connected to the housing; and a jaw detachably connected to the housing. The cartridge has a length of cable material. The jaw is configured to extend around the set of elongate members to install the length of cable around the set of elongate members. A welding horn is detachably connected to the housing. At least one processor is configured to read a programmable chip. The programmable chip stores a set of parameters for at least one of the cartridge, the jaw, or the welding horn.

FIELD

This disclosure relates generally to cables. More particularly, this disclosure relates to automated cable bundling and automated adjustment of cable welding parameters.

BACKGROUND

An automated cable bundling tool is generally configured with set operating parameters based on material characteristics. However, when these conditions change, due to a change in materials, cable geometry, and bundle size, the welding parameters have to change accordingly to protect the cable being used.

SUMMARY

In some embodiments, a system includes a tool for installing a cable material around a set of elongate members. In some embodiments, the tool includes a housing; a cartridge detachably connected to the housing, the cartridge having a length of cable material; and a jaw detachably connected to the housing. In some embodiments, the jaw is configured to extend around the set of elongate members to install the length of cable around the set of elongate members. In some embodiments, a welding horn is detachably connected to the housing. In some embodiments, at least one processor is configured to read a programmable chip. In some embodiments, the programmable chip stores a set of parameters for at least one of the cartridge, the jaw, or the welding horn.

In some embodiments, the programmable chip includes a first programmable chip secured to the cartridge; a second programmable chip secured to the jaw; and a third programmable chip secured to the welding horn.

In some embodiments, the programmable chip includes a first programmable chip embedded in the cartridge; a second programmable chip embedded in the jaw; and a third programmable chip embedded in the welding horn.

In some embodiments, the at least one processor is further configured to program the programmable chip with updated parameters.

In some embodiments, the set of parameters includes at least one of jaw size, safety code, cartridge manufacturer, cable material, cable geometry, bundle size, cable cartridge feeding length, tension force, welding power, welding time, or any combination thereof.

In some embodiments, the tool automatically adjusts one or more settings according to the set of parameters read by the at least one processor from the programmable chip.

In some embodiments, the programmable chip is encrypted, and the at least one processor is further configured to decrypt the programmable chip.

In some embodiments, by being encrypted, the programmable chip prevents a user from installing an incompatible component with the tool.

In some embodiments, the programmable chip is an EEPROM or RFID.

In some embodiments, a method includes receiving a first set of parameters from a component of a cable bundling tool by a processor of the cable bundling tool. In some embodiments, the method includes modifying one or more settings of the cable bundling tool based on the first set of parameters.

In some embodiments, the first set of parameters are received in response to at least one of a cartridge, a jaw, and a welding horn being connected to a housing of the cable bundling tool.

In some embodiments, the first set of parameters are received from a programmable chip secured to at least one of the cartridge, the jaw, or the welding horn.

In some embodiments, the method includes storing, in a memory of the cable bundling tool, the one or more settings of the cable bundling tool as modified.

In some embodiments, the first set of parameters are received from a programmable chip secured to at least one of a cartridge, a jaw, or a welding horn; and further comprising decrypting a security key on the programmable chip with the processor through a decryption key stored in a memory of the cable bundling tool.

In some embodiments, a cable bundling tool includes a housing. In some embodiments, the cable bundling tool includes at least one receptacle for interchangeably attaching a component. In some embodiments, the cable bundling tool includes at least one processor for reading at least one programmable chip on the component.

In some embodiments, the at least one receptacle further includes a first receptacle configured to receive a cartridge, the cartridge having a first programmable chip secured to the cartridge; a second receptacle configured to receive a jaw, the jaw having a second programmable chip secured to the jaw; and a third receptacle configured to receive a welding horn, the welding horn having a third programmable chip secured to the welding horn.

In some embodiments, the at least one processor further includes a first processor disposed at the first receptacle; a second processor disposed at the second receptacle; and a third processor disposed at the third receptacle.

In some embodiments, the at least one programmable chip is encrypted, and the at least one processor is configured to decrypt the at least one programmable chip to access information stored on the at least one programmable chip.

In some embodiments, the at least one processor is configured to update information stored on the at least one programmable chip depending on usage of a component while attached to the cable bundling tool.

In some embodiments, the cable bundling tool includes an indicator light, the indicator light configured to at least one of alarm a user that the cable bundling tool requires preventative maintenance, an error with a connection to the component, or when a consumable is depleted.

Like reference numbers represent the same or similar parts throughout.

DETAILED DESCRIPTION

Embodiments of this disclosure are directed to a cable bundling system including a cable bundling tool and its components. More specifically, the cable bundling system described in this disclosure includes a hand-held tool that distributes a continuously extruded cable that is tensioned and bonded around a cable bundle.

In some embodiments, various components may be attached to the tool. In some embodiments, each component can include a programmable chip embedded therein that stores information about the particular component. In some embodiments, the tool is equipped with a processor configured to read the information on the programmable chip from the various components and to automatically calibrate one or more operating parameters of the tool based on the information as read from the components. In some embodiments, the functionality of automatically obtaining these values and automatically adjusting the operating characteristics of the tool can, for example, protect the strap being used, protect the wires being bundled, and prevent incompatible components from being introduced to the tool, thereby achieving consistent welding quality, and improving operator experience.

FIG.1is a schematic view of a cable bundling system10, according to some embodiments. In some embodiments, the cable bundling system10can be used to secure a cable around a bundle of elongated members such as, but not limited to, a bundle of wires, cables, or the like.

In some embodiments, the cable bundling system10includes a cable bundling tool15. In some embodiments, the cable bundling tool15can include a cartridge20including a spool of material, a jaw25for dispensing the material around a bundle, and a welding horn30for welding the material together around the bundle. In some embodiments, the cartridge20is configured to include a length of cable material for securing around the bundle of elongated members. In some embodiments, the jaw25includes an arc-shaped pair of jaws that are configured to extend around the set of elongate members being joined together. The jaws25are configured to provide the cable material so that it surrounds the elongate members being joined. The welding horn30is configured to weld a portion of the cable material together to secure the cable material around the elongate members being joined together.

The cable bundling tool15includes a housing35having a plurality of receptacles including at least a first receptacle40(e.g., for detachably receiving the cartridge20), a second receptacle45(e.g., for detachably receiving the jaw25), and a third receptacle50(e.g., for detachably receiving the welding horn30). It is to be appreciated that a number of receptacles can be greater than three. The number of receptacles is dependent upon a number of detachable components of the cable bundling tool15.

In some embodiments, the housing35includes a processor55, a memory57, and a communication module60. In some embodiments, the communication module60includes a transmit-receive circuit and an antenna. The communication module60is configured to communicate with and interpret a signal from a programmable chip65, a programmable chip70, and a programmable chip75. The programmable chip65can be installed on the cartridge20. The programmable chip70can be installed on the jaw25. The programmable chip75can be installed on the welding horn30. In some embodiments, one or more of the cartridge20, the jaw25, or the welding horn30may not include a programmable chip.

In some embodiments, the programmable chip65, the programmable chip70, and the programmable chip75can each include an antenna80, a controller85, and a memory90.

In some embodiments, the antenna80of the respective one of the programmable chip65, the programmable chip70, or the programmable chip75can communicate with the communication module60of the cable bundling tool15. In such embodiments, the communication can include providing a set of parameters stored in the memory90to the cable bundling tool15. In some embodiments, the programmable chip65, the programmable chip70, the programmable chip75, or any combination thereof, can be encrypted. In such embodiments, the processor55may utilize a decryption key to decrypt the information included on the programmable chip65, the programmable chip70, the programmable chip75, or any combination thereof.

In some embodiments, the memory90can store one or more parameters relevant to the usage of the cable bundling tool15. In some embodiments, the set of parameters can include, but is not limited to, a jaw size, a safety code, a cable material, a cartridge manufacturer, a cable cross-section, a cable geometry, a cable force rating, a bundle size, an optimal jaw size, a welding parameter including feeding length, tension force, welding power, and welding time, similar characteristics, or any combination thereof.

In some embodiments, the programmable chip65, the programmable chip70, or the programmable chip75is an electrically erasable programmable read-only memory (EEPROM), radio frequency identification (RFID), or other suitable chip that stores parameters related to the material and strap geometry or the parameters of the joining method (e.g., welding parameters) so that when cartridge20, jaw25, or welding horn30is connected to the cable bundling tool15, it is automatically recognized without user input. In some embodiments, the programmable chip65, the programmable chip70, and the programmable chip75may communicate with the processor55via, for example, a near field communication (NFC) protocol.

In some embodiments, the memory90of one or more of the programmable chip65, the programmable chip70, or the programmable chip75may be capable of being written to as well. For example, the cable bundling tool15may be able to provide feedback on the usage of the tool to the memory90that can be stored. In some embodiments, this can include tracking consumption of the material in the cartridge20. For example, for the cartridge20, the memory90can be updated with information on how much material is remaining. When the material is almost consumed, a signal may alert the user to replace the cartridge20. In some embodiments, preventative maintenance of the cable bundling tool15may be recommended based off of consumable usage and lifetime.

In some embodiments, the cable bundling tool15is configured to automatically adjust the operating parameters of the cable bundling tool15based on the component that is attached to the cable bundling tool15. For example, when the jaw25is replaced (or installed in the first place), the cable bundling tool15can authenticate the jaw25if a security code is present. In some embodiments, if the security code is not authenticated, the cable bundling tool15may disable the cable bundling tool15. In some embodiments, if the security code is authenticated, the processor55can read the memory90of the associated component and determine, for example, a jaw size, and automatically adjust, for example, a feed length of the material for welding based on the determined parameters. In some embodiments, if the cable bundling tool15is unable to communicate with the component, the cable bundling tool15may interpret this as a faulty or otherwise incompatible component, and may disable the cable bundling tool15until a proper communicating component is connected.

In some embodiments, the welding horn30may be used to identify a given cable material installed on the cable bundling tool15and the ultrasonic welding parameters of the given cable material. Consequently, the cable bundling tool15may tune welding parameters of the cable bundling tool15based on the ultrasonic welding parameters of the given cable material. For example, the ultrasonic welding parameters of a given cable material can be unique and inherent to that material (e.g., an energy consumption of HDPE cables, 5 Joules (J), is lower than for POM or PA66, which is approximately 15 J). Thus, the ultrasonic welding parameters of the welding horn, and/or any components of the welding stack, can have unique electrical properties such as the resonant frequency, impedance, and amplitude.

In some embodiments, the cable bundling tool15includes a display95, at least one button100, and at least one indicator105. In some embodiments, the display95can include a touchscreen display, in which case the least one button100may be integral with the display95, not separate from the display95. In some embodiments, the at least one indicator105can include a visual indicator (e.g., an indicator light such as a light-emitting diode (LED) or the like), an audible indicator (e.g., a speaker or the like), or a haptic indicator (e.g., a vibration device or the like). In some embodiments, the processor55executes a program stored in the memory to operate the cable bundling tool15to bundle cables.

In some embodiments, the display95can show various features of the cable bundling tool15including, but not limited to, the type and features of the component attached to the cable bundling tool15, the cycle count of a particular attached component, the circumference of, for example, the jaw25, the length of material remaining on the cartridge20, an impedance of the welding horn30while bonding the material around a set of cables, and when the welding horn30detects the material, and other features. It is to be appreciated that the types of data displayed by the display95are not intended to be limiting. Additionally, in some embodiments, the display95is not present.

In some embodiments, the at least one indicator105can provide an indication to a user that a component is attached to the tool. In some embodiments, the at least one indicator105can indicate to a user an alarm condition. For example, the at least one indicator105can indicate to the user a condition of the cable bundling tool15including, but not limited to, being due for preventative maintenance, material being exhausted, an error with connecting to an attached component or reading the programmable chip of the component by the processor55, or the like.

Examples of computer-readable storage media include, but are not limited to, any tangible medium capable of storing a computer program for use by a programmable processing device to perform functions described herein by operating on input data and generating an output. A computer program is a set of instructions that can be used, directly or indirectly, in a computer system to perform a certain function or determine a certain result. Examples of computer-readable storage media include, but are not limited to, a floppy disk; a hard disk; a random access memory (RAM); a read-only memory (ROM); a semiconductor memory device such as, but not limited to, an erasable programmable read-only memory (EPROM), an electrically erasable programmable read-only memory (EEPROM), Flash memory, or the like; a portable compact disk read-only memory (CD-ROM); an optical storage device; a magnetic storage device; other similar device; or suitable combinations of the foregoing.

In some embodiments, the processor55and the memory57can be in electronic communication with the cable bundling tool15, but physically separate from the cable bundling tool15. For example, the cable bundling tool15can be connected to a control system110and the processor55and the memory57can be part of the control system110. In some embodiments, the control system110can be wired to the cable bundling tool15and can provide power to the cable bundling tool15.

FIG.2is a flowchart of a method150, according to some embodiments. The method150can generally be used to control one or more parameters in a cable bundling tool (e.g., the cable bundling tool15ofFIG.1).

At block155, the method150includes receiving, by a processor (e.g., the processor55ofFIG.1) on the cable bundling tool15, a first set of parameters. In some embodiments, the first set of parameters can be received from the processor55through communication with at least one of the programmable chip65, the programmable chip70, or the programmable chip75. In some embodiments, the processor55can be onboard the cable bundling tool15or part of a control system connected in communication with the cable bundling tool15. In some embodiments, at block155the processor55can receive a plurality of sets of parameters. In some embodiments, a number of sets of parameters is dependent upon a number of components connected to the cable bundling tool15. For example, in some embodiments, a first set of parameters can be received from the programmable chip65, a second set of parameters can be received from the programmable chip70, and a third set of parameters can be received from the programmable chip70. It is to be appreciated that in some embodiments, a number of sets of parameters received can be less than the number of installed components.

At block160, the method150includes modifying one or more settings of the cable bundling tool15based on the first set of parameters.

Optionally, at block165, the method150includes displaying the one more settings of the cable bundling tool15as modified based on the first set of parameters. In such embodiments, the display can be on the cable bundling tool15itself (when a display is present on the cable bundling tool15) or can be on a peripheral display that is connected to the control system.

Optionally, at block170, the method150includes bundling a set of elongate members (e.g., wires or the like) with a cable material from the cartridge and using the one or more settings of the cable bundling tool15as modified based on the first set of parameters.

FIG.3is a perspective view of the cable bundling tool15ofFIG.1, according to some embodiments. The cable bundling tool15includes the cartridge20installed in the illustrated embodiment. The cable bundling tool15includes the housing35. The housing35includes a first end200and a second end205. In some embodiments, the first end200can be referred to as a handle end and the second end205can be referred to as the tip end or workpiece end. The first receptacle40is disposed at the first end200and the second receptacle45and the third receptacle50are disposed at the second end205. The jaw25and the welding horn30are not shown inFIG.3. The cable bundling tool15includes a trigger215for triggering the welding of the cable material around the bundle of elongate members (e.g., wires, cables, or the like). Additional functionality of the cable bundling tool15has been previously described with respect toFIG.1and will not be repeated in additional detail for simplicity of this Specification.

FIG.4is a perspective view of the cartridge20ofFIG.1, according to some embodiments. As shown in the illustrated embodiment, the cartridge20includes the programmable chip65secured thereto. In some embodiments, the programmable chip65can be disposed in a different location. For example, in some embodiments, the programmable chip65can be on an inner surface of the cartridge20or the like. It is also to be appreciated that the appearance of the programmable chip65is an example and is not intended to be limiting. In some embodiments, the programmable chip65being secured to the cartridge20can include embedding the programmable chip65into the cartridge20to reduce likelihood that the programmable chip65can be removed, replaced, or tampered with. In some embodiments, the programmable chip65may not be visible to a user (e.g., covered with one or more layers of material.

FIG.5is a view of the connector of the jaw25ofFIG.1, according to some embodiments. As shown in the illustrated embodiment, the jaw25includes the programmable chip70secured thereto. In some embodiments, the programmable chip70can be disposed in a different location. For example, in some embodiments, the programmable chip70can be on a different surface of the jaw25or the like. It is also to be appreciated that the appearance of the programmable chip70is an example and is not intended to be limiting. In some embodiments, the programmable chip70being secured to the jaw25can include embedding the programmable chip70into the jaw25to reduce likelihood that the programmable chip70can be removed, replaced, or tampered with. In some embodiments, the programmable chip70may not be visible to a user (e.g., covered with one or more layers of material.

FIG.6is a perspective view of the welding horn30ofFIG.1, according to some embodiments. As shown in the illustrated embodiment, the welding horn30includes the programmable chip75secured thereto. In some embodiments, the programmable chip75can be disposed in a different location. For example, in some embodiments, the programmable chip75can be on a different surface of the75or the like. It is also to be appreciated that the appearance of the programmable chip75is an example and is not intended to be limiting. In some embodiments, the programmable chip75being secured to the welding horn30can include embedding the programmable chip75into the welding horn30to reduce likelihood that the programmable chip75can be removed, replaced, or tampered with. In some embodiments, the programmable chip75may not be visible to a user (e.g., covered with one or more layers of material.