Patent Publication Number: US-11640862-B2

Title: Automated methods and apparatus for installing a sleeve on a cable

Description:
RELATED PATENT APPLICATION 
     This application is a divisional of and claims priority from U.S. patent application Ser. No. 16/195,520 filed on Nov. 19, 2018, which issued as U.S. Pat. No. 11,120,928 on Sep. 14, 2021. 
    
    
     BACKGROUND 
     This disclosure generally relates to methods and apparatus for processing shielded cable. In particular, this disclosure relates to methods and apparatus for installing a sleeve on a cable. 
     Shielded cables incorporate shielding in an attempt to prevent electromagnetic interference. For example, the conductors may be surrounded by braided shielding made of metal. Because the shielding is made of metal, it may also serve as a path to ground. Usually a shielded cable incorporates a grounding wire that contacts the shield in an unjacketed portion of the shielded cable. Typically the grounding wire is attached to the unjacketed portion using a solder sleeve. Typically the solder sleeve is placed around a portion of a shielded cable having exposed shield and then melted in place. 
     One current process for installing a solder sleeve on a shielded cable is manual and labor-intensive. The process also requires additional steps, as a protective slug must be created and left in place as a solder sleeve is fed onto the cable; the slug then must be manually removed from the cable. 
     More specifically, the aforementioned process requires that a jacket slug protect the shield strands from damage as a solder sleeve is threaded onto a cable. The inner diameter of a solder sleeve is highly variable down the length of the solder sleeve due to the internal components contained within the sleeve, including the solder ring, ground wire, and insulation rings. In addition, the tolerance values of solder sleeves are large, adding even more variability to the interior surface of the sleeves. This variability in addition to the interior components makes it difficult for a cable with exposed shielding to pass through a solder sleeve without strands of the shield being damaged, usually due to snagging on the edge of an internal component and crumpling as the cable is pushed through the sleeve. However, creating a jacket slug requires that the cable be scored twice in two different locations, and then removing the two segments of outer jacket in two separate steps. The manual process poses a higher risk of damaging the underlying shield and/or conductors, and is reliant on operator skill. Removing the protective slug also introduces a second point of strain on the shield and underlying conductors, as operators use tubing to manually pull off the slug once the solder sleeve has been fed onto the cable. Additionally, the time required to perform this step adds to the cycle time of the entire process. It would be advantageous to provide an automated solution that avoids damaging the exposed shield of the cable and reduces labor cost associated with processing and installing solder sleeves on shielded cables. 
     SUMMARY 
     The subject matter disclosed in some detail below is directed to providing fully automated (with automated feeding) solutions for installing a sleeve on a cable. For example, the apparatus and methods disclosed herein may be used to install a solder sleeve or a dead end sleeve on a portion of a shielded cable that includes a length of exposed shield. The automation of the sleeve installation operation enables repeatable and consistent quality across end products that is unachievable with a fully manual process. 
     One method disclosed in some detail below utilizes a funnel system and robotic end effector grippers to feed an unjacketed portion of a shielded cable through a solder sleeve. This method uses a specialized funnel system designed to accommodate the different sizes of sleeves. The funnel is designed with one or more thin extensions on which a solder sleeve is placed prior to a cable entering the funnel. The funnel extensions (hereinafter “prongs”) may be attached to or integrally formed with the funnels. Preferably two or more prongs are employed, although a single prong may be used if properly configured to both guide a cable and fit between the sleeve and cable. The prongs close off the uneven surface internal to a sleeve and provide a smooth surface for the cable to slide along and through the sleeve, preventing any damage to the exposed shielding. The sleeve is picked up and held on the prongs using a robotic end effector. If the sleeve is a solder sleeve, the robotic end effector has grippers designed to make contact with the portions of the sleeve that are between the insulating rings and the central solder ring. 
     In accordance with some embodiments, the funnel has an open top. In such cases, the robotic end effector includes a cover that is a part of the end effector. This cover is designed to close off the opening in the funnel to ensure the cable passes fully through the funnel and through the sleeve during the insertion process. As the cable continues to travel through the sleeve, the end effector travels with the cable, maintaining the sleeve&#39;s central position over the exposed shield of the cable. Alternatively, the end effector repositions the sleeve over the shield once the cable has come to a stop; this operation brushes the shield strands down against the cable prior to the melting process. Once the sleeve has been positioned for processing, the end effector releases the sleeve and is removed from the processing area (e.g., a heating zone). A heat source can be moved into position to shrink the sleeve in place, or the sleeve can remain on the cable to be processed in a separate method. The cable is able to exit the funnel through the open slit that is no longer closed off by the end effector, and can then be retracted from the processing area. This method enables automation of the sleeve installation process, which reduces labor costs. 
     As used herein, the term “sleeve” means a tube made of shrinkable material, such as a solder sleeve made of thermoplastic material (which shrinks) and a solder ring (which melts) or a dead end sleeve made of thermoplastic material and having no solder ring. Installation of a solder sleeve involves shrinking of the thermoplastic material and melting of the solder ring; installation of a dead end sleeve involves shrinking of the thermoplastic material. As used herein, “melting a solder sleeve” includes shrinking the thermoplastic material with melting of a solder ring, while “shrinking a sleeve” includes shrinking the thermoplastic material with (e.g., solder sleeve) or without (e.g., dead end sleeve) melting of a solder ring. 
     In accordance with some embodiments proposed herein, the apparatus consists of a set of funnels designed to thread cables with exposed shields through solder sleeves. These funnels are designed with a slit opening that permits cables to exit the funnel without having to fully retract back through the funnel. The funnel system is designed such that a cable with exposed shielding can be fed through a solder sleeve without damaging the shield. For example, three different funnels may be designed to accommodate five different sizes of solder sleeves. A solder sleeve to be installed is fed onto the prongs extending from a funnel designed for that solder sleeve&#39;s size; the prongs are designed to have a diameter that is slightly smaller than the inside diameter of the solder sleeve, so that the sleeve can still slide over the prongs without the prongs taking up too much space inside the sleeve. The funnel and prongs are not completely closed; there is an opening that permits the cable to be removed from the system without passing the solder sleeve through the funnel. This feature accommodates cables to still be fed through a funnel prior to the time a solder sleeve is melted in place; the solder sleeve increases the overall outer diameter of the cable, so the cable is unable to pass back through the funnel again. However, the slit opening in the top of the funnel (hereinafter “open-top funnel”) permits the cable to be lifted out of the funnel. The inside diameter of each funnel is sized large enough to accommodate any cable approved for a solder sleeve of a particular size. 
     The apparatus described in the immediately preceding paragraph further includes a robotic end effector comprising a pair of grippers designed to pick and place solder sleeves of multiple sizes. The grippers are configured to grip the portions of the solder sleeve that exist between the insulation rings and central solder ring, which features possess a larger outer diameter. By gripping the portions of the sleeve with a smaller outer diameter, the sleeve is held securely in place without slipping. Additionally, if it is desired to apply heat to the solder sleeve while it is held by the grippers, the portions of the solder sleeve requiring the least amount of heat to shrink are covered by the grippers, leaving the insulation rings and solder ring exposed. 
     The apparatus disclosed herein may be incorporated in an automated production line that includes a cable delivery system and a multiplicity of workstations situated accessible to the cable delivery system. In the automated production line, each workstation is equipped with a respective cable processing module (including hardware and software) that performs a respective specific operation in a sequence of operations designed to produce a shielded cable having a solder sleeve installed on one end of the cable. One of the workstations has the solder sleeve installation apparatus disclosed in detail below. 
     Although various embodiments of methods and apparatus for installing a sleeve on a cable will be described in some detail below, one or more of those embodiments may be characterized by one or more of the following aspects. 
     One aspect of the subject matter disclosed in detail below is an apparatus for installing a sleeve on a cable, the apparatus comprising: a funnel having a channel that narrows in width from an entry side to an exit side; a funnel extension attached to or integrally formed with the funnel and extending from the exit side of the funnel, the funnel extension comprising a prong configured to fit between a cable and a sleeve that surrounds the cable; a robotic arm; an end effector mounted to the robotic arm and configured to grip the sleeve when in a closed state; and a computer system configured to control movements of the robotic arm and a state of the end effector in accordance with a program in which the end effector picks up the sleeve, then places the sleeve on the prong and then, after a delay of sufficient duration to enable an end of the cable to pass through the funnel and the sleeve, moves the sleeve off the prong to a zone at a distance from the funnel extension. 
     The apparatus described in the immediately preceding paragraph may be used in various applications. For example, the apparatus may further comprise a heater capable of producing enough heat to melt material of the sleeve in a heating zone at a distance from the funnel extension, in which case the computer system is further configured to control the heater to produce heat in the heating zone sufficient to melt the sleeve on the cable. As used herein, the term “heating zone” means a volume of space which receives heat from the heater and is partly occupied by the sleeve and the portion of the cable inside the sleeve. 
     In accordance with some embodiments, the cable is a shielded cable having an exposed shield, the sleeve is a solder sleeve comprising a solder ring and a pair of insulating rings, and the solder sleeve is melted over the exposed shield. The end effector is configured to grip the solder sleeve between the solder ring and the insulating rings when in a closed state. 
     In accordance with one embodiment, the channel of the funnel is open, and the system further comprises: a linear actuator having a retracted state and an extended state; and a lever arm mounted to the linear actuator, the lever arm being movable upward along a path that engages the cable when the linear actuator transitions from the retracted state to the extended state, thereby lifting the cable out of the funnel extension. The computer is further configured to send a control signal to activate the linear actuator to transition from the retracted state to the extended state after the sleeve has been moved to the heating zone at a distance from the funnel. 
     Another aspect of the subject matter disclosed in detail below is an apparatus for processing a cable comprising: a heater capable of producing enough heat to melt a material in a form of a sleeve; a pair of wheels arranged to form a nip capable of moving a cable therethrough; a motor operatively coupled to at least one of the pair of wheels for driving rotation of the wheels; a funnel configured to guide the cable from an entry side to an exit side; a funnel extension attached to or integrally formed with the funnel and extending from the exit side of the funnel, the funnel extension comprising a prong configured to fit between the cable and the sleeve; and a computer configured to perform the following operations: activate the motor to drive rotation of the wheels in a cable pushing direction to cause a length of cable to be inserted into the funnel; control the heater to melt the sleeve on a portion of the length of cable that extends beyond the funnel extension; and activate the motor to drive rotation of the wheels in a cable pulling direction after melting the sleeve. 
     In accordance with some embodiments, the apparatus described in the immediately preceding paragraph further comprises: a robotic arm; an end effector mounted to the robotic arm and configured to grip the sleeve when in a closed state; and a robot controller configured to control movements of the robotic arm and a state of the end effector in accordance with a program in which the end effector picks up the sleeve, then places the sleeve on the prong and later removes the sleeve from the prong. In these embodiments, the apparatus further comprises a cover having one end attached to the end effector, wherein the prong has an open top and the cover is configured to cover the open top of the prong when the sleeve is placed on the prong. 
     In accordance with one embodiment, the funnel is a split funnel comprising first and second funnel halves, the split funnel having an open state in which the first and second funnel halves are separated by a gap and a closed state in which the first and second funnel halves are in contact with each other. In this case, the apparatus further comprises an actuator for selectively moving one or both of the first and second funnel halves to achieve a transition between the open and closed states. The computer is further configured to activate the actuator to move the first and second funnel halves away from each other before activating the motor to drive rotation of the wheels in the cable pulling direction. 
     A further aspect of the subject matter disclosed in detail below is a method for processing a shielded cable comprising: (a) robotically picking up a sleeve, transporting the sleeve to a vicinity of first and second prongs of a funnel extension, and placing the sleeve on the first and second prongs; (b) passing an end of the cable through a funnel, between the first and second prongs and through the sleeve until a specified portion of the cable is positioned in a processing zone separated from the ends of the first and second prongs by a distance; (c) robotically moving the sleeve from a position in contact with the first and second prongs to a position in the processing zone whereat the sleeve surrounds the specified portion of the cable; and (d) processing the sleeve in the processing zone while the sleeve surrounds the specified portion of the cable. Step (c) may occur after (the sleeve is moved after the cable has stopped moving) or during step (b) (the sleeve and surrounded portion of the cable are moved in unison to the processing zone). In one application, step (d) comprises generating heat in the processing zone until the sleeve melts on the cable. 
     In accordance with some embodiments of the method described in the immediately preceding paragraph, the funnel has an open top, and the method further comprises lifting the cable up until no portion of the cable is between the first and second prongs. In accordance with other embodiments, the funnel comprises funnel halves, and the method further comprises separating the funnel halves to enable the melted sleeve to pass between the separated funnel halves when the cable is retracted. 
     Yet another aspect of the subject matter disclosed in detail below is a method for processing a shielded cable, the method comprising: placing a portion of the shielded cable between a pair of wheels that form a nip; robotically placing a sleeve on an extension of a funnel having an entry side that faces the nip; driving rotation of the wheels in a cable pushing direction to cause an end of the shielded cable to move through the funnel until an exposed shield of the shielded cable is positioned in a heating zone at a distance from the funnel; robotically moving the sleeve from the extension of the funnel to a position in the heating zone; and heating the sleeve in the heating zone until material of the sleeve is melted over the exposed shield. 
     Other aspects of methods and apparatus for installing a sleeve on a cable are disclosed below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features, functions and advantages discussed in the preceding section may be achieved independently in various embodiments or may be combined in yet other embodiments. Various embodiments will be hereinafter described with reference to drawings for the purpose of illustrating the above-described and other aspects. None of the diagrams briefly described in this section are drawn to scale. 
       In addition, the depiction of shielded cabling in the drawings has been simplified by assuming that the cable being viewed in the drawing has a circular outer profile of constant diameter along its length, although some shielded cabling having a jacket that conforms to the undulations in the electrical wires has an outer profile that varies along its length. 
         FIG.  1    is a diagram representing and identifying components of an automated system for performing respective operations on an end of a cable at a plurality of cable processing modules in accordance with one embodiment. 
         FIGS.  2 A and  2 B  are diagrams representing top views of a cable-carrying, drive wheel-equipped pallet in two states: when the drive wheel is separated from an idler wheel ( FIG.  2 A ) and when the drive wheel is in contact with the idler wheel ( FIG.  2 B ). 
         FIG.  3    is a diagram representing a top view of the pallet depicted in  FIG.  2 B  in a position adjacent a cable processing module where a tip of the cable is positioned in front of a funnel. 
         FIG.  4 A  is a diagram representing a side view of a cable-carrying, drive wheel-equipped pallet in a position adjacent a cable processing module. 
         FIG.  4 B  is a diagram representing a top view of the apparatus depicted in  FIG.  4 A . 
         FIG.  5    is a block diagram identifying components of a cable processing workstation in accordance with one embodiment. 
         FIG.  6    is a diagram representing a side view of a portion of a cable having an unjacketed end with an exposed shield that has been trimmed. 
         FIG.  7 A  is a diagram representing a side view of the solder sleeve having a pre-installed ground wire. 
         FIG.  7 B  is a diagram representing a side view of the solder sleeve depicted in  FIG.  7 A  when overlying a portion of the cable that includes exposed shielding. 
         FIG.  7 C  is a diagram representing a side view of the solder sleeve depicted in  FIG.  7 A  when installed by melting on the portion of the cable that includes exposed shielding. 
         FIGS.  8 A and  8 B  are diagrams representing a side view of a portion of a sleeve-cable assembly having an “out front” solder sleeve before ( FIG.  8 A ) and after melting ( FIG.  8 B ). 
         FIGS.  9 A and  9 B  are diagrams representing a side view of a portion of a sleeve-cable assembly having an “out back” solder sleeve before ( FIG.  9 A ) and after melting ( FIG.  9 B ). 
         FIG.  10 A  is a diagram showing a view of a portion of an end effector in accordance with one embodiment having two pairs of prongs gripping a solder sleeve. 
         FIG.  10 B  is a diagram showing a view of an end effector having a pair of sleeve gripper fingers and respective pairs of prongs attached to the gripper fingers. 
         FIG.  11    is a diagram showing a view of some components of a cable processing module including a set of three open-top funnels designed to thread cables with exposed shields through solder sleeves of different sizes. 
         FIG.  12    is a diagram showing a view of the components depicted in  FIG.  11   , with the addition of an end effector having fingers that grip the sleeve of the sleeve-cable assembly and a cover plate that covers the open top of the central funnel. 
         FIG.  13    is a diagram showing a view of the components depicted in  FIG.  11    at an instant in time after a solder sleeve has been placed on a funnel extension and a cable has been passed through the open-top funnel and the solder sleeve as part of an automated solder sleeve installation operation. 
         FIG.  14    is a diagram representing a view of an apparatus for melting a solder sleeve onto a portion of a cable having exposed shielding using hot air as part of an automated solder sleeve installation operation. 
         FIG.  15    is a diagram representing a view of an infrared heater in position to melt a solder sleeve onto a portion of a cable having exposed shielding as part of an automated solder sleeve installation operation. 
         FIGS.  16 A through  16 D  are diagrams showing a sleeve-cable assembly at respective instances in time after a solder sleeve has been melted on a cable: (a) before the sleeve-cable assembly is lifted upward ( FIG.  16 A ); (b) during lifting of the sleeve-cable assembly ( FIG.  16 B ); (c) during retraction of the sleeve-cable assembly after lifting ( FIG.  16 C ); and (c) during further retraction of the sleeve-cable assembly ( FIG.  16 D ). 
         FIG.  17    is a diagram s representing a front view of a lever arm of a cable lift mechanism in accordance with one embodiment. 
         FIG.  18 A  is a diagram representing a top view of an open-top funnel having a funnel extension in accordance with one embodiment. 
         FIG.  18 B  is a diagram representing a top view of the open-top funnel depicted in  FIG.  18 A  with a sleeve-cable assembly overlying and aligned with an open channel that extends through the funnel and funnel extension. 
         FIGS.  19 A and  19 B  are diagrams representing a top view of a split funnel in open ( FIG.  19 A ) and closed ( FIG.  19 B ) states respectively. 
         FIG.  20    is a flowchart identifying steps of a method for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment. 
         FIG.  21    is a block diagram identifying some components of an automated system for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment. 
         FIG.  22    is a flowchart identifying steps of a method for controlling a system having a plurality of workstations for performing a sequence of operations for installing a solder sleeve on an end of a cable in accordance with one embodiment. 
     
    
    
     Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals. 
     DETAILED DESCRIPTION 
     Illustrative embodiments of methods and apparatus for installing a sleeve on a cable are described in some detail below. However, not all features of an actual implementation are described in this specification. A person skilled in the art will appreciate that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer&#39;s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
     For the purpose of illustration, various embodiments of an apparatus for installing a solder sleeve on a shielded cable will now be described. Such an apparatus may be included in cable processing equipment at one or more modules at separate workstations in a fully automated production line or may be benchtop cable processing equipment (e.g., equipment mounted on a workbench and accessible to a human operator). 
     As used herein, the term “tip of a cable” means a portion of a cable exposed by cutting the cable in a cross-sectional plane. As used herein, the term “end of a cable” means a section of cable having a tip and a length of cable extending from the tip. For example, removal of a length of the jacket of a cable that extends to the cable tip creates an end of the cable in which the shielding is exposed. 
       FIG.  1    is a diagram representing and identifying components of a system  110  for performing respective operations on an end of a cable  10 . The system  110  includes a cable delivery system  60  cable delivery system  60 . For example, the cable delivery system  60  may take the form of a conveyor system with locating modules (not shown in  FIG.  1   ). Locating modules are components for positioning pallets in preparation for performance of an automated operation. In accordance with the embodiment depicted in  FIG.  1   , the cable delivery system  60  cable delivery system  60  includes a conveyor track  62  in the form of an endless belt or chain. The entire conveyor track  62  is continuously moving. In alternative embodiments, the cable delivery system  60  is not endless, in which case pallets  64  arriving at the end of a linear conveyor track may be transported to the starting point by other means. In accordance with alternative embodiments, the cable delivery system  60  may be a gantry robot or a robotic arm. 
     The system  110  depicted in  FIG.  1    further includes a multiplicity of automated workstations situated adjacent to and spaced at intervals along the conveyor track  62 . Each workstation is equipped with hardware that performs a respective specific operation in a sequence of operations designed to produce a shielded cable  10  having a solder sleeve  12  installed on one end of the cable  10 . The locating modules (not shown in  FIG.  1   ) of the system  110  are used to lift each pallet  64  off of the conveyor track  62  when an operation has to be performed at a workstation on the coil carried by that pallet  64  and later place the pallet  64  back on the conveyor track  62  after the operation has been completed so that the pallet  64  can move onto the next workstation. 
     Each pallet  64  carries a respective coil of cable  10 . Pallets  64  move intermittently along the conveyor track  62  in the forward direction indicated by the arrows in  FIG.  1   , advancing from one automated workstation to the next and then stopping. (This aspect of the cable delivery system  60  will be referred to hereinafter as “pulsing”.) A respective bar code reader (not shown in the drawings) is mounted on the side of the conveyor track  62  opposite to each workstation. Each pallet  64  has a bar code printed on a forward side portion thereof. When the bar code reader detects the arrival of a pallet  64 , each workstation has a respective controller (e.g., a computer programmed to execute computer numeric control (CNC) commands) that activates the cable processing module of that workstation to begin an automated cable processing operation. 
     Each shielded cable  10  to be processed is carried on a respective pallet  64  that is conveyed along the conveyor track  62 . The pallets  64  pulse down the conveyor track  62  and the end of each shielded cable  10  is inserted into a series of cable processing modules in sequence, each cable processing module including cable processing equipment for performing successive operations of a solder sleeve installation process. In accordance with the embodiment depicted in  FIG.  1   , the cable processing modules include the following: a de-reeler module  32 , a laser marker  34 , a coiler module  36 , a cable tip positioning module  38 , a laser scoring module  40 , a jacket slug pulling module  42 , a shield trimming module  44 , a shield trim inspection module  46 , two solder sleeve installation modules  52  and  54  (also referred to herein as “solder sleeve pick, place and melt modules”), and a ground wire detection module  58 . In accordance with the proposed implementation depicted in  FIG.  1   , there are three open positions where cable processing does not occur. These open positions, where a pallet may be parked, are referred to herein as buffers  48 ,  50  and  56 . 
     As indicated in  FIG.  1    by triangle symbols, some of the workstations include funnels  22  which center the inserted end of the cable  10  in the cable processing equipment at the respective workstation. Other workstations, such as the workstation where the cable tip positioning module  38  is located, do not have a funnel. The workstations where the two solder sleeve installation modules  52  and  54  are located have open-top funnels  170 , which also guide the end of the cable  10 , but differ in structure from the funnels  22  in that the cable may be lifted vertically out of the open-top funnel  170  upon completion of the solder sleeve melting operation. In accordance with alternative embodiments described in some detail later, split funnels  171  of the type depicted in  FIGS.  19 A and  19 B  may be used. 
     Each of the automated cable processing operations identified in  FIG.  1    will now be briefly described in some detail. The respective cable processing modules will be described in the order in which the respective cable processing operations are performed on one cable. 
     The starting material is a continuous length of multi-conductor shielded cable of a particular type wound on a reel. The de-reeler module  32  de-reels the continuous length of cable and then cuts the cable to a specified length, which length of cable will be referred to hereinafter as “cable  10 ”. Preferably a multi-spool de-reeler is used so that multiple cable types can be selected for processing off of a single machine. For each length of cable  10 , the laser marker  34  laser marks the outer jacket  2  of the cable  10  with pertinent information (bundle number, wire number, gauge). 
     The coiler module  36  receives each length of cable  10  from the de-reeler module  32  and laser marker  34  and coils the cable  10 . This creates a repeatable configuration for the cable that is easy to transport and maintain as it goes through the system. The coiler module  36  coils cables  10  and applies a sticker label. This label contains information about the cable (e.g., airplane effectivity, bundle, dash, wire identification, etc.), as well as a bar code. In accordance with one proposed implementation, the coiler module  36  ensures that one end of the coiled cable  10  has seven inches of “free” cable. 
     The coil of cable  10  is taken off of the coiler and placed on a pallet  64 . The pallet  64  is then transferred from the coiler module  36  to the cable tip positioning module  38 . This may be done manually by an operator or automatically by a robotic end effector (or some other apparatus). 
     The cable tip positioning module  38  serves to initially position the tip of the cable  10  at a preset cable tip position prior to the cable  10  continuing through the system  110 . It is the first “stop” along the conveyor track  62 , and is where the cable  10  is first placed onto the system. The preset cable tip position is selected to prevent the cable end from being too long as it travels along the conveyor track (hitting other objects within the system, being crushed or otherwise damaged, etc.). After the cable tip positioning module  38  has positioned the cable tip  10   b  at the preset cable tip position, the pallet  64  leaves the cable tip positioning module  38 . 
     In accordance with the embodiment depicted in  FIG.  1   , after the cable tip positioning module  38  has positioned the cable tip  10   b , the pallet  64  moves to the laser scoring module  40 . The workstation where the laser scoring module  40  is located also includes a funnel  22  for guiding a cable  10  into the cable processing equipment of the laser scoring module  40 . The laser scoring module  40  lightly scores the jacket  2  of the cable  10  along a score line  3  which extends circumferentially in a plane that intersects an annular region of the jacket  2 . The presence of the laser score line  3  prepares the applicable segment of jacket  2  (hereinafter “the jacket slug  2   a ”) to be removed. 
     After the laser scoring module  40  has scored the jacket  2  of the cable  10 , the pallet  64  moves to the jacket slug pulling module  42 . The workstation where the jacket slug pulling module  42  is located also includes a funnel  22  for guiding a cable  10  into the cable processing equipment of the jacket slug pulling module  42 . The jacket slug pulling module  42  removes the jacket slug  2   a  to reveal the shield  4  in the unjacketed portion of the cable  10 . An electrical continuity shield sensor (not separately depicted in  FIG.  1   ) may be integrated with the jacket slug pulling module  42  to detect that the jacket slug  2   a  was removed prior to retracting the cable  10  from the jacket slug pulling module  42 . 
     After the jacket slug pulling module  42  has pulled off the jacket slug  2   a  of the cable  10 , the pallet  64  moves to the shield trimming module  44 . The workstation where the shield trimming module  44  is located also includes a funnel  22  for guiding a cable  10  into the cable processing equipment of the shield trimming module  44 . The shield trimming module  44  trims off a portion of the exposed portion of the shield  4  to reveal respective portions of the wires  6  and  8  of the cable  10 . In accordance with one proposed implementation, the shield trimming module  44  trims the shield  4  of the cable  10  about 0.25″ from the edge of the jacket  2 . 
     After the shield trimming module  44  has trimmed the shield  4  of the cable  10 , the pallet  64  moves to the shield trim inspection module  46 . The workstation where the shield trim inspection module  46  is located also includes a funnel  22  for guiding a cable  10  into the cable processing equipment of the shield trim inspection module  46 . The shield trim inspection module  46  performs a quality check of the trimmed shield using a vision inspection system. The quality check ensures that the shield  4  meets the specifications for the particular type of cable  10  (e.g., shield strands are not too long or too short, not damaged, etc.) prior to installing a solder sleeve  12 . 
     After the shield trim inspection module  46  has inspected the trimmed shield  4  of the cable  10 , the pallet  64  moves to one of two solder sleeve installation modules  52  and  54 . The workstations where the solder sleeve installation modules  52  and  54  are located also include an open-top funnel  170  for guiding a cable  10  into the cable processing equipment of the solder sleeve installation modules  52  and  54 . The solder sleeve installation modules  52  and  54  are configured to install a solder sleeve  12  with a ground wire  14  onto the cable  10  using automated picking, placing and melting operations. Each solder sleeve installation modules preferably includes a sensor system that actively measures the diameter of the cable with solder sleeve and monitors the shrinking diameter of the solder sleeve during the melting process using dimensional analysis. The sensor system activates or deactivates the heating element based on the dimensional analysis of the solder sleeve; this may also control the transportation of the cables through the device. 
     Solder sleeves are limited in how quickly they are able to fully melt without burning due to their design and materials. The type of heat source used (hot air, infrared) has no significant impact on the melt time. This creates a bottleneck on the moving line, due to the fact that all processes prior to the solder sleeve melting operation take much less time to complete, and limits the lowest achievable cycle time of the overall line. 
     In accordance with one proposed implementation, two cables  10  may have solder sleeves installed concurrently using the two solder sleeve installation modules  52  and  54 . After the solder sleeve  12  has been installed on the cable  10  by one of the solder sleeve installation modules  52  and  54 , the pallet  64  moves to ground wire detection module  58 . The workstation where the ground wire detection module  58  is located also includes a funnel  22  for guiding a cable  10  into the cable processing equipment of the ground wire detection module  58 . The ground wire detection module  58  detects the ground wire  14  of the solder sleeve  12 . This may be done through physical sensing or an electrical continuity test, all of which are commercially available off the shelf. 
     As seen in  FIG.  1   , the cable delivery system  60  includes multiple pallets  64  that travel on the conveyor track  62 , each pallet  64  carrying a respective coil of cable  10 . In accordance with some embodiments, the apparatus on the pallet  64  includes a pair of cable-displacing wheels (e.g., a motor-driven drive wheel and a spring-loaded idler wheel that is movable between positions that are respectively in contact with and not in contact with the motor-driven drive wheel) designed to push and pull cables through a cable-guiding funnel which centers the cable for insertion into the cable processing equipment. The ability of the drive and idler wheels to move apart enables wires or cables of varying diameters and cross-sectional profiles to be placed between the drive and idler wheels. This apparatus is intended to be universal, i.e., to be able to be used on any equipment (including benchtop equipment) that processes wires and/or cables. Additionally, a user would be able to define the amount (length) of cable that is fed into the equipment, depending on the cable that is to be processed and its related requirements. 
     Some features of a pallet  64  in accordance with one embodiment will now be described with reference to  FIGS.  2 A and  2 B ; other features of the pallet  64  not shown in  FIGS.  2 A and  2 B  will be described later with reference to other drawings. As seen in  FIGS.  2 A and  2 B , each pallet  64  has a drive wheel  16  and an idler wheel  18  which are rotatably coupled to the pallet  64 . The drive wheel  16  and idler wheel  18  are preferably padded with a compliant material capable of conforming to different cross-sectional profiles (e.g., single-versus multi-conductor cable). An encoder may be attached to one or both of the wheels in order to more accurately track how far the cable  10  has been moved by the wheels. The encoder tracks the “distance traveled” of a drive roller by multiplying the number of rotations by the circumference of the drive wheel  16 . 
     The pallet  64  also includes a corral  66  in the form of a curved wall that is contoured to guide the cable end  10   a  toward the drive wheel  16  and idler wheel  18 . The drive wheel  16  and idler wheel  18  cooperate to move the cable end  10   a  into and out of an adjacent cable processing module  30 .  FIGS.  2 A and  2 B  show the pallet  64  in two states: when the drive wheel  16  is separated from the idler wheel  18  ( FIG.  2 A ) and when the drive wheel  16  is in contact with the idler wheel  18  ( FIG.  2 B ). 
     As seen in  FIG.  2 A , the free end  10   a  of the cable  10  is placed between the drive wheel  16  and idler wheel  18  so that the cable tip  10   b  is at a position in front of the nip, while the cable  10  is intersected by a vertical scanning plane  11  (indicated by a dashed line in  FIGS.  2 A and  2 B ) located at a known position. This known position is a known distance from a preset cable tip position. Although  FIG.  2 A  shows the cable tip  10   b  located beyond the vertical scanning plane  11 , the starting position of the cable tip  10   b  may be either beyond or short of the vertical scanning plane  11 . 
     The force holding the idler wheel  18  apart from drive wheel  16  is then discontinued, following which the idler wheel  18  is urged by springs (not shown in  FIGS.  2 A and  2 B ) into contact with the drive wheel  16 , thereby forming a nip that squeezes the shielded cable  10 . As will be described in further detail below, the drive wheel  16  and idler wheel  18  are configured so that sufficient frictional forces are produced that enable the shielded cable  10  to be either pushed or pulled through the nip depending on the directions of wheel rotation. Upon detection of the presence of the cable tip  102   b  at a position beyond the vertical scanning plane  11 , the drive wheel  16  and idler wheel  18  are rotated in a cable pulling direction to cause the cable end  10   a  to retract and the cable tip  10   b  to move toward the vertical scanning plane  11 . Conversely, if the cable tip  102   b  were at a position short of the vertical scanning plane  11  (hereinafter “scanning plane  11 ”), the drive wheel  16  and idler wheel  18  would be rotated in a cable pushing direction to cause the cable end  10   a  to extend and the cable tip  10   b  to move toward the scanning plane  11 . The remainder of the description of FIGS.  2 A and  2 B will discuss the case wherein the cable end  10   a  is initially placed in a position such that the cable tip  102   b  is beyond (not short of) the scanning plane  11   
     The movement of the cable tip  10   b  is monitored by detecting when the cable tip  10   b  reaches the scanning plane  11 . This is accomplished by a photoelectric sensor (not shown in  FIGS.  2 A and  2 B , but see photoelectric sensor  28  in  FIGS.  4 A and  4 B ) mounted to the pallet  64  and configured to function as a light gate. In accordance with some embodiments, the photoelectric sensor  28  is configured to act as a light gate that detects when there is no portion of the cable  10  blocking a light beam propagating in the scanning plane  11  from one side of the light gate to the other side.  FIG.  2 B  shows the state wherein the cable tip  10   b  is aligned with the scanning plane  11  following retraction of the cable end  10   a . In response to the photoelectric sensor  28  detecting a transition between a state of light being interrupted (e.g., blocked) in the scanning plane  11  and a state of light not being interrupted, the photoelectric sensor  28  issues a cable tip position signal indicating the transition between interruption and no interruption of transmitted light at the scanning plane. In response to issuance of the cable tip position signal, the computer of the cable positioning module activates a motor (not shown in  FIGS.  2 A and  2 B , but see motor  72  in  FIGS.  4 A and  4 B ) to rotate the drive wheel  16  an amount and in a direction such that at the end of the rotation, the cable  10  does not extend beyond a preset cable tip position. This preset cable tip position is a known distance from the scanning plane  11 . The preset cable tip position may be selected to ensure that the cable tip  10   b  may travel along the conveyor track  62  with sufficient clearance to avoid damage from stationary objects. 
     The cable tip positioning module  38  includes a computer system (not shown in  FIG.  3   . The cable tip positioning signal from the photoelectric sensor  28  is received by the computer  162   a . The computer  162   a  is configured to de-activate the motor  72  that drives rotation of the drive wheel  16  (thereby ceasing driving rotation of the drive wheel  16  in the cable pulling direction) after a predetermined angular rotation of the drive wheel  16  subsequent to issuance of the cable tip position signal. In other words, there is a time delay during which the drive wheel  16  and idler wheel continue to move the cable end  10   a , causing the cable tip  10   b  to move from the current position depicted in  FIG.  2 B  (in this instance, corresponding to the position of the scanning plane  11 ) to a preset cable tip position a short distance (e.g., 0.5 inch) from the scanning plane  11 . More specifically, the computer  162   a  is configured to start a count of pulses output by a rotation encoder (mounted on the drive wheel shaft  88  or the motor output shaft, for example) in response to issuance of the cable tip position signal and then de-activate the motor  72  in response to the count reaching a specified value representing the distance separating the preset cable tip position from the scanning plane  11 . 
     In accordance with an alternative embodiment, the preset cable tip position and the position of the scanning plane may be one and the same, provided that the movement of the cable  10  can be stopped precisely at the instant in time when the photoelectric sensor  28  issues the cable tip position signal. 
     The above-described cable tip positioning process ensures that the cable tip  10   b  is in a repeatable position and does not extend beyond the preset cable tip position prior to continuing down the conveyor track  62 . At this juncture, the conveyor track  62  pulses forward, causing the pallet to move to the next workstation. 
       FIG.  3    is a diagram representing a top view of the pallet  64  in a position adjacent a cable processing module  30 . The apparatus includes a drive wheel  16  and an idler wheel  18  configured for driving the cable  10  forwards or backwards between the wheels and a funnel  22  capable of capturing the cable end  10   a . While the wheels control the motion of the cable  10 , the funnel  22  serves to center the cable  10  for insertion into the cable processing equipment. This function will be used to insert and position the cable  10  into different modules for processing as the cable  10  is transported through the system. 
     More specifically, the cable tip  10   b  is positioned in front of a funnel  22  that is configured to center a cable end  10   a  as it is fed into the cable processing equipment  24  of a cable processing module  30 . Each cable processing module  30  is equipped with a funnel  22  (or an open-top funnel not shown) and a photoelectric sensor (not shown in  FIG.  3   , but see photoelectric sensor  28  in  FIG.  5   ) for detecting the presence of the cable tip  10   b  in a scanning plane  11  (indicated by a dashed line in  FIG.  3   ). It is important that the interior surface of the funnel  22  be smooth and devoid of any rough or sharp edges that may abrade, tear, or otherwise damage the cable  10 . Preferably the funnel  22  is made of a thermoplastic material with a low coefficient of friction to prevent the funnel  22  from slowing the cable  10  down as it is moved by the drive wheel  16  and idler wheel  18  (preventing slippage). The funnel  22  may be configured in different ways. In lieu of a basic hole on the exit side of the funnel  22  (small diameter side), the funnel  22  may have a flexible piece of material featuring an X-shaped cut centered within the funnel  22 . This helps to provide a repeatable, centered position for the cable  10  as it is either pushed forward or pulled back. It also permits the cable-guiding funnel to accurately center cables with varying diameters and cross sectional profiles. Other cable-guiding funnels may also be split and/or feature an open top. 
     In accordance with some embodiments, each workstation includes a stationary motor (not shown in  FIG.  3   , but see motor  72  in  FIGS.  4 A and  4 B ). In accordance with one proposed implementation, the motor  72  is an electric stepper motor. The motor shaft speed will control how fast the drive wheel rotates (the speed at which the end of the cable  10  is moved), as well as which directions the wheels rotate in. The motor  72  is configured to rotate either clockwise or counterclockwise. 
     In response to detection of the arrival of the pallet  64  at the cable processing module  30  by a pallet detector (not shown in  FIG.  3   , but see pallet detector  160  in  FIG.  5   ), the motor  72  is operatively coupled to the drive wheel  16 . Subsequently the motor  72  is activated to drive the drive wheel  16  to rotate in the cable pushing direction. The shaft of the motor  72  is optionally equipped with a rotation encoder  73  (see  FIG.  5   ) for determining the angular rotation of the drive wheel  16 . During rotation of the drive wheel  16  in the cable pushing direction, the rotation encoder  73  tracks the rotation of the motor shaft to generate digital position information representing the length of cable  10  which has been fed past the scanning plane  11 . 
     When a pallet  64  stops at the cable processing module  30 , the drive wheel  16  and idler wheel  18  are driven to rotate in a cable pushing direction to cause the cable tip  10   b  to pass the photoelectric sensor  28 , through the funnel  22 , and into the cable processing equipment  24 . Once the photoelectric sensor  28  is triggered, the rotation encoder  73  will begin to record the position of the cable tip  10   b . This provides a way to track the inserted length of the cable  10  in real time, and subsequently cause the motor  72  to stop once the correct length of cable  10  has been fed into the cable processing equipment  24 . The drive wheel  16  and idler wheel  18  continue to rotate in the cable pushing direction until a specified length of cable  10  has been inserted into the cable processing equipment  24  via the funnel  22 . 
       FIG.  4 A  is a diagram representing a side view of a pallet  64  in a position adjacent a cable processing module  30 , which pallet  64  is equipped with a reelette  26  for holding a coil of cable  10  and a drive wheel  16  (not visible in  FIG.  4 A ) for feeding an end of the cable  10  into the cable processing module  30  in accordance with a further embodiment.  FIG.  4 B  shows a top view of the pallet  64  in a position adjacent the cable processing module  30 . The pallet  64  further includes a cable positioning mechanism  19  that is controlled to place the tip  10   b  of the cable  10  at a repeatable position at each cable processing module  30 . 
     As seen in  FIG.  4 A , the cable processing module  30  is mounted on a stationary plate  68 . A stanchion  70  is affixed to the stationary plate  68  in a position in front of the cable processing module  30 . A motor  72  is mounted to a base  70   a  of the stanchion  70 . The motor  72  has an output shaft  74  which drives rotation of the drive wheel  16  (not visible behind the idler wheel  18  in  FIG.  4 A ). In addition, a photoelectric sensor  28  is mounted to an upright portion  70   b  of the stanchion  70 . The photoelectric sensor  28  is placed at an elevation such that the photoelectric sensor  28  is able to detect the cable tip  10   b  when it passes through a scanning plane  11  (indicated by a dashed line in  FIGS.  4 A and  4 B ) during cable pushing. 
     In accordance with the embodiment depicted in  FIG.  4 A , each coil of cable  10  is individually wound onto its own reelette  26 , which reelette  26  is supported by and rotatably coupled to the pallet  64 . The corral  66  (see in  FIGS.  2 A- 2 C ) is not shown in  FIG.  4 A  so that the reelette  26  is visible. The reelette  26  has an opening (not shown in  FIG.  4 A ) on its outer periphery through which a portion of the cable  10  (including cable end  10   a ) passes.  FIG.  4 A  shows a state in which the cable end  10   a  is disposed between rotating drive wheel  16  and idler wheel  18  (drive wheel  16  is located directly behind the idler wheel  18  and not visible in  FIG.  4 A ), while the cable tip  10   b  is moving in a direction (indicated by an arrow in  FIG.  4 A ) toward the cable processing module  30 . 
       FIG.  4 B  shows a top view of the pallet  64  when the cable tip  10   b  is positioned at a scanning plane  11  of the photoelectric sensor  28 . The double-headed straight arrow superimposed on the idler wheel  18  indicates that the idler wheel  18  is laterally movable away from and toward the drive wheel  16 . Meanwhile the curved arrows superimposed on the drive wheel  16  and idler wheel  18  are intended to indicate that the drive wheel  16  and idler wheel  18  are rotating in a cable pushing direction. At the instant of time depicted in  FIG.  4 B , the cable tip  10   b  is positioned at the scanning plane  11  and is moving toward the cable processing module  30 . 
     The cable processing module  30  includes a computer (not shown in  FIGS.  4 A and  4 B )  FIG.  5    is a block diagram identifying some components of a cable processing workstation in accordance with one embodiment. As previously described, each cable processing workstation includes a funnel  22  and cable processing equipment  24  (not shown in  FIG.  5   , but see  FIG.  3   ). The cable processing workstation further includes a computer  162  that is configured to control various actuators and motors by executing pre-programmed sequences of machine control commands, such as computer numerical control commands.  FIG.  5    depicts an example wherein the computer  162  is programmed to send control signals to various electrically controlled valves  80  which may be opened to supply compressed air from a compressed air supply  82  to one or more of a multiplicity of pneumatic cylinders  84 ,  86  and  88 . The pneumatic cylinders  84 ,  86  and  88  may be used to move various components of the cable processing equipment  24 . In alternative embodiments, the pneumatic cylinders may be replaced by electric motors. 
     The cable processing workstation depicted in  FIG.  5    further includes a motor  72  and a rotation encoder  73  operatively coupled to the output shaft  74  of the motor  72 . The rotation encoder  73  generates pulses which the computer  162  is configured to count for the purpose of determining the number of degrees of motor output shaft rotation, which angular measurement in turns represents a distance traveled by the cable tip  10   b  during that output shaft rotation. The computer  162  also receives sensor feedback from a photoelectric sensor  28  used to detect a cable tip position and a pallet detector  160  used to detect a pallet position. The computer  162  is configured to send commands to a motor controller  164  for controlling the motor  72  in accordance with feedback from photoelectric sensor  28 , rotation encoder  73  and pallet detector  160 . 
     The computer  162  of each cable processing module  30  is configured to perform the following operations: activate the motor  72  to drive rotation of the drive wheel  16  in a cable pushing direction to cause a specified length of cable  10  to be inserted into the cable processing equipment  24 ; activate the cable processing equipment  24  to perform an operation on the inserted cable end  10   a ; and activate the motor  72  to drive rotation of the drive wheel  16  in a cable pulling direction to cause the specified length of cable  10  to be removed from the cable processing equipment  24 . 
     Each workstation comprises a rotation encoder  73  configured to output pulses representing the incremental angular rotations of an output shaft of the motor  72 . The photoelectric sensor  28  is positioned and configured to issue a cable tip position signal indicating that interruption of transmitted light in the scanning plane  11  has started. In other words, the cable tip position signal is issued in response to the photoelectric sensor  28  detecting that a state of light not being blocked in the scanning plane  11  has transitioned to a state of light being blocked. The computer  162  is further configured to start a count of pulses output by the rotation encoder  73  in response to the cable tip position signal and then de-activate the motor  72  in response to the count reaching a specified value corresponding to a specific target length of cable  10  having been inserted in the cable processing equipment  24 . 
     The photoelectric sensor  28  that detects the position of the cable tip  10   b  in each cable processing module  30  may be of the same type as the photoelectric sensor  28  incorporated in the cable tip positioning module  38 . For example, digital laser sensors of various types are suitable. Many adaptable options are available off the shelf, such as proximity sensors and vision sensors. 
     In accordance with some embodiments, the photoelectric sensor  28  used to detect cable tip position is of a type that is also capable of measuring the diameter of the cable  10  to ensure that false positives are not caused by fingers or other objects larger than the typical cable diameter. The diameter measurement may also be used to confirm that the cable  10  is of the type expected by the computer  162  of the cable processing module  30 . 
     In accordance with one proposed implementation, the photoelectric sensor  28  is a laser sensor of the “position recognition” type (a.k.a. a laser scan micrometer). In a laser scanner of this type, a scanning laser beam is emitted from a scanning light beam transmitter  28   a , which scanning light beam scans in the scanning plane  11  and is then received by the light-detecting sensor  28   b . In accordance with one embodiment, the light-detecting sensor  28   b  includes a linear array of light-detecting elements (e.g., a column of pixels in a charge coupled device). The area where the scanning laser beam is interrupted is identified clearly on the light-detecting sensor  28   b . This type of laser sensor may be used for in-line cable tip position detection or cable outer diameter measurement. 
     The computer  162  of the cable processing module  30  is further configured to perform the following operations: compute a length of an interruption in light received by the light-detecting sensor  28   b  from the scanning light beam transmitter  28   a ; compare the computed length of the interruption to reference data representing a diameter of the type of cable  10  to be processed; and issue an alert signal when a difference of the computed length of the interruption and the reference data exceeds a specified threshold. 
     In accordance with other embodiments, the above-described cable positioning system may be used to position the tip of the cable at multiple positions within any given processing module. Such feature allows multi-step processing within a single module. The tip of the cable, for example, could be positioned at multiple positions within the laser scoring module  40  to allow the laser to score the cable in multiple locations. For very long strip lengths (four inches for example) the cable could be laser scored every inch. The jacket slug pulling module  42  would then pull of each one-inch slug one at a time (again using multi-step insertion). Thus the jacket puller only needs to overcome pull-off friction forces for one inch of jacket instead of four inches of jacket. 
     Referring again to  FIG.  1   , after the jacket slug pulling module  42  has pulled off the jacket slug  2   a  of the cable  10 , the pallet  64  moves to the shield trimming module  44 . The shield trimming module  44  incorporates equipment for trimming off a portion of the exposed portion of the shield  4  to reveal respective end portions of the wires  6  and  8  of the cable  10 . After the shield trimming module  44  has trimmed the shield  4  of the cable  10 , the pallet  64  moves to the shield trim inspection module  46  (see  FIG.  1   ). The shield trim inspection module  46  performs a quality check of the trimmed shield using a vision inspection system. 
       FIG.  6    is a diagram representing a side view of a portion of a cable  10  having an unjacketed end with an exposed shield  4  that has been trimmed. The trimming of the shield  4  in turn exposes the wires  6  and  8  of the cable  10 . The shield trim is inspected using a vision system that includes a camera system arranged to capture a 360-degree view of the trimmed shield and a computer programmed to analyze the captured images. More specifically, the computer is configured to determine whether excessive gaps are present in the exposed shield (e.g., caused by broken shield strands) or not. The evaluation system compares perceived gaps in the image with a maximum allowable gap value to ensure that the percentage of shield coverage is within the specified tolerance. 
     Shield coverage percentages below a specified minimum percentage of coverage indicate to the evaluation system that an unacceptable number of shield strands may be broken. The computer may also be configured to determine whether the length of the exposed shield on the cable is within an allowable range. 
     After the shield trim inspection module  46  has inspected the trimmed shield  4  of the cable  10 , the pallet  64  moves to one of two solder sleeve installation modules  52  and  54  (see  FIG.  1   ). The solder sleeve installation modules  52  and  54  are configured to install a solder sleeve  12  with a ground wire  14  onto the cable  10  using automated picking, placing and melting operations. 
       FIG.  7 A  is a diagram representing a side view of a typical solder sleeve  12  having a pre-installed ground wire  14 . The solder sleeve  12  includes a sleeve  7  made of transparent, heat-shrinkable thermoplastic material. The internal diameter of the sleeve is greater than the outer diameter of the cable being processed. The solder sleeve  12  further includes a central solder ring  9  adhered to the inside of the sleeve  7  at a central position and a pair of thermoplastic sealing rings  13   a  and  13   b.    
       FIG.  7 B  is a diagram representing a side view of the solder sleeve  12  depicted in  FIG.  7 A  when placed in a position overlying a portion of a cable  10  having a jacket  2  and an unjacketed portion where the shield  4  is exposed. The exposed shield  4  is surrounded by the central solder ring  9 , which when melted and then solidified will form an electrical connection between the shield  4  and the ground wire conductor strand  15 . The sleeve  7  has not yet been melted. 
       FIG.  7 C  is a diagram representing a side view of the solder sleeve  12  depicted in  FIG.  7 A  after the solder sleeve  12  has been melted on the cable  10 . 
     As disclosed above, the solder sleeve installation module  52  and  54  (see  FIG.  1   ) are each configured to install a solder sleeve  12  onto the end of a cable  10 . The cable processing equipment of a solder sleeve installation module may be used to install a solder sleeve  12  (e.g., of the type described with reference to  FIG.  7 A ) or a dead end sleeve made of electrical insulation material only. Solder sleeves are melted and shrunk onto an end of a cable; a dead end sleeve is shrunk without melting onto an end of a cable. Solder sleeves and dead end sleeves are separated by part number and distributed onto different vibration tables. (Vibration tables could be replaced with tape-and-reels or cartridges). If the solder sleeve is on a tape-and-reel or cartridge, the solder sleeve will be pushed out of the cavity (via pneumatic actuator, electric actuator, etc.) so that an end effector can grip it. 
       FIGS.  8 A and  8 B  are diagrams representing a side view of a portion of a sleeve-cable assembly  1   a  having an “out front” solder sleeve  12 . The sleeve-cable assembly  1   a  includes a solder sleeve  12  having a ground wire  14  that extends away from the jacket  2  of cable  10 . The solder sleeve  12  is threaded onto the wires  6  and  8  until the solder sleeve  12  is in a position surrounding the exposed shield  4 . As seen in  FIG.  8 A , the “out front” solder sleeve  12  also surrounds an end segment of the jacket  2  and unshielded portions of wires  6  and  8 .  FIG.  8 A  shows sleeve-cable assembly  1   a  before the “out front” solder sleeve  12  is melted on the cable  10 .  FIG.  8 B  shows sleeve-cable assembly  1   a  after the “out front” solder sleeve  12  has been melted on the cable  10 . 
       FIGS.  9 A and  9 B  are diagrams representing a side view of a portion of a sleeve-cable assembly  1   a  having an “out back” solder sleeve  12 . The sleeve-cable assembly  1   a  includes a solder sleeve  12  having a ground wire  14  that extends toward the jacket  2  of cable  10 . The solder sleeve  12  is threaded onto the wires  6  and  8  until the solder sleeve  12  is in a position surrounding the exposed shield  4 .  FIG.  9 A  shows sleeve-cable assembly  1   a  before the “out back” solder sleeve  12  is melted on the cable  10 .  FIG.  9 B  shows sleeve-cable assembly  1   a  after the “out back” solder sleeve  12  has been melted on the cable  10 . 
     At the start of a solder sleeve installation procedure, a robotic end effector is controlled to move to whichever one of a plurality of vibration tables (or other solder sleeve storage devices) has the correct type of solder sleeve  12  to be installed on the cable  10 . The robotic end effector picks up a solder sleeve and carries it to the apparatus depicted in  FIGS.  11 - 14   . The robotic end effector has a pair of gripper fingers designed to grip a particular type of solder sleeve. The robotic end effector may be integrated onto a robotic arm or gantry with a vision system that recognizes the solder sleeve, thereby enabling the robot arm to be properly aligned when attempting to pick up the sleeve with a predetermined pigtail orientation. Pick and place vision systems are commercially available off the shelf and could be adapted to grip a particular solder sleeve  12 . 
       FIG.  10 B  is a diagram showing a view of an end effector  108  having a pair of gripper fingers  112  and  114  and respective pairs  116  and  118  of prongs (or claws) attached to the gripper fingers  112  and  114  respectively for forming a sleeve gripper  111 .  FIG.  10 A  is a diagram showing a view of the two pairs  116  and  118  of prongs of the sleeve gripper  111  gripping a solder sleeve  12 . The insulation rings  13   a  and  13   b  on each end of the solder sleeve  12  have a larger outer diameter than the rest of the solder sleeve  12 . When the prongs  116  and  118  close over the portions of the solder sleeve  12  between the insulation rings  13   a ,  13   b  and the central solder ring  9 , it is impossible for the insulation rings  13   a  and  13   b  to slip/pass through the opening between opposing prongs, thus making it impossible for the solder sleeve  12  to be able to inadvertently slip out of the sleeve gripper  111 . 
     In one embodiment, the prongs  116  and  118  of the gripper fingers  112  and  114  are designed to cover or shield as little surface area of the solder sleeve  12  as possible. By maximizing the exposed surface area, it would be possible to apply heat to the solder sleeve  12  and perform the melt process while still gripping the solder sleeve  12  with the sleeve gripper  111 . This would ensure that the solder sleeve  12  does not inadvertently become misaligned or move out of place prior to the heat application. This would also require that the prongs  116  and  118  be fabricated from a heat-resistant or metal material. 
     The robotic end effector  108  may be designed to pick and place solder sleeves or dead end sleeves. The end effector  108  is intended to be used as a part of a solder sleeve pick, place and melt module  52  or  54  that has been integrated into a fully automated system. 
     The prongs  116  and  118  of the gripper fingers  112  and  114  make contact with and grip the solder sleeve  12 . The gripper fingers  112  and  114  may be attached to a pick-and-place air cylinder or some other device capable of moving gripper fingers  112  and  114  together and apart. The prongs  116  and  118  are designed to be able to hold solder sleeves of different sizes. In some in cases, solder sleeve parts may be constructed using large tolerance values; thus in actuality may vary in diameter, length, etc. The sleeve gripper  111  is designed to contact and grip the solder sleeve  12  between the central solder ring  9  and the insulating rings  13   a ,  13   b , regardless of solder sleeve size thus avoiding the solder sleeve  12  from slipping out. The solder sleeve may have an indent in that space and can be held from it as shown in  FIG.  10 A . The opposing pairs of prongs  116  and  118  have semi-circular cutouts which prevent the solder sleeve  12  from being crushed and center the solder sleeve  12  within the sleeve gripper  111  for accurate placement during the installation process. The prongs  116  and  118  should be made of a rigid, heat-resistant material. Examples include aluminum, steel, etc. 
     In accordance with various proposed embodiments, the solder sleeves  12  will be separated by part number and located on reels of tape, in cartridges, or on vibration tables. The end effector  108  will be able to pick up a solder sleeve  12  from any of these configurations. Vibration tables are flat surfaces that vibrate to shift products from the end of the table (where they are loaded) to the front. In the case of solder sleeves carried by a carrier tape wound on a reel, the solder sleeves would be extracted from the cavity prior to gripping with the gripper fingers (using an underside actuator, gravity, etc.). In the case of a cartridge loaded with solder sleeves, a solder sleeve would need to be extracted from a cavity prior to gripping with the gripper fingers. 
     The end effector may be adapted for coupling to a robotic arm or a gantry robot. A gantry robot consists of a manipulator mounted onto an overhead system that allows movement across a horizontal plane. Gantry robots are also called Cartesian or linear robots. The robotic arm may be part of a robot having multi-axis movement capabilities. The robot includes one or more positional sensors (not shown) at, or otherwise associated with, each of the pivots that provide positional data (X, Y, and Z in three-dimensional space) to the data acquisition system for accurately locating the solder sleeves. An example of a robot that could be employed with the end effector  108  shown in  FIG.  10 A  is robot Model KR-150 manufactured by Kuka Roboter GmbH (Augsburg, Germany), although any robot or other manipulator capable of control the position of the end effector  108  in the manner disclosed herein. The term “gantry/robot arm” will be used herein to mean a robot of either type having a robot controller configured to move and control the end effector  108  to perform the solder sleeve pick and place operations disclosed herein. 
     The sleeve gripper  111  will be used as a part of an end effector within the solder sleeve pick, place and melt module. The end effector  108  picks up a solder sleeve  12 , places it over the prongs of a funnel  170  to partially encase them, and waits for the cable  10  to be passed through the funnel  170  and the solder sleeve  12 . Once the cable  10  is through, the end effector  108  moves back to position the solder sleeve  12  over the desired area of cable  10 . In accordance with embodiment, the desired area includes the exposed portion of the trimmed shield  4 , an adjacent portion of the jacket and adjacent portions of the wires  6  and  8 . The end effector  108  then releases the solder sleeve  12  and moves out of the way of the heating elements, which close over the solder sleeve  12  and melt the sleeve in place on the cable  10 . In another embodiment, the end effector  108  does not release the solder sleeve and instead remains in place to hold the sleeve and cable stationary during the heating process. The heating elements are moved in position and then activated to heat the solder sleeve  12  while the prongs  116  and  118  hold the solder sleeve. 
     This end effector  108  enables the solder sleeve installation process to be fully automated. By automating this process, risks associated with the current manual process (repeatable quality, ergonomic issues, slower cycle times) are eliminated. 
     The cable processing equipment at each solder sleeve installation module  52  and  54  further comprises a set of funnels  170  (see  FIG.  1   ) designed to accommodate shielded cables before and after a solder sleeve has been installed onto the cable. These funnels not only serve to guide the cable movement, but also to protect the exposed shielding of the cable as the cable  10  is fed through the solder sleeve  12  and positioned such that the exposed shield  4  is surrounded by the solder sleeve  12 . 
     Once a solder sleeve  12  is installed onto a cable  10  on the intended area, the overall diameter of the combination of the cable  10  and solder sleeve  12  (sleeve-cable assembly  1  as shown later in  FIG.  16 A ) is thus larger in diameter at that area than cable  10  originally. To the extent that the narrowest point along the open-top funnel  170  has been sized to match the outer diameter of the cable  10 , a cable  10  with an installed solder sleeve  12  is unable to pass through the open-top funnel  170  for the purpose of exiting the solder sleeve installation module  52  or  54 . To remove this obstacle, an “open top” funnel  170  has been designed in which a slot (hereinafter “opening  76 ”) was created in the top portion of each funnel  170 . Such a slot  76  enables funnel  170  to accommodate changes and variations to the cable exterior size as it undergoes modifications through sleeve installation. 
       FIG.  11    is a diagram showing a view of some components of a solder sleeve installation module including a set of three open-top funnels  170   a - 170   c  designed to thread cables with exposed shields through solder sleeves of different sizes. The openings  76   a - 76   c  formed in the top portions of the open-top funnels  170   a - 170   c  enable removal of the cable  10  from the funnel after a solder sleeve  12  has been installed. The open-top funnels  170   a - 170   c  are mounted on a sliding plate  176  that is capable of sliding side to side to place a correct open-top funnel. As depicted in  FIG.  12   , an open-top funnel  170   b  is placed in front of a notch  175   b  of a cable guide block  175 . The cable guide block further includes a guide surface  175   a  for guiding the end of the cable  10  into the notch  175   b  during cable insertion. 
     The funnel system further includes multiple funnel extensions  172   a - 172   c . The plastic open-top funnels  170   a - 170   c  are effectively extended by attaching respective funnel extensions  172   a - 172   c . Alternatively, the funnel extensions  172   a - 172   c  may be integrally formed with the respective open-top funnels  170   a - 170   c . Each of the funnel extensions  172   a - 172   c  may terminate in a pair of prongs  78   a  and  78   b . The prongs  78   a  and  78   b  are sized and configured to fit within the inner diameter of the applicable solder sleeve. More specifically, the prongs  78   a  and  78   b  are tapered along their lengths so that they easily enter the solder sleeve  12  as the solder sleeve is moved into position. Preferably the prongs  78   a  and  78   b  are made of a material having a low coefficient of friction (e.g., metal) so that the cable  10  may easily slide along the interior surface of the prong. Also the prongs  78   a  and  78   b  are thin enough that the prongs do not adversely impact the cable&#39;s ability to fit through the solder sleeve  12 . The prongs  78   a  and  78   b  preferably have smooth interior surfaces devoid of rough patches or sharp edges that might damage the shield  4  and/or cable  10 . The prongs  78   a  and  78   b  close off a large portion of the internal surface of the solder sleeve  12 , and provide a smooth surface for the cable  10  to slide along as it is fed through the open-top funnel  170  and the solder sleeve  12 . The prongs  78   a  and  78   b  eliminate the need to create, and then later remove, a sacrificial jacket slug. 
     When the trimmed shield cable  10  is inserted through the solder sleeve  12 , snagging or otherwise catching of the shield strands or wire ends against the inner surface of the solder sleeve (which could damage the cable) is prevented by the intervening prongs  78   a  and  78   b . The size and length of the funnel extensions are designed/determined based on the size of the solder sleeve  12  to be installed. The prongs  78   a  and  78   b  should be long enough to extend through at least a portion if not most of the solder sleeve  12 , and should taper down along the length of the prongs  78   a  and  78   b  to facilitate easy placement of the solder sleeve  12  over the prongs  78   a  and  78   b.    
       FIG.  12    is a diagram showing a view of the components depicted in  FIG.  11   , with the addition of an end effector  108  for placing a solder sleeve  12  (not visible in  FIG.  12   , but see  FIG.  13   ) onto a portion of a cable  10  having an exposed shield  4  as part of an automated solder sleeve installation operation.  FIG.  12    depicts one state during the solder sleeve installation process wherein the solder sleeve  12  has already been placed around the funnel extension  172   b  by the end effector  108  and the cable  10  has already been fed through the open-top funnel  170   b  and solder sleeve  12 . 
     More specifically, the solder sleeve installation process in accordance with one embodiment includes the following steps which are performed before the state of the apparatus depicted in  FIG.  12    is attained, The end effector  108  picks up a solder sleeve  12  from a vibration table (or other sleeve supply mechanism), places it over the end of the funnel extension  172   b , and then in one embodiment remains stationary while the cable  10  is being fed through the solder sleeve  12  by the cable positioning mechanism  19 . As seen in  FIG.  12   , the end effector  108  is equipped with a plastic cover plate  178  which closes off the open-top funnel  170   b  to prevent the cable  10  from escaping the open-top funnel  170   b  as it is fed through the solder sleeve  12 . Next, in one embodiment, the end effector  108  remains holding the sleeve  12  with the wire inserted through it, and awaits the soldering operation to be performed on the sleeve. In another embodiment, he end effector  108  releases the solder sleeve  12  and moves out of the way prior to the solder sleeve melt process, which situation is shown in  FIG.  13   . 
       FIG.  13    is a diagram showing a view of the components depicted in  FIG.  11    at an instant in time after a solder sleeve  12  has been placed on a funnel extension  172   b  and after a cable  10  has been passed through the open-top funnel  170   b  and the solder sleeve  12  as part of an automated solder sleeve installation operation. As seen in  FIG.  13   , the solder sleeve  12  is seated on the funnel extension  172   b . The funnel extension  172   b  closes off a large portion of the internal surface of the solder sleeve  12 , and provides a smooth surface for the cable  10  to slide along as it is fed through the open-top funnel  170   b  and the solder sleeve  12 . 
     The system controller (not shown in  FIG.  13   , but see system controller  100  in  FIG.  20   ) may either calculates how far the cable positioning mechanism  19  (see  FIG.  4 B ) should drive the cable  10  into the module based on cable strip length information or uses a known pre-set value. The cable shield  4  is stopped at a repeatable position for processing. Thereafter the end effector  108  (see  FIG.  10 B ) moves the solder sleeve  12  to the repeatable position seen in  FIG.  14    for processing. These repeatable positions are such that the solder sleeve  12  is centered over the exposed area of the trimmed shield  4  of the cable  10 . In one embodiment, the end effector  108  then releases the solder sleeve  12  and moves out of the way (back to the origin position) prior to the start of the solder sleeve melt process. In another embodiment, the end effector  108  remains holding the sleeve  12  during the heating process.  FIG.  14    shows one embodiment of an apparatus for melting a solder sleeve  12  onto a portion of a cable  10  having exposed shielding using hot air as part of an automated solder sleeve installation operation. The system controller  100  sends commands to a robotic apparatus that places the components of the heating tool  174  in the positions seen in  FIG.  14   . In this example, the heating tool  174  includes two hot air guns  174   a  and  174   b  placed on opposite sides of the solder sleeve  12  and a curved-tip nozzle  174   c  attached to the outlet of the hot air gun  174   a . The curved-tip nozzle  174   c  projects from the hot air gun  174   a  and overhangs the solder sleeve  12 . In addition, the hot air gun  174   b  may have a flat-tip nozzle attached that is roughly the length of the solder sleeve. The hot air gun  174   b  moves laterally from the right of the solder sleeve  12  into position. The hot air gun  174   a  rotates down over the solder sleeve  12 . The hot air guns  174   a  and  174   b  may be moved into heating position by activation of respective linear actuators (not shown). Other embodiments may use a single hot air gun, or more than two. 
     During the heating stage, the two hot air guns  174   a  and  174   b  apply heat to the solder sleeve  12 . The curved-tip nozzle  174   c  “reflects” the generated hot air and causes it to flow around the solder sleeve  12 . The heating tool  174  generates sufficient heat in the heating zone that the solder ring  9  of the solder sleeve  12  melts onto the cable  10 . Using two hot air guns improves the even application of heat to all sides of the solder sleeve  12 , as well as enables an increase in the speed of the overall melting process. At no point should the hot air guns make physical contact with the solder sleeve  12  or cable  10  due to the possibility of charring or damaging the jacket  2  of the cable  10 . 
     In accordance with alternative embodiments, other types of heating devices, such as infrared heaters, may be employed in the solder sleeve melting process. An infrared heater or heat lamp is a body with a higher temperature which transfers energy to a body with a lower temperature through electromagnetic radiation. Depending on the temperature of the emitting body, the wavelength of the peak of the infrared radiation ranges from 780 nm to 1 mm. No contact or medium between the two bodies is needed for the energy transfer. 
       FIG.  15    shows an infrared heating tool  94  in position to melt a solder sleeve  12  onto a portion of a cable  10  having exposed shielding as part of an automated solder sleeve installation operation. The infrared heating tool  94  includes a pair of quartz-encapsulated heating elements  120   a  and  120   b  which are plugged into respective heat sinks  121   a  and  121   b . The quartz-encapsulated heating elements  120   a  and  120   b , when closed, are configured to encircle a workpiece. Such heating elements are capable of providing instant radiant heat at temperatures up to 1500° F. 
     The heating process may be integrated with a method for performing an active monitoring method such as dimensional analysis to monitor solder sleeves during melting, or temperature monitoring to avoid over or spotty heating of the solder sleeve. In the case of dimensional analysis, laser measurement devices can be used and configured to record diameter data at specific points on the fused cable and solder sleeve in order to determine when the solder sleeve has been fully melted. 
     Once the solder sleeve  12  has been fully melted on the cable  10 , the cable  10  may be popped up and out of the open-top funnel  170   b  (e.g., by a pneumatic lever that lifts the cable  10  upward or manually) and then retracted back toward the pallet  64  by the cable positioning mechanism  19  (e.g., drive wheel  16  and idler wheel  18  shown in  FIG.  4 B ) or manually. 
       FIGS.  16 A through  16 D  are diagrams showing a sleeve-cable assembly  1  at respective instances in time after a solder sleeve  12  has been melted on a cable  10 .  FIG.  16 A  shows the sleeve-cable assembly  1  after melting and before being lifted upward to be removed from the funnel  170  and funnel extensions  172 . In the situation depicted in  FIG.  16 A , the solder sleeve  12  is still located at the aforementioned repeatable position in a heating zone and the jacketed portion of the cable  10  (indicated by jacket  2 ) extends from the heating zone to the pallet  64 . The jacketed portion of the cable  10  passes through the nip between the drive wheel  16  and the idler wheel  18  (not visible in  FIG.  16 A ) and through the open-top funnel  170 . In this vertical position, the sleeve-cable assembly  1  would be unable to pass through the open-top funnel  170 , due to dimensional mismatch if the sleeve-cable assembly  1  were to be retracted due to the drive wheel  16  being rotated in a cable pulling direction (rightward in  FIG.  16 A ). 
     In accordance with the embodiment depicted in  FIG.  16 A , the solder sleeve installation module further includes a cable lifting mechanism  123  that includes a lever arm  122  that is extended/retracted by a linear actuator  124 . The linear actuator  124  may take the form of a pneumatic cylinder or a servo motor. In either case, the lever arm  122  includes a coupling  132  for attaching the lever arm to a distal end of a linearly vertically displaceable rod  133  of the linear actuator  124 . The distance between the lever arm  122  and the tip  173  of the funnel extension  172  should not be more than the length from the tip  10   b  of the cable wires  6  and  8  to the forward edge  12   a  of the solder sleeve  12 . In the state depicted in  FIG.  16 A , the lever arm  122  is retracted and not in contact with the cable  10 . Other lifting mechanisms could also be used to lift the sleeve-cable assembly  1  out of the prongs and then remove it from the solder sleeve installation module  52  or  54 . 
       FIG.  16 B  shows the cable lifting mechanism  123  after the lever arm  122  has been raised first to a vertical position whereat the lever arm  122  comes into contact with a portion of cable  10  and then to a higher vertical position whereby the contacted portion of the cable is lifted. While the cable portion in front of the open-top funnel  170  is being lifted, the portion of the cable  10  that is in the nip between the drive wheel  16  and idler wheel  18  stays in the nip at the same elevation. 
     Referring now to  FIG.  16 C , the opening formed in the open-top funnel  170  (not visible in  FIG.  16 B or  16 C ) is configured so that when the lever arm  122  lifts the cable  10  as shown in  FIG.  16 B , the solder sleeve  12  is now able to be retracted by rotating the drive wheel  16  in the cable pulling direction, as indicated by the arrow in  FIG.  16 C  parallel to the sleeve-cable assembly  1 .  FIG.  16 D  shows a later instant in time during passage of the solder sleeve  12  through the open-top funnel  170  as the cable  10  is retracted. The lever arm  122  and the tip of the funnel extension  172  are set up to ensure that the edge of the solder sleeve  12  that is closest to the prongs is able to clear the prongs without snagging when the cable  10  is lifted and removed. 
       FIG.  17    is a diagram representing a front view of a lever arm  122  of a cable lift mechanism  123  in accordance with one embodiment. The lever arm  122  includes a horizontal base  130  and a pair of vertical walls  126  and  128  extending upward from the side edges of the base  130 . The surfaces of the lever arm  122  should be smooth in order to permit the cable  10  to slide across the surface without excessive friction. There should be no sharp edges or rough surfaces that could potentially cause damage to the cable  10  or solder sleeve  12 . The design shown in  FIG.  17    includes raised sides in order to ensure that the cable  10  does not fall off of the cable lift mechanism  123  prematurely. The lever arm  122  may be made of plastic or metal. In other embodiments, the cable lifting mechanism  123  may be equipped with a magnetic device that would attract the metal parts in the cable and ensure the cable does not slip off of the cable lift mechanism  123 . 
       FIG.  18 A  is a diagram representing a top view of an open-top funnel  170  having a funnel extension  172  in accordance with one proposed implementation. The open-top funnel  170  has an opening  76  that extends from the entry side  134  of the funnel  170  to the exit side  136 .  136 . The funnel extension  172  in turn has an opening  77  extending the length of the funnel extension  172 . 
       FIG.  18 B  is a diagram representing a top view of the open-top funnel  170  depicted in  FIG.  18 A  with a sleeve-cable assembly  1  overlying and aligned with openings  76  and  77 . In this example, the jacket  2  has an outer diameter equal to or slightly less than the opening  77  in the funnel extension  172 , whereas the solder sleeve  12  has an outer diameter greater than the opening  77 . Thus the solder sleeve  12  cannot pass through the channel in funnel extension  172  and instead must be lifted and then passed over the opening  77 . 
     As seen in  FIG.  18 B , although the outer diameter of the solder sleeve  12  is also greater than the width of opening  76  at the exit side  136  of the open-top funnel, again the uplifted solder sleeve  12  may again pass over that obstacle. As the opening  76  widens in the cable pulling direction however, as some point the opening  76  becomes wider than the outer diameter of the solder sleeve  12 , which allows the solder sleeve  12  to pass through that portion of the open-top funnel  170 , thereby facilitating retraction of sleeve-cable assembly  1 . 
     An alternative funnel system design may use a “split funnel”.  FIG.  19 A  is a top view of a split funnel  171  in an open state;  FIG.  19 B  is a top view of split funnel  171  in a closed state. The split funnel  171  consists of two separable funnel halves  180   a  and  180   b . The split funnel  171  has an open state in which the first and second funnel halves  180   a  and  180   b  are separated by a gap and a closed state in which the first and second funnel halves  180   a  and  180   b  are in contact with each other. The funnel halves  180   a  and  180   b  may be closed as the cable  10  is fed into the system and later opened in order to remove and retract the cable  10 . If the funnels are split, they may remain closed until the solder sleeve installation. 
     In cases where split funnels  171  are employed, the solder sleeve installation apparatus further comprises an actuator (e.g., pneumatic cylinder  84  identified in  FIG.  5   ) for selectively moving one or both of the first and second funnel halves  180   a  and  180   b  to achieve a transition between the open and closed states, and a computer  162  (see  FIG.  5   ) configured to activate the actuator to move the first and second funnel halves  180   a  and  180   b  away from each other before activating the motor  72  to drive rotation of the drive wheel  16  in the cable pulling direction. 
       FIG.  20    is a flowchart identifying steps of a method  200  for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment. First, the system controller  100  sends information to the computer  162  controlling operation of the solder sleeve pick, place and melt module (step  202 ). The information includes which type of solder sleeve to pick and the orientation of the pigtail if one is to be attached to the sleeve. An example of a pigtail could be an insulated ground wire, or a ground braid strap, or any other wire that needs to be attached to the cable  10 . The solder sleeve type is used as a factor to determine which funnel of a set of funnels should be used to pass a cable through that solder shield. 
     In accordance with one proposed implementation, solder sleeves and dead end sleeves are separated by part number onto different vibration tables (not shown in the drawings). Vibration tables could be replaced with tape-and-reels or cartridges. The system controller  100  tells the robotic arm or gantry with the attached end effector  108  where to move based on the solder sleeve part number that is to be installed on a cable  10 . If the solder sleeve  12  is on a tape-and-reel or cartridge (not shown in the drawings), the solder sleeve  12  will be pushed out of the cavity (via pneumatic actuator, electric actuator, etc.) so that the end effector  108  can grip it. 
     Next the gantry/robot arm positions an end effector over the location of solder sleeves of the correct type (step  204 ). A pick-and-place vision system is used to assist the positioning of the end effector to pick up a solder sleeve in the correct orientation (step  206 ). When the end effector is properly positioned and oriented, the end effector is actuated to grip a solder sleeve (step  208 ). A verification step is performed to ensure the solder sleeve has been gripped and that the ground wire of the gripped solder sleeve is correctly oriented. A vision system can be used for such purposes. 
     The gantry/robot arm then moves the end effector so that the gripped solder sleeve is transported toward a vicinity of the corresponding funnel and then placed on the prongs of the funnel extensions (step  210 ). While the solder sleeve is seated on the prongs, the cable positioning mechanism at the solder sleeve installation module pushes the cable through the funnel and the solder sleeve (step  212 ). In certain embodiments, the cable is pushed through only a certain pre-specified length that has been calculated or is pre-programmed according to the application, wire type and shield trim characteristics. 
     The gantry/robot arm then moves the end effector to a repeatable position for processing (step  214 ) while holding the sleeve  12 . This position is such that the solder sleeve is centered over the exposed shield on the cable. In accordance with one embodiment, the exposed shield of the cable and the solder sleeve may be moved concurrently and at the same speed while the solder sleeve is already centered over the exposed shield. In accordance with other embodiments, the cable is fed through the funnel until the exposed shield of the cable arrives at the repeatable position and thereafter the end effector moves the solder sleeve off of the prongs to the repeatable position. In accordance with one proposed implementation, the respective repeatable positions of the solder sleeve and the exposed shield are such that the solder sleeve surrounds the entire exposed shield. The end effector is then actuated open to release the solder sleeve and then the gantry/robot arm is moved out of the way and possibly back to an origin position (step  216 ). 
     The heating tool is then moved into position within a heating zone of the solder sleeve and activated (step  218 ). The heating tool generates heat in the heating zone sufficient to melt the solder sleeve onto the cable. During the melting operation, the state of the solder sleeve is monitored using active dimensional analysis (step  220 ). For example, a laser scan micrometer may be used to measure the decreasing outer diameter of the solder sleeve. Once the solder sleeve is melted to the desired level, the heating process is stopped. This can be achieved by turning heating tool off and pulling it away from the cable (step  222 ). For example, when the laser measurement indicates that the outer diameter of the solder sleeve has reached a target value indicative of a state of fully melted or melted to a desired level, the heating process is stopped. This can be achieved by turning the heating tool, such as hot-air guns, off automatically. Then the cable is lifted at least partially out of the open-top funnel and then retracted out of the pick, place and melt module (step  224 ). In accordance with an alternative embodiment having split (not open-top) funnels, two funnel halves are opened to provide sufficient space for the sleeve-cable assembly  1  to be retracted. 
       FIG.  21    is a block diagram identifying some components of an automated system for picking, placing and melting a solder sleeve on a shielded cable in accordance with one embodiment. The computer  162  is programmed to send control signals to various electrically controlled valves  80  which may be opened to supply compressed air to pneumatic cylinders  84 ,  86  and  88  as previously described. The pneumatic cylinders  84 ,  86  and  88  may be used to move various components of the cable processing equipment  24 , such as funnel halves  180   a ,  180   b  and hot air guns  174   a ,  174   b . In alternative embodiments, the pneumatic cylinders may be replaced by electric motors. 
     Still referring to  FIG.  21   , the computer  162  communicates with a robot controller  98  via a suitable wired or wireless connection using a suitable communication protocol (e.g., Ethernet or Bluetooth). The robot controller  98  is a computer configured to control the operation of various robot motors  104  (via motor controllers  102 ) that move the gantry/robot arm  106  to achieve the previously described path for the end effector  108 . The robot controller  98  is also configured to control the gripping action of the end effector  108 . 
     The computer  162  also controls the temperature in the heating zone. More specifically, the computer  162  outputs heater power control signals that control the power supplied to the infrared heating tool  94 . The heater power control signals are sent by the computer  162  to a signal conditioner  90 , which in turn outputs conditioned heater power control signals to a heater power controller  92 . The heater power controller  92  is configured to convert conditioned heater power control signals to an output voltage which is used to power the infrared heating tool  94 . In accordance with one embodiment, the outer diameter of the solder sleeve  12  may be monitored during melting using a laser scan micrometer  96 . In response to measurement data from laser scan micrometer  96  indicating that the outer diameter of the shrinking solder sleeve has reached a target value, the computer  162  turns the infrared heating tool  94  off. 
     The system depicted in  FIG.  1    may be operated under the control of a system controller  150  (shown in  FIG.  22   ).  FIG.  22    is a flowchart identifying steps of a method  300  for controlling a system having a plurality of workstations for performing a sequence of operations for installing a solder sleeve  12  on an end of a cable  10  in accordance with one embodiment. The system controller  150  receives work packages and information  304  from a database  302  and also receives cable information  308  from static look-up tables  306 . The system controller  150  parses the data and uses the information to run the system. The cables to be processed may be intended for installation on an airplane or other vehicle or in other types of electrical systems. In the case of cables intended for installation on an airplane, the cables in a work package are organized by airplane effectivity, bundle number, wire type, and then group code. 
     An example of a work package is production data or information and may include the wire bundle that includes the identifying numbers of the cable to be processed by the system and the solder sleeve to be installed the overall cable length, to what equipment the cable will connect from and to, the cable type, the airplane effectivity, what type of airplane (program code), the wire bundle dash number, the wire gauge (this is the gauge of the wires in the cable), the bundle group code, and the termination code (designates what kind of contact or other termination is applied to the wires and shield of the cable). 
     Static look-up tables are used to configure the system parameters based on the parameters of a cable in the production file (work package). Examples of data stored in the static lookup tables include: the size of the dead end sleeve that fits the cable; the size and type of solder sleeve that fits the cable; an alternative size of solder sleeve that fits the cable if the primary solder sleeve size is out of stock or otherwise unavailable; the size of funnel that should be used to feed the cable into the solder sleeve pick, place and melt station; the wire colors that are present on the cable (to be sent to the vision inspection system after the shield is trimmed); the solder sleeve “fully installed” diameter, which is the value that is sent to the solder sleeve pick, place and melt station if active dimensional analysis is used to monitor the installation of a sleeve part; the strip length of the cable if a solder sleeve is to be installed (which is determined by both what equipment the cable is terminated to, as well as the termination type code); the strip length of the cable if a dead end sleeve is to be installed; and the orientation of the ground wire (pigtail) if a solder sleeve is installed. 
     The system controller  150  sends signals for controlling movements of the various components of the cable delivery system  60  or  61  (step  316 ). The system controller  150  also receives signals representing the states of the light gates from all modules (step  309 ). The system controller  150  also determines, derives or retrieves from a lookup table how far the cable positioning mechanism  19  should drive the cable  10  into each module based on cable strip length information. The cable strip length is used to calculate the length of the cable that needs to be driven into each module such that the cable is processed at the correct location. The system controller  150  sends control signals to the various motor controllers (or computer in command of the motor controller) to cause the motors to move based on signals received from the various light gates and the cable strip length (step  318 ). 
     Still referring to  FIG.  22   , cables are sent one at a time to the de-reeler module  32  to be cut and loaded onto the system. The system controller  150  sends cable type and length information to the de-reeler module  32  (step  320 ). The de-reeler module  32  de-reels a continuous length of cable of the specified type and then cuts the cable to the specified length. For each length of cable  10 , the laser marker  34  laser marks the outer jacket  2  of the cable  10  with pertinent information (bundle number, wire number, gauge). 
     In addition, the system controller  150  uses cable insulation information to select the appropriate laser setting and send it to the laser scoring module  40  (step  322 ). The system controller  150  also uses the cable type information to determine the correct type of solder sleeve or dead end sleeve and then sending commands to the solder sleeve installation modules  52  and  54  specifying which open-top funnel should be used (based on cable diameter) and where the solder sleeve  12  should be positioned after its removal from the prong (step  328 ). The same signals specifying which open-top funnel should be used are sent to the shield trimming module  44  (step  324 ). In addition, the system controller sends cable type information to the shield trim inspection module  46  (step  326 ). 
     The system controller  150  is also configured to monitor the system for errors. For example, the system controller  150  receives signals from the shield sensor in the jacket slug pulling module  42  (step  310 ). If the signal is not present, the system controller  150  issues an error alarm. Also, the system controller  150  receives image data from cameras at the shield trim inspection module  46 , which image data is processed using a pass/fail algorithm (step  312 ). In addition, the system controller  150  receives signals from the ground wire detection module  58  (step  314 ). If the signal is not present, the system controller  150  generates an error message. 
     While methods and apparatus for installing a sleeve on a cable have been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the teachings herein. In addition, many modifications may be made to adapt the teachings herein to a particular situation without departing from the scope thereof. Therefore it is intended that the claims not be limited to the particular embodiments disclosed herein. 
     The embodiments disclosed above use one or more computer systems. As used in the claims, the term “computer system” comprises a single processing or computing device or multiple processing or computing devices that communicate via wireline and/or wireless connections or over the cloud. Such processing or computing devices typically include one or more of the following: a processor, a computer, a controller, a central processing unit, a microcontroller, a reduced instruction set computer processor, an application-specific integrated circuit, a programmable logic circuit, a field-programmable gated array, a digital signal processor, and/or any other circuit or processing device capable of executing the functions described herein. For example, the control computer  162  and robot controller  98  identified in  FIG.  21    form a “computer system”. The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the term “computer system”. 
     The methods described herein may be encoded as executable instructions embodied in a non-transitory tangible computer-readable storage medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processing or computing system, cause the system device to perform at least a portion of the methods described herein. 
     The process claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order (any alphabetical ordering in the claims is used solely for the purpose of referencing previously recited steps) or in the order in which they are recited unless the claim language explicitly specifies or states conditions indicating a particular order in which some or all of those steps are performed. Nor should the process claims be construed to exclude any portions of two or more steps being performed concurrently or alternatingly unless the claim language explicitly states a condition that precludes such an interpretation.