Abstract:
There is provided an apparatus for applying tape on a plurality of wire to form a harness thereof, the apparatus comprising a casing defining a fixed portion adapted to rotatably receive a moveable portion rotatable about a moveable portion axis, the moveable portion being adapted to secure a roll of tape thereon such that the roll of tape revolves with the moveable portion in a fashion allowing unwinding of the tape on the plurality of wires, the fixed portion and the moveable portion defining cooperating indentations encompassing the moveable portion axis, the indentation in the moveable portion being adapted to be selectively aligned with the indentation of the fixed portion to receive and allow positioning of the plurality of wires about the moveable portion axis such that the tape on the rotating moveable portion being unwounded on the plurality of wires to secure the plurality of wires in a harness.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority on U.S. Provisional Application No. 61/136,926, filed on Oct. 15, 2008, which is herein incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to an apparatus and a method for consolidating a bundle of cables. More precisely, the present invention is concerned with an apparatus and a method for consolidating a harness with a surrounding tape applied over the bundle of cables. 
     BACKGROUND OF THE INVENTION 
     Complex products or industrial equipments are using wires to channel power and control signals between various components therein. In modern vehicles, for instance, it is possible to find a significant number of wires or electric cables disposed between various electronic and electrical components. These cables need to be conveniently packaged in a harness to be safely and easily installed. 
     The harness has a generally arbitrary shape adapted to its unique use. The harness comprises nodes, from which branches of electrical wires project toward connection ends in order to interconnect each components such as lights, electronic boards, actuators and sensors. A harness can be more or less complex depending on the number of systems it has to interconnect. 
     The wires forming the harness are tied together with a protective layer disposed thereon. The protective layer is commonly a layer of tape that is installed over the group of wires to ensure that all wires routed similarly are joined together. Additionally, the tape can be discontinuously applied on over the wires to leave some desired area uncovered thus leaving direct access to the wires. If the harness provides a number of branches leading to various connection ends the branches are also protected with a layer of tape. 
     The tape can be manually installed over the bundle of wires. Alternatively, a machine can be used to apply significant amount of tape over the wires. 
     A prior art taping machine  10  is illustrated on  FIG. 1 . The taping machine  10  is a portable taping machine in the sense that it must be manually held by the user. The user grabs the handle  12 , pass the group of wires to be taped together within the safety cover  14  through the aperture  16 . For so doing, the aperture  16  needs to be aligned with the opened door  18  to have access to the central opening  20 . 
     Once the group of wires is located in the central opening  20  the user press the actuation button  26  to power the motor  22  to rotate the central portion  24  of the taping machine  10 . The central portion of the taping machine  10  accommodates a roll of tape (not visible on  FIG. 1 ) to revolve the roll of tape about the group of wires to secure the group of wires together and form a harness of wires. 
     The illustrated prior art taping device  10  can be suspended by the hook  26  to reduce the weight supported by the user. Once the taping machine  10  is properly held and wires are disposed inside the central opening  20  the user actuates the rotation of the central portion  24  and slowly moves along the cables to wrap the desired portion of cables with tape. 
     Due to the complexity of certain harnesses having different lengths and number of branches a solution for automating the taping procedure in a sufficiently simple and viable manner has yet to be found. A problem with prior art solutions is the possibility of providing inconsistent quality and, therefore, in certain cases, defects in the harness. Another issue present with the prior art is that they need to be manually manipulated thus increasing the fatigue of the person operating the taping machine. One other downfall of prior art solutions is that the operator moves the machine as opposed to move the harness, which is usually lighter. 
     It would therefore be desirable to render the harness taping procedure less labor intensive, in a cost effective manner, whilst ensuring flexibility, simplicity and reliability. An improved apparatus and an improved method for taping wires to form a harness are therefore desirable over the existing art. 
     SUMMARY OF THE INVENTION 
     In accordance to the present invention, there is provided an apparatus and a method for applying a layer of tape over a group of cables, electric wires, communication wires and/or fiber optic cables to consolidate the group of cables/wires in a harness. 
     An aspect of the present invention provides a taping machine having a doorless central rotating portion. 
     Another aspect of the present invention provides a portable taping machine that can be easily disposed on a surface. 
     An aspect of the present invention provides a battery powered taping machine. 
     An additional aspect of the present invention provides a rechargeable mechanism adapted to recharge the battery and to selectively draw power from the grid to power the taping machine. 
     An aspect of the present invention provides a battery powered portable taping machine. 
     One other aspect of the present invention provides a taping machine having a vented enclosed structure. 
     Another aspect of the present invention provides a taping machine comprising a counter weight counter balancing the weight of the roll of tape when the roll of tape revolves about the moveable portion axis. 
     One aspect of the present invention provides a moveable portion held in place by a grooved portion defined therein in conjunction with a series of bearings engaging the grooved portion. 
     An aspect of the present invention provides a moveable portion that is rotated by at least one driven wheel engaging a grooved portion defined therein. 
     One aspect of the present invention provides a friction-enhancing surface on the driven wheel to increase the friction between the driven wheel and the grooved portion. 
     Another aspect of the present invention provides a safety lever laterally disposed from the moveable portion and adapted to influence the movement of the moveable portion when actuated. 
     One aspect of the present invention provides an array of moveable portion supports from which at least one is a bearing and at least one is a driven wheel adapted to apply motion to the moveable portion. 
     Another aspect of the present invention provide a tape roll support adapted to receive a tape roll, the tape roll support defining an axis that is not parallel with the axis defined by the moveable portion wherein the angle formed therebetween tend to force the taping motion toward the untaped portion of the wire to be taped. The tape roll support also provides an adjustable tension on the tape roll to provide a desired tension of the tape on the harness. 
     One additional object of the present invention provides a remote actuator to remotely actuate the taping machine; the remote actuator being preferably a pedal actuator to free the hand of the operator. 
     An additional objet of the present invention provides a variable speed taping machine wherein the revolving speed of the tape roll is variable. 
     An aspect of the present invention provides a belt drive mechanism adapted to couple the electric motor to the drive wheels. 
     One additional aspect of the present invention provides a clutch adapted to couple the electric motor to the drive wheels over a predetermine range of torque. 
     An other aspect of the present invention provides an apparatus for applying tape on a plurality of wire to form a harness thereof, the apparatus comprising a casing defining a fixed portion adapted to rotatably receive a moveable portion rotatable about a moveable portion axis, the moveable portion being adapted to secure a roll of tape thereon such that the roll of tape revolves with the moveable portion in a fashion allowing unwinding of the tape on the plurality of wires, the fixed portion and the moveable portion defining cooperating indentations encompassing the moveable portion axis, the indentation in the moveable portion being adapted to be selectively aligned with the indentation of the fixed portion to receive and allow positioning of the plurality of wires about the moveable portion axis such that the tape on the rotating moveable portion being unwounded on the plurality of wires to secure the plurality of wires in a harness. 
     Another aspect of the present invention provides a method for manufacturing a wiring harness, the method comprising aligning an indentation of a moveable portion with an indentation of a fixed portion; inserting a plurality of wires in the aligned indentations; and actuating a rotation of the moveable portion such that a roll of tape attached thereto revolves about the plurality of wires to tapedly secure the plurality of wires into a wiring harness. 
     An additional aspect of the present invention provides a taping apparatus adapted to apply tape on a plurality of wires to manufacture a wiring harness, the apparatus comprising a rotatable means adapted to rotate a roll of tape about the plurality of wires, the rotatable means further defining a doorless recess therein adapted to receive the plurality of wires therein, the recess being selectively accessible by rotating the rotating means. 
     The foregoing and other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of an illustrative embodiment thereof, given by way of example only, with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the appended drawings: 
         FIG. 1  is perspective view of a prior art taping machine; 
         FIG. 2  is a perspective view of an illustrative example of a taping machine in accordance with the present invention; 
         FIG. 3  is a perspective view of the taping machine of  FIG. 2  with a group of wires; 
         FIGS. 4-6  are left elevation side views of the taping machine of  FIG. 2  illustrated at different stages of the taping process; 
         FIG. 7  is a perspective view of the taping machine of  FIG. 2 ; 
         FIG. 8  is an exploded view of a portion of the taping machine of  FIG. 7 ; 
         FIG. 9  is a perspective view of the taping machine of  FIG. 2  with a removed portion of the casing; 
         FIG. 10  is a front elevational view of the taping machine of  FIG. 2  with a sectional view of the front face of the taping machine; 
         FIG. 11  is a top elevational view of the taping machine of  FIG. 2  with a section of the casing removed to see a portion of the driving mechanism; 
         FIG. 12  is a right side elevational section view of the taping machine of  FIG. 2 ; 
         FIG. 13  is a perspective view of the taping machine of  FIG. 2  partially viewed from behind; 
         FIG. 14  is a perspective view of the taping machine of  FIG. 2  partially viewed from the bottom; and 
         FIG. 15  is a left side elevational view of the taping machine of  FIG. 2  illustrating the movement of the safety arm. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An apparatus for taping at lest one wire or a plurality of wires into a harness, and a method thereof, in accordance with a non-restrictive illustrative embodiment of the present invention, will now be described. 
     An illustrative example of the taping apparatus of the present invention is shown on  FIG. 2 . The taping apparatus  50  comprises a casing  52  defining an upper top portion  54 , a lower top portion  56 , an upper front portion  58 , a lower front portion  60 , a right side portion  62 , a left side portion  64  and a bottom portion  66 . All these casing portions are illustratively made of sheet aluminum assembled together to form the casing  52  but could otherwise be made of another material without departing from the scope of the present invention. A fiber filled plastic casing is another option that would provide a reduced weight enclosure to the taping apparatus  50 . 
     The taping apparatus  50  is transportable using the handle  72  secured to the casing  52 . Other means for holding the taping apparatus  50  can be added to the actual embodiment in accordance with the possible dedicated uses of the taping apparatus  50 . The taping apparatus  50  is also designed to rest on a table or a flat surface. A power pack  68 , not visible on  FIG. 2 , is included in the casing  52  to remotely use the taping apparatus  50 . The power pack  68  is a battery  74  in the present embodiment. A 12-Volt battery  74  is electrically connected to the DC motor (that will be discussed later in the description) that powers the taping apparatus  50 . The battery  74  powers the taping apparatus  50  without requiring the taping apparatus  50  to be connected to the electric grid. However, the taping apparatus  50  can be used when the power pack  68  is connected to the electric grid. The taping apparatus  50  can be plugged in to the grid to recharge the power pack  68  with a removable wire removably connected into a connector located on the casing  52 . The taping apparatus  50  can alternatively be powered from the grid if the battery is weak while the battery is recharging. A series of venting holes  70  are disposed on the right side portion  62  to allow air to access the interior of the casing  52  to vent and cool the power pack  68 . 
     Still referring to  FIG. 2 , the casing  52  accommodates a cable receiving portion  80 . The cable receiving portion  80  includes a lower top portion extension  82 . The lower top portion extension  82  extends the lower top portion  56  toward the fixed portion  84  to reduce the gap that can be formed therebetween and help prevent wires to jam therein. 
     The cable receiving portion  80  further includes a fixed portion  84 , a moveable portion  86  and an array of rollers  88  individually secured to the fixed portion  84  with a nut  90 . The rollers  88  are miniature can follower as they can be found into NTN Corporation&#39;s Cam Followers &amp; Roller Followers Catalogue No. 3604-VI/JE. The NTN catalog can be found at www.ntn.co.jp/English/products/pdf/camandroller/pdf/camandror_all.pdf 
     The rotation of the moveable portion  86  is performed about a moveable portion axis  94 . The moveable portion  86  defines a circumferential guide  92  adapted to receive a portion of the rollers  88  therein to rotatably axially secure the moveable portion  86  to the fixed portion  84 . As best seen on  FIG. 3 , whenever a wire or a group of wires is taped with the machine, the wire(s) should ideally be located as close as possible to the moveable portion axis  94  to help ensure a more consistent tape wrapping over the wire(s)  112 . In the present illustrative embodiment the taping apparatus  50  is provided with a cable receiving portion  80  defining an opening with a diameter of about fifty (50) millimeters. A smaller or larger receiving portion  80  is encompassed by the present invention if required by the size of the harness. 
     Still referring to  FIG. 2  the fixed portion  84  defines a fixed portion indentation  96  while the moveable portion  86  defines an axially cooperating moveable portion indentation  98 . Both indentations  96 ,  98  are encompassing the moveable portion axis  94  and are adapted to be aligned to receive the wire(s) to be taped therein. The rotation of the moveable portion  86  alternatively close the fixed portion indentation  96  and might need to be aligned in order to insert the wire(s) in the indentations  96 ,  98  along the moveable portion axis  94 . 
     The moveable portion  86  further includes a tape roll support  100  adapted to receive a roll of tape  102  and a counterweight  104 . The roll of tape  102  is disposed in such a way that the tape  114  (not visible on  FIG. 2 ) can be unwound on the wire(s) put in the indentations  96 ,  98  along the moveable portion axis  94 . The securing of the roll of tape  102  is adjustable to provide the desired tension on the tape when the tape is installed on the harness. The counterweight  104 , disposed on the opposite side of the tape roll support  100 , helps reduce the vibration provided by the weight of the roll of tape  102  when the moveable portion  86  revolves at a significant speed. A safety lever  106  is also visible and will be described in details later in the present description. 
     Turning now to  FIG. 3  illustrating the same taping apparatus  50  as  FIG. 2  with the addition of a cable  110  installed thereon. The cable  110  is formed from a plurality of smaller wires  112  that are consolidated into a single bigger cable  110 , or harness, once covered by the tape  114 . The rotational movement of the moveable portion  86  is illustrated by arrow  116  on  FIG. 3 . 
     Referring now to  FIGS. 4-6  where is illustrated the rotational movement, still illustrated by arrow  116 , of the moveable portion  86  about the moveable portion axis  94 . It is possible to appreciate the unwinding of the tape  114  from the roll of tape  102  over the plurality of small wires  112 . Each time the roll of tape  102  performs a complete revolution about the wires  112  the tape  114  covers a portion of the length of the wires  112 . The user longitudinally moves the wires  112  at a speed corresponding to the speed at which the tape  114  covers the wires  112 . Once the desired portion of wires  112  is covered with tape  102  the user stop the taping apparatus  50 , cut the tape  102  and remove the wire from the aligned indentations  96 ,  98 . A sensor  108  can be mounted to the cable receiving portion  80  to sense the position of a corresponding mark  118  disposed on the moveable portion  86  to stop the motion of the moveable portion  86  when the indentations  96 ,  98  are aligned. The sensor  108  is also used for counting the number of revolutions performed by the moveable portion  86  for maintenance purposes. 
     Additionally on  FIGS. 4-6  is depicted a small ventilator  120  used in cooperation with the series of venting holes  70  disposed on the opposite side of the casing  52 . The ventilator  120  helps channel air through the casing  52  to prevent overheating of the power pack  68  and the motor  122  inside the casing  52 , that will be described in further details in Figures to come, that actuates the moveable portion  86 . A switch  124  used to cut the electric current from the power pack  68  and a rotational speed adjustment  128  (not visible on  FIG. 4 ) are also seen on the control panel  126 . 
     Turning now to  FIG. 7  where is illustrated the taping apparatus  50  in a different angle so that the cable receiving portion  80  is not hidden by the casing  52 . The cable receiving portion  80  is isolated and illustrated in an exploded view at  FIG. 8 . 
     The driving mechanism of the moveable portion  86  is better seen on the exploded view of  FIG. 8  showing the motor  140 , the drive gear  142 , the tensioner  144 , the endless belt  146  and the driven gears  148 . All these parts are contained inside the casing  52  and are cooperating to transfer rotational power from the motor  140  to the moveable portion  86  via two drive wheels  150 . The pair of drive wheels  150  is replacing two rollers  88  and is turning with the driven gears  148  in which they are engaged thereto. The drive wheels  150  preferably have the same size as the rollers  88  to fit in the circumferential guide  92  of the moveable portion  86 . The exterior surface of the drive wheels  150  contacting the moveable portion  86  are preferably equipped with a friction enhancing surface ensuring good gripping to the moveable portion  86 . 
     The motor  140 , the drive gear  142 , tensioner  144 , the endless belt  146  and the driven gears  148  are mounted to a support  152  to ensure proper interactions among all the parts. The support  152  is spaced apart from the left side portion  64  with a pair of spacers  154  to allow sufficient space for the drive gear  142 , tensioner  144 , the endless belt  146  and the driven gears  148  assembly. The drive gear  142  is mounted to a shaft  156  adapted to fit into a bearing member  158  disposed into the lower portion of the fixed portion  84  thus preventing the drive gear  142  to be in cantilever. Additionally, the driven gears  148  are mounted on bearings  160  secured to the support  152 . The driven gears  148  include a support bearing  162  adapted to engage corresponding openings  164  in the fixed portion  84 . Therefore, when the motor  140  is powered, it turns the driven gears  148  that turn the two drive wheels  150  contacting the moveable portion  86  and rotating the moveable portion  86 . 
       FIGS. 9-12  illustrate how the motor  140  and the other transmission parts are disposed into the casing  52 . The motor  140  is located under the lower top portion  56  (the lower top portion is removed on  FIG. 9  for a better understanding of the layout). It can be appreciated from  FIG. 10  that the motor  140  is connected to the drive gear  142  using a coupling  170  helping to reduce vibration transfer between the engine and the rest of the cable receiving portion  80  and to ease removal of the motor  140  for maintenance. 
     The taping apparatus  50  is optionally provided with a clutch (not illustrated on the Figures) intervening between the motor  140  and the drive wheels  150 . The optional clutch is preferably preset to a maximum torque as a safety measure in case the movable portion  86  is stopped while the taping apparatus  50  is powered. The clutch can be a well known dry friction clutch installed directly at the output of the motor  140 . 
     Turning now to  FIG. 13-15  where the focus is put on the safety lever  106 . The safety lever  106  is adapted to prevent injuries of the user when the user uses his hand to position the wires  112  before the tape  114  is applied. The safety lever  106  pivots about pivot  168  in accordance with the movement indicated with arrow  166 . A safety sensor (not visible) is actuated by the movement of the safety lever  106  to stop the movement of the moveable portion  80 . A lateral movement of the safety lever  106  toward the left side portion  64  could also trigger the safety sensor to stop the taping apparatus  50 . 
     Although the present invention has been described hereinabove by way of non-restrictive, illustrative embodiments thereof, these embodiments can be modified at will, within the scope of the appended claims, without departing from the spirit and nature of the subject invention.