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

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

Additionally, cutting of the cable braid is difficult because the cable braid is manufactured from a metal, braided material. Typically, a punch and die machine is used for cutting the cable braid where a die is inserted under the cable braid and a punch is closed around the cable braid and the die to cut the cable braid. Such machines are complex and expensive. Additionally, loading of the die between the cable braid and the inner insulator is difficult. The cable braid is typically flared outward, such as by hand, to create a space for the die, which is time consuming and may injure the operator.

The problem to be solved is to provide a cable preparation machine capable of preparing and cutting braid shields in a cost effective and reliable manner.

This problem is solved by a cable preparation machine according to claim <NUM>.

In one embodiment the cable preparation machine further comprising a pulley assembly rotatably coupled to a frame about the cable axis and a drive assembly operably coupled to the pulley assembly to rotate the pulley assembly about the cable axis, the blade assembly being operably coupled to the pulley assembly and rotated with the pulley assembly about the cable axis.

The arms are configured to position the braid blades in clearance positions, cutting positions, and pinching positions. The braid blades engage the cable braid in the pinching position; in the pinching position the braid blades are moved relative to the cutting positions. The braid blades may be moved to the pinching position after the cable braid is cut to hold the removed slugs of the cable braid while the cable is removed from the cable opening to discard the removed slugs from the end of the cable.

Alternatively, the braid blades may be moved to the pinching position to hold the cable braid as the mandrel is inserted onto the end of the cable. Furthermore the braid blades amy be moved to the pinching position to flare the cable braid outward prior to inserting the mandrel on to the end of the cable.

The arms of the cable preparation machine may be moved between a retracted position and an advanced position by rotating the blade assembly about the cable axis. The position of the arms may be electronically controlled to control a depth of cutting of the braid blades on the cable braid. The cutting force of the braid blades (<NUM>) against the cable braid (<NUM>) may be used to control the position of the arms (<NUM>).

The invention will now be described by way of example with reference to the accompanying drawings:.

<FIG> illustrates a cable preparation machine <NUM> in accordance with an exemplary embodiment. The cable preparation machine <NUM> includes a cable cutting device <NUM> configured to cut and remove one or more insulators from an end <NUM> of a cable <NUM>, such as an outer insulator <NUM> (for example, a cable jacket) and/or an inner insulator <NUM>, and configured to cut and remove a cable braid <NUM> from the end <NUM> of the cable <NUM>. The inner insulator <NUM> separates the cable braid <NUM> from an inner conductor <NUM> of the cable <NUM>. The cable braid <NUM> provides electrical shielding for the inner conductor <NUM>. The inner conductor <NUM> may be a solid core wire or a stranded wire. In an exemplary embodiment, the cable preparation machine <NUM> is configured to flare the cable braid <NUM>. Optionally, the cable preparation machine <NUM> may be configured to fold the cable braid <NUM> at the end of the cable <NUM>. The cable preparation machine <NUM> is able to prepare the end of the cable <NUM> without moving the cable <NUM> between machines. The cable cutting device <NUM> includes different blades for cutting the insulator(s) <NUM>, <NUM> and the cable braid <NUM> during different cable cutting steps within the cable preparation machine <NUM> without removing the cable <NUM> from the cable cutting zone of the cable cutting device <NUM>. The blades used for cutting the cable braid <NUM> may be used for flaring the end of the cable braid <NUM> prior to cutting. For example, the cable braid <NUM> is flared to insert a mandrel <NUM> between the cable braid <NUM> and the inner insulator <NUM> that is used for cutting the cable braid <NUM>. The end of the cable <NUM> may be processed and prepared quickly and efficiently using a single machine.

The cable preparation machine <NUM> includes a frame <NUM> supporting the various components of the cable preparation machine <NUM>. The frame <NUM> forms a cable preparation zone <NUM> where the end of the cable <NUM> is processed and prepared. For example, the cable cutting device <NUM> is located at the cable preparation zone <NUM>. The frame <NUM> includes a base <NUM> and support members <NUM> mounted to the base <NUM>. The support members <NUM> support various components of the cable preparation machine <NUM>, such as the cable cutting device <NUM> and the mandrel <NUM> used for cutting the cable braid <NUM>. In an exemplary embodiment, the frame <NUM> includes a cabinet <NUM> housing the cable cutting device <NUM> in a chamber <NUM> of the cabinet <NUM>. The cabinet <NUM> surrounds the cable cutting device <NUM> to prevent injury to the operator of the cable preparation machine <NUM>. The cabinet <NUM> includes one or more walls <NUM> surrounding the chamber <NUM>. Optionally, the cabinet <NUM> includes a door <NUM> for accessing the chamber <NUM>. In an exemplary embodiment, the cabinet <NUM> includes a cable opening <NUM> through one or more of the walls <NUM> to allow the cable <NUM> to be loaded into the chamber <NUM> to the cable preparation zone <NUM>. The mandrel <NUM> is rearward of the cabinet <NUM> and may extend into the cabinet <NUM>. In an exemplary embodiment, the mandrel <NUM> is axially aligned with the cable opening <NUM> and the cable preparation zone <NUM>; however, the mandrel <NUM> may be at other locations in alternative embodiments.

In an exemplary embodiment, the cable preparation machine <NUM> includes a cable holder <NUM> (shown in <FIG>) in the cabinet <NUM> that holds the cable <NUM> during the cable preparation process. For example, the cable holder <NUM> holds the cable <NUM> in the cable preparation zone <NUM> for removal of the insulator(s) <NUM>, <NUM> and the cable braid <NUM>. Optionally, the cable holder <NUM> is movable relative to the frame <NUM> to position the cable <NUM> in the cable preparation zone <NUM>. The cable <NUM> may be moved by the cable holder <NUM> axially forward or rearward within the cable preparation zone <NUM>, such as relative to the cable cutting device <NUM>, during the various cable preparation processes.

In an exemplary embodiment, the cable preparation machine <NUM> includes a braid manipulation device <NUM> configured to flare the cable braid <NUM> during processing of the end of the cable <NUM> and/or configured to fold the cable braid <NUM> backwards during processing of the end of the cable <NUM>. The cable cutting device <NUM> may form part of the braid manipulation device <NUM>. The mandrel <NUM> may form part of the braid manipulation device <NUM>. The cable holder <NUM> may form part of the braid manipulation device <NUM>.

Optionally, the cable preparation machine <NUM> may include a chute <NUM> for discarding the removed slugs of insulator(s) <NUM>, <NUM> and/or the removed slugs of cable braid <NUM> after being cut and removed from the end of the cable <NUM>. The chute <NUM> transfers the discarded slugs away from the cable preparation zone <NUM>.

<FIG> is a perspective view of a portion of the cable preparation machine <NUM> showing the cable cutting device <NUM> in accordance with an exemplary embodiment. <FIG> illustrates a base <NUM> and a support wall <NUM> of the frame <NUM> used to support the cable cutting device <NUM>. The support wall <NUM> of the frame <NUM> includes a cable opening <NUM> along a cable axis <NUM> at the cable preparation zone <NUM> that receives the end <NUM> of the cable <NUM> (shown in <FIG>).

The support wall <NUM> of the frame <NUM> includes drive openings <NUM> therethrough between a front <NUM> and a rear <NUM> of the support wall <NUM>. The drive openings <NUM> may be located generally on opposite sides of the cable opening <NUM>; however, other locations are possible in alternative embodiments, such as above and/or below the cable opening <NUM>.

The cable cutting device <NUM> includes a pulley assembly <NUM>, a drive assembly <NUM> and a blade assembly <NUM>. The pulley assembly <NUM> is rotatably coupled to the support wall <NUM> of the frame <NUM> about the cable axis <NUM>. The pulley assembly <NUM> is located forward of the front <NUM> of the support wall <NUM>. The drive assembly <NUM> is operably coupled to the pulley assembly <NUM> to rotate the pulley assembly <NUM> about the cable axis <NUM>. The blade assembly <NUM> is operably coupled to the pulley assembly <NUM> and is rotated with the pulley assembly <NUM> about the cable axis <NUM>. In an exemplary embodiment, the blade assembly <NUM> is configured to flare the end of the cable braid <NUM> prior to cutting off the end of the cable braid <NUM>. For example, various blades of the blade assembly <NUM> pinch against the cable braid <NUM> to flare outward the end of the cable braid <NUM>, such as to insert the mandrel <NUM> into the space between the cable braid <NUM> and the inner insulator <NUM>. In various embodiments, the blade assembly <NUM> is rotated clockwise and/or counterclockwise while pinching the end of the cable braid <NUM> to flare the end of the cable braid <NUM>. In various embodiments, the blade assembly <NUM> is translated relative to the end of the cable braid <NUM> (for example, the cable <NUM> is moved forward and/or rearward) to flare the end of the cable braid <NUM>. The translation may occur in addition to or in lieu of the rotation of the blade assembly <NUM> to flare the end of the cable braid <NUM>.

The blade assembly <NUM> is configured for cutting the insulator(s) <NUM>, <NUM> from the end <NUM> of the cable <NUM> in a first cutting configuration of the cable cutting device <NUM> when the cable <NUM> is positioned in the cable opening <NUM>. Optionally, the blade assembly <NUM> may be configured for removing the insulator slug that is removed from the cable <NUM>, such as by holding the insulator slug in the cable opening <NUM> as the cable <NUM> is drawn forward in the cable opening <NUM> until the insulator slug falls off the end of the cable <NUM>. The cable <NUM> may then be repositioned in the cable opening <NUM>, such as for removal of the cable braid <NUM> or manipulation of the cable braid <NUM>, such as flaring or folding of the cable braid <NUM>.

The blade assembly <NUM> is configured for cutting the cable braid <NUM> from the end <NUM> of the cable <NUM> in a second cutting configuration of the cable cutting device <NUM> when the cable <NUM> is positioned in the cable opening <NUM>. The drive assembly <NUM>, the pulley assembly <NUM> and the blade assembly <NUM> are operated differently in the second cutting configuration than the first cutting configuration. Optionally, the blade assembly <NUM> may be configured for removing the cable braid slug that is removed from the cable <NUM>, such as by holding the cable braid slug in the cable opening <NUM> as the cable <NUM> is drawn forward in the cable opening <NUM> until the cable braid slug falls off the end of the cable <NUM>. The cable <NUM> may then be repositioned in the cable opening <NUM>, such as for removal of the inner insulator <NUM> or manipulation of the cable braid <NUM>.

In an exemplary embodiment, the blade assembly <NUM> includes multiple blades <NUM> disposed about the cable axis <NUM>. For example, the blades <NUM> may triangulate the cable <NUM> within the cable opening <NUM> during the cutting operations to ensure that the cable <NUM> remains centered within the cable opening <NUM> for consistent cutting depth by the blades <NUM>. In an exemplary embodiment, the blade assembly <NUM> includes a plurality of insulation blades <NUM> configured for cutting the insulators <NUM>, <NUM> of the cable <NUM>. In an exemplary embodiment, the blade assembly <NUM> includes a plurality of braid blades <NUM> configured for cutting the cable braid <NUM> of the cable <NUM>. In an exemplary embodiment, the braid blades <NUM> are used to flare outward the end of the cable braid <NUM> during a braid manipulation process. In alternative embodiments, the blade assembly <NUM> may include blades other than cutting blades for manipulating and flaring the cable braid <NUM>. The braid blades <NUM> are different than the insulation blades <NUM> for cutting the hard metal cable braid <NUM> as opposed to cutting the soft plastic insulators <NUM>, <NUM>. In the illustrated embodiment, the insulation blades <NUM> are fixed blades having a razor-like or a knife-like cutting edge for cutting the insulators <NUM>, <NUM>. In the illustrated embodiment, the braid blades <NUM> are roller blades that have circular edges that spin during manipulation and cutting of the cable braid <NUM>. Other types of blades may be used for cutting the insulators <NUM>, <NUM> and/or the cable braid <NUM> in alternative embodiments.

In an exemplary embodiment, the pulley assembly <NUM> includes a front pulley <NUM> operably coupled to a first drive unit <NUM> of the drive assembly <NUM> and a rear pulley <NUM> operably coupled to a second drive unit <NUM> of the drive assembly <NUM>. The front pulley <NUM> is forward of the rear pulley <NUM> and both pulleys <NUM>, <NUM> are located forward of the front <NUM> of the support wall <NUM> of the frame <NUM>. The front pulley <NUM> is rotatable independent of and relative to the rear pulley <NUM>. For example, the first drive unit <NUM> may be operated independently of the second drive unit <NUM>. The first drive unit <NUM> may be operated to rotate the front pulley <NUM> in a forward direction and in a reverse direction. Similarly, the second drive unit <NUM> may be operated to rotate the rear pulley <NUM> in a forward direction and in a rearward direction. During operation, the front pulley <NUM> may be operated at a different rate than the rear pulley <NUM> or may be operated at the same rate as the rear pulley <NUM>. In certain operations, the front pulley <NUM> and the rear pulley <NUM> may be operated in different directions. In certain operations, the front pulley <NUM> or the rear pulley <NUM> may remain stationary while the other of the front pulley <NUM> or the rear pulley <NUM> may be operated in a forward direction or a rearward direction. When the front pulley <NUM> and the rear pulley <NUM> are operated at different speeds and/or in different directions, the pulley assembly <NUM> actuates the blade assembly <NUM>, such as for opening or closing the blades <NUM> around the cable <NUM>. The blades <NUM> are rotated with the pulley assembly <NUM> about the cable axis to circumscribe the cable <NUM> for cutting the cable <NUM>.

In the illustrated embodiment, the first drive unit <NUM> of the drive assembly <NUM> includes a first drive motor <NUM>, a first driveshaft <NUM>, a first drive pulley <NUM> and a first drive belt <NUM> coupled to the front pulley <NUM>. The drive motor <NUM> is located rearward of the support wall <NUM> and the drive pulley <NUM> is located forward of the support wall <NUM>. The driveshaft <NUM> passes through the drive opening <NUM>. The drive motor <NUM> rotates the driveshaft <NUM>, which rotates the drive pulley <NUM>. The drive motor <NUM> may be rotated in a forward direction or a reverse direction. As the drive pulley <NUM> is rotated, the drive belt <NUM> rotates the front pulley <NUM>. In various embodiments, the drive motor <NUM> may be a stepper motor. In other various embodiments, the drive motor <NUM> may be a servo motor. Other types of drivers may be used in alternative embodiments, such as a hydraulic driver, a pneumatic driver, or another type of drive unit. Other types of drive systems may be used in alternative embodiments. For example, rather than using the drive belt <NUM>, the drive pulley <NUM> may define a drive gear directly engaging the front pulley <NUM>.

In the illustrated embodiment, the second drive unit <NUM> of the drive assembly <NUM> includes a second drive motor <NUM>, a second driveshaft <NUM>, a second drive pulley <NUM> and a second drive belt <NUM> coupled to the rear pulley <NUM>. The drive motor <NUM> is located rearward of the support wall <NUM> and the drive pulley <NUM> is located forward of the support wall <NUM>. The driveshaft <NUM> passes through the drive opening <NUM>. The drive motor <NUM> rotates the driveshaft <NUM>, which rotates the drive pulley <NUM>. The drive motor <NUM> may be rotated in a forward direction or a reverse direction. As the drive pulley <NUM> is rotated, the drive belt <NUM> rotates the rear pulley <NUM>. In various embodiments, the drive motor <NUM> may be a stepper motor. In other various embodiments, the drive motor <NUM> may be a servo motor. Other types of drivers may be used in alternative embodiments, such as a hydraulic driver, a pneumatic driver, or another type of drive unit. Other types of drive systems may be used in alternative embodiments. For example, rather than using the drive belt <NUM>, the drive pulley <NUM> may define a drive gear directly engaging the rear pulley <NUM>.

The drive assembly <NUM> is operated to rotate the pulley assembly <NUM> about the cable axis <NUM>. The drive assembly <NUM> rotates the pulley assembly <NUM> in a first drive configuration to actuate the insulation blades <NUM>, such as to open or close the insulation blades <NUM> relative to the cable <NUM>. The first drive configuration is used for cutting the outer insulator <NUM> or the inner insulator <NUM> of the cable <NUM>. In an exemplary embodiment, when the drive assembly <NUM> is operated in the first drive configuration, the blade assembly <NUM> is operated in the first cutting configuration. The drive assembly <NUM> rotates the pulley assembly <NUM> in a second drive configuration to actuate the braid blades <NUM>, such as to open or close the braid blades <NUM> relative to the cable <NUM>. The second drive configuration is used for cutting the cable braid <NUM> of the cable <NUM>. In an exemplary embodiment, when the drive assembly <NUM> is operated in the second drive configuration, the blade assembly <NUM> is operated in the second cutting configuration. In an exemplary embodiment, the drive assembly <NUM> is operable in another drive configuration for driving the braid blades <NUM> to manipulate and flare the cable braid <NUM> during a braid flaring configuration of the blade assembly <NUM>. The insulation blades <NUM> and the braid blades <NUM> are rotatable with the pulley assembly <NUM> around the same cable axis <NUM>.

<FIG> is a front perspective view of the cable cutting device <NUM> in accordance with an exemplary embodiment. <FIG> is a front view of the cable cutting device <NUM> in accordance with an exemplary embodiment. The pulley assembly <NUM> includes a hub <NUM> received in the cable opening <NUM> of the support wall <NUM>. The hub <NUM> is hollow and configured to receive the end <NUM> of the cable <NUM> (shown in <FIG>). The front pulley <NUM> and the rear pulley <NUM> are rotatable on the hub <NUM>.

The rear pulley <NUM> includes arm actuation pins <NUM> extending forward from the rear pulley <NUM> into slots <NUM> in the front pulley <NUM>. The arm actuation pins <NUM> extend through the front pulley <NUM> to engage the blade assembly <NUM>. The arm actuation pins <NUM> actuate the blade assembly <NUM> during operation of the cable cutting device <NUM>. For example, as the front pulley <NUM> rotates relative to the rear pulley <NUM>, the arm actuation pin <NUM> engages the blade assembly <NUM> to actuate the blade assembly <NUM>. In various embodiments, when the front pulley <NUM> rotates faster than the rear pulley <NUM>, the blade assembly <NUM> is operated such that the braid blades <NUM> are actuated. Conversely, when the rear pulley <NUM> rotates faster than the front pulley <NUM>, the blade assembly <NUM> is operated such that the insulation blades <NUM> are actuated.

In an exemplary embodiment, the pulley assembly <NUM> has a normal position wherein the front pulley <NUM> is rotationally centered with respect to the rear pulley <NUM>. The front pulley <NUM> may include hard stop pins <NUM> extending forward of the front pulley <NUM> that engage the blade assembly <NUM> to position the blade assembly <NUM> in the normal position. The pulley assembly <NUM> may be operated to advance the insulation blades <NUM> from the normal position or may be operated to advance the braid blades <NUM> from the normal position. For example, relative rotation of the front pulley <NUM> with respect to the rear pulley <NUM> may cause the insulation blades <NUM> to advance or may cause the braid blades <NUM> to advance. The pulley assembly <NUM> may be operated to retract the insulation blades <NUM> to the normal position or may be operated to retract the braid blades <NUM> to the normal position. For example, relative rotation of the front pulley <NUM> with respect to the rear pulley <NUM> may cause the insulation blades <NUM> to retract or may cause the braid blades <NUM> to retract.

The blade assembly <NUM> includes arms <NUM> holding the blades <NUM>. The arms <NUM> are pivotably coupled to the front pulley <NUM> of the pulley assembly <NUM>. The arms <NUM> pivot relative to the front pulley <NUM> to open or close the corresponding blades <NUM>. In the illustrated embodiment, the arms <NUM> are arranged in sets, each set including a first arm <NUM> and a second arm <NUM>. The first arm <NUM> holds the corresponding insulation blades <NUM> for cutting the insulators <NUM>, <NUM> and the second arm <NUM> holds the corresponding braid blade <NUM> for cutting the cable braid <NUM>. In the illustrated embodiment, the blade assembly <NUM> includes three sets of the arms <NUM> with each set of arms <NUM> holding the corresponding insulation blade <NUM> and the corresponding braid blade <NUM>. For example, the blade assembly <NUM> includes three of the first arms <NUM> holding the insulation blades <NUM> and includes three of the second arms <NUM> holding the braid blades <NUM>. The three sets of arms <NUM>, <NUM> triangulate the blades <NUM> around the cable opening <NUM>. Greater or fewer sets of arms <NUM>, <NUM> may be provided in alternative embodiments. In other alternative embodiments, rather than sets of arms <NUM>, <NUM>, the blade assembly <NUM> may be provided with single arms <NUM> that each holds an insulation blade <NUM> and a braid blade <NUM>. Forward rotation of such arms <NUM> may actuate the insulation blade <NUM> for cutting the insulators <NUM>, <NUM>, whereas rearward rotation of such arms <NUM> may actuate the braid blade <NUM> for cutting the cable braid <NUM>.

The arms <NUM> are pivotably coupled to the front pulley <NUM> by an arm pivot pin <NUM>. The arms <NUM> are pivoted relative to the front pulley <NUM> of the pulley assembly <NUM> to change a cutting depth of the corresponding blade <NUM> (for example, the insulation blade <NUM> or the braid blade <NUM>). For example, the relative movement (for example, angular position) of the front pulley <NUM> relative to the rear pulley <NUM> determines the amount of pivot of the arm <NUM>, and thus the location of the blade <NUM> relative to the cable opening <NUM> to control the position of the blade <NUM>. The cable cutting device <NUM> may accommodate cables <NUM> of various diameters by changing the cutting depth of the blades <NUM>. In an exemplary embodiment, the arm pivot pin <NUM> is offset from the arm actuation pin <NUM>. When the arm actuation pin <NUM> engages and drives against the arm <NUM>, the arm <NUM> is pivoted about the arm pivot pin <NUM> to close the blade <NUM> for cutting the cable <NUM>.

The arm actuation pin <NUM> causes the arm <NUM> to pivot when the front pulley <NUM> is rotated at a different rate than the rear pulley <NUM>. For example, in a first drive configuration, the front pulley <NUM> is rotated at a faster rate than the rear pulley <NUM> to actuate the blade assembly <NUM>. For example, depending on the location of the arm actuation pin <NUM> in the slot <NUM>, the pulley assembly <NUM> may be used to advance the insulation blade <NUM> from the normal position for closing the insulation blade <NUM> on the cable <NUM> for cutting/manipulating the insulator <NUM> or <NUM> or may be used to retract (for example, open) the braid blade <NUM> from a closed position back to the normal position in the first drive configuration. In a second drive configuration, the rear pulley <NUM> is rotated at a faster rate than the front pulley <NUM> to actuate the blade assembly <NUM>. For example, depending on the location of the arm actuation pin <NUM> and the slot <NUM>, the pulley assembly <NUM> may be used to advance the braid blade <NUM> from the normal position for closing the braid blade <NUM> on the cable <NUM> for cutting/manipulating/flaring the cable braid <NUM> or may be used to retract (for example, open) the insulation blade <NUM> from a closed position back to the normal position in the second drive configuration. In a third drive configuration, the front pulley <NUM> and the rear pulley <NUM> are rotated at the same rate. In the third drive configuration, the arm <NUM> remains stationary relative to the front pulley <NUM> and thus does not open or close when the front pulley <NUM> is rotated at the same speed as the rear pulley <NUM>. The blade <NUM> may be held at a constant depth and rotated with the front pulley <NUM> when the front pulley <NUM> and the rear pulley <NUM> are rotated at the same speed.

In an exemplary embodiment, each arm <NUM> is coupled to an arm return spring <NUM>. The arm return spring <NUM> biases the arm <NUM> to an open position. As the arm actuation pin <NUM> is retracted, the arm return spring <NUM> opens or returns the arm <NUM> to the normal position against the hard stop pin <NUM>. The hard stop pin <NUM> holds the arm <NUM> in the normal position. The arm return spring <NUM> returns the arm <NUM> to a position where the arm <NUM> engages the hard stop pin <NUM>, defining the normal position. The arm <NUM> is unable to open further than the normal position because the arm <NUM> bottoms out against the hard stop pin <NUM>. In the illustrated embodiment, each set of arms <NUM> includes a corresponding arm return spring <NUM> coupled between the first arm <NUM> and the second arm <NUM> of the set of arms.

In operation, when the front pulley <NUM> is rotated in a first direction, the arm actuation pin <NUM> presses against the first arm <NUM> to actuate the first arm <NUM> and close the insulation blades <NUM> around the cable <NUM>. The hard stop pins <NUM> hold the second arms <NUM> in the normal position. The arm return spring <NUM> is stretched as the first arm <NUM> pivots away from the second arm <NUM>. When the front pulley <NUM> is rotated in an opposite second direction, the arm actuation pin <NUM> moves back toward the second arm <NUM> and the arm return spring <NUM> returns the first arm <NUM> to the normal position where the first arm <NUM> abuts against the hard stop pin <NUM>. Further rotation of the front pulley <NUM> in the second direction causes the arm actuation pin <NUM> to press against the second arm <NUM> to actuate the second arm <NUM> and close the braid blades <NUM> around the cable <NUM>. The hard stop pins <NUM> hold the first arms <NUM> in the normal position. The arm return spring <NUM> is stretched as the second arm <NUM> pivots away from the first arm <NUM>. When the front pulley <NUM> is rotated in the opposite first direction, the arm actuation pin <NUM> moves back toward the first arm <NUM> and the arm return spring <NUM> returns the second arm <NUM> to the normal position where the second arm <NUM> abuts against the hard stop pin <NUM>.

In an exemplary embodiment, each arm <NUM> includes a body <NUM> extending between a first side <NUM> and a second side <NUM>. The body <NUM> extends between an inner end <NUM> and an outer end <NUM>. The first sides <NUM> of the first and second arms <NUM>, <NUM> face each other. The first sides <NUM> face the hard stop pins <NUM> and the arm actuation pins <NUM>. In the normal positions, the first sides <NUM> abut against the hard stop pins <NUM>. In the illustrated embodiment, the arm pivot pin <NUM> is located proximate to the first side <NUM> and proximate to the inner end <NUM>. Other locations are possible in alternative embodiments. In the illustrated embodiment, the arm return spring <NUM> is located proximate to the outer end <NUM>. Other locations are possible in alternative embodiments. The arm return springs <NUM> may be coupled to the front pulley <NUM> rather than between the arms <NUM> in alternative embodiments. In the illustrated embodiment, the arm actuation pin <NUM> engages the first sides <NUM> of the first and second arms <NUM>, <NUM> proximate to the outer ends <NUM>. Other locations are possible in alternative embodiments. In the illustrated embodiment, the insulation blade <NUM> is mounted to the first arm <NUM> proximate to the second side <NUM> at the inner end <NUM>. The insulation blade <NUM> extends inward from the inner end <NUM>. When the first arm <NUM> is pivoted, the cutting edge of the insulation blade <NUM> is closed inward toward the cable opening <NUM> to engage and cut the cable <NUM>. In the illustrated embodiment, the braid blade <NUM> is mounted to the second arm <NUM> proximate to the second side <NUM> at the inner end <NUM>. The braid blade <NUM> extends inward from the inner end <NUM>. When the second arm <NUM> is pivoted, the cutting edge of the braid blade <NUM> is closed inward toward the cable opening <NUM> to engage and cut the cable <NUM>.

In an alternative embodiment, rather than having first and second arms <NUM>, <NUM>, the blade assembly <NUM> may include single arms <NUM> each holding one of the insulation blades <NUM> and one of the braid blades <NUM>. For example, rather than having the arms <NUM> split down the middle at the location of the hard stop pins <NUM> and the arm actuation pins <NUM>, the first and second arms <NUM>, <NUM> may be part of a single unitary body having a pocket or opening that receives the arm actuation pin <NUM>. When the single arm is pivoted in the first direction, the insulation blade <NUM> is moved closer to the cable opening <NUM> to close the insulation blade <NUM> on the cable <NUM> and the braid blade <NUM> is moved further from the cable opening <NUM>. When the single arm is pivoted in the second direction, the braid blade <NUM> is moved closer to the cable opening <NUM> to close the braid blade <NUM> on the cable <NUM> and the insulation blade <NUM> is moved further from the cable opening <NUM>.

In an exemplary embodiment, the drive assembly <NUM> includes a position sensor assembly for sensing a rotational position of the pulley assembly <NUM>. For example, the position sensor assembly includes a fixed position sensor <NUM> and a rotating position sensor <NUM>. In the illustrated embodiment, the rotating position sensor <NUM> is fixed to the front pulley <NUM> and rotates relative to the fixed position sensor <NUM> with the front pulley <NUM>. The fixed position sensor <NUM> senses a rotational position of the front pulley <NUM> based on the location of the rotating position sensor <NUM>. For example, the fixed position sensor <NUM> may be a proximity sensor. Optionally, the rear pulley <NUM> may additionally or alternatively hold the rotating position sensor <NUM> to sense a position of the rear pulley <NUM>. Other types of position sensors may be used to determine the rotational positions of the front pulley <NUM> and/or the rear pulley <NUM>. In other various embodiments, the drive motors <NUM>, <NUM> may be servo motors having internal position sensors for determining rotational positions of the drive units <NUM>, <NUM> to determine the corresponding rotational positions of the front and rear pulleys <NUM>, <NUM>.

<FIG> is a partial sectional view of a portion of the cable preparation machine <NUM> showing the cable cutting device <NUM>, the cable holder <NUM> and the mandrel <NUM>. The mandrel <NUM> is configured to be inserted onto the end of the cable <NUM> for cutting the cable braid <NUM>. For example, the mandrel <NUM> may be inserted between the cable braid <NUM> and the inner insulator <NUM> after the cable braid <NUM> is flared outward. The mandrel <NUM> is hollow and receives the inner insulator <NUM> and the inner conductor <NUM>. The mandrel <NUM> includes an outer surface <NUM> and an inner surface <NUM> that receives the inner insulator <NUM>. In an exemplary embodiment, an edge <NUM> of the mandrel <NUM> is chamfered to aide in inserting the mandrel <NUM> in the gap between the inner insulator <NUM> and the cable braid <NUM>. For example, the mandrel <NUM> may be chamfered at the inner surface <NUM> and/or the outer surface <NUM>.

The outer surface <NUM> of the mandrel <NUM> provides a hard surface for supporting the cable braid <NUM> during the cutting operation. For example, the braid blades <NUM> may press inward during cutting the cable braid <NUM> against the mandrel <NUM> to cut through the strands of the cable braid <NUM>. Optionally, the mandrel <NUM> includes a shear feature <NUM> that aides in cutting the strands of the cable braid <NUM>. For example, the shear feature <NUM> may be a groove around the outer surface <NUM> of the mandrel <NUM>. The groove has an edge used to shear the strands of the cable braid <NUM> during the cutting process.

In an exemplary embodiment, the mandrel <NUM> is operably coupled to a carriage <NUM> that moves the mandrel <NUM> relative to the cable opening <NUM>. The carriage <NUM> slides the mandrel <NUM> forward and rearward along the cable axis <NUM> during operation. For example, after the cable braid <NUM> is flared outward, the mandrel <NUM> is moved forward onto the end <NUM> of the cable <NUM>. The inner insulator <NUM> is loaded into the hollow core of the mandrel <NUM>. Once the mandrel <NUM> is positioned under the cable braid <NUM>, the blade assembly <NUM> is used to cut the cable braid <NUM> against the outer surface <NUM> of the mandrel <NUM>. The mandrel <NUM> may be moved rearward after the end of the cable braid <NUM> is cut off. Optionally, the rearward movement of the mandrel <NUM> may be coordinated to remove or discard the removed slug of the cable braid <NUM>. The mandrel <NUM> may be coupled to the end of the cable <NUM> by other devices or by other movements in alternative embodiments and is not necessarily movable along the cable axis <NUM> in alternative embodiments.

The cable holder <NUM> includes a chuck <NUM> for holding the cable <NUM>. The cable holder <NUM> includes a slide <NUM> from moving the chuck <NUM> toward and away from the cable cutting device <NUM>. Once the cable <NUM> is secured in the chuck <NUM>, the slide <NUM> moves the end <NUM> of the cable <NUM> into the cable opening <NUM> at the cable preparation zone <NUM>. In an exemplary embodiment, the cable holder <NUM> may move the cable <NUM> while the cable cutting device <NUM> is being operated. For example, the cable <NUM> may be moved forward or rearward while the cable cutting device <NUM> rotates the blade assembly <NUM> around the cable axis <NUM>. The cable cutting device <NUM> may be operated with the cable <NUM> remaining in the cable opening <NUM> to remove the various layers of the cable <NUM> to prepare the end of the cable <NUM>. For example, the cable cutting device <NUM> is configured to remove a portion of the outer insulator <NUM>, a portion of the cable braid <NUM> and a portion of the inner insulator <NUM> to expose the inner conductor <NUM> and to expose the cable braid <NUM> for termination of the cable <NUM> to another component. The cable cutting device <NUM> is able to remove each of the layers of the cable <NUM> without removing the cable <NUM> from the cable preparation machine <NUM>. A single cable preparation machine <NUM> is able to perform multiple processing steps using the cable cutting device <NUM>. Because the cable cutting device <NUM> includes two different types of the blades <NUM>, such as the insulation blades <NUM> and the braid blades <NUM>, the cable cutting device <NUM> is able to process the cable <NUM> in a cost effective and reliable manner without the need for multiple machines or time-consuming transferring of the cable <NUM> between different machines.

<FIG> illustrates the end <NUM> of the cable <NUM> showing an end <NUM> of the cable braid <NUM> flared outward. A gap <NUM> is formed between the end <NUM> of the cable braid <NUM> and the inner insulator <NUM> area the mandrel <NUM> is configured to be received in the gap <NUM> during processing of the cable <NUM>. The strands of the cable braid <NUM> are spread apart to flare the end <NUM> of the cable braid <NUM>. In an exemplary embodiment, the cable braid <NUM> is pinched inward by the braid blades <NUM> (shown in <FIG>) against the inner insulator <NUM> to flare the end <NUM> of the cable braid <NUM>. Optionally, the braid blades <NUM> may be rotated about the cable braid <NUM> while pinching inward to flare the end <NUM> of the cable braid <NUM>. The braid blades <NUM> may be rotated clockwise and/or counterclockwise to flare the end <NUM> of the cable braid <NUM>. Optionally, the cable <NUM> may be translated along the cable axis while the braid blades <NUM> are pinching inward on the cable braid <NUM> to flare the end <NUM> of the cable braid <NUM>. The translation of the cable <NUM> may occur while rotating the braid blades <NUM> about the cable braid <NUM>.

<FIG> illustrate various processing steps for cutting the end <NUM> of the cable braid <NUM>. <FIG> illustrates the braid blades <NUM> flaring the end <NUM> of the cable braid <NUM>. <FIG> illustrates the mandrel <NUM> being inserted onto the end <NUM> of the cable <NUM> with the braid blades <NUM> holding the cable braid <NUM>. <FIG> illustrates the mandrel <NUM> being inserted onto the end <NUM> of the cable <NUM> with the braid blades <NUM> spaced apart from the cable braid <NUM>. <FIG> illustrates the mandrel <NUM> partially inserted onto the end <NUM> of the cable <NUM>. <FIG> illustrates the mandrel <NUM> fully inserted onto the end <NUM> of the cable <NUM>. <FIG> illustrates the braid blades <NUM> cutting the cable braid <NUM>. <FIG> illustrates the cut slug of the cable braid <NUM> partially removed from the end of the cable <NUM>. <FIG> illustrates the cut slug of the cable braid <NUM> partially removed from the end of the cable <NUM>. <FIG> illustrates the cut slug of the cable braid <NUM> removed from the end of the cable <NUM>. <FIG> illustrates the cut slug of the cable braid <NUM> discarded from the end of the cable <NUM>.

During the cable flaring operation (<FIG>), the blade assembly <NUM> is used to flare the end <NUM> of the cable braid <NUM>. The braid blades <NUM> pinch inward on the cable braid <NUM> to flare the cable braid <NUM>. Optionally, the blade assembly <NUM> may be rotated about the cable axis <NUM> to cause the strands of the cable braid <NUM> to separate and further flare outward. In an exemplary embodiment, the cable <NUM> may be translated rearward to lengthen the end <NUM> of the cable braid <NUM> that is flared, which increases the diameter of the flare of the cable braid <NUM>.

After the cable braid <NUM> is flared outward, the mandrel <NUM> is loaded (<FIG>) onto the end of the cable <NUM> in the gap <NUM> between the cable braid <NUM> and the inner insulator <NUM>. In an exemplary embodiment, the braid blades <NUM> are moved to pinching positions where the braid blades <NUM> engage the cable braid <NUM> when the mandrel <NUM> is initially loaded into the gap <NUM>. For example, the braid blades <NUM> may pinch against the cable braid <NUM> to hold the cable braid <NUM> from being pushed rearward as the mandrel <NUM> is loaded into the gap <NUM>. Optionally, the braid blades <NUM> may engage the cable braid <NUM> at the base of the flared section. Alternatively, the braid blades <NUM> may engage the cable braid <NUM> along the flared section. In an exemplary embodiment, after the mandrel <NUM> is initially loaded onto the end of the cable <NUM> in the gap <NUM>, the braid blades <NUM> are retracted away from the cable braid <NUM> to clearance positions (<FIG>) to provide clearance and allow the mandrel <NUM> to be further advanced onto the end of the cable <NUM>. For example, the mandrel <NUM> may be advanced beyond the base of the flared section to a fully loaded position.

<FIG> illustrates the mandrel <NUM> advanced forward of the braid blades <NUM> on the end of the cable <NUM>. The flared section provides a funneled area of the cable braid <NUM> that allows the mandrel <NUM> to be initially loaded into the gap <NUM>. Once the mandrel <NUM> is loaded forward of the end of the cable braid <NUM>, the mandrel <NUM> may be pushed onto the end of the cable <NUM> between the cable braid <NUM> and the inner insulator <NUM> to force the cable braid <NUM> outward for loading the mandrel <NUM> onto the cable <NUM>. In an exemplary embodiment, the braid blades <NUM> may engage the flared section of the cable braid <NUM> to support and hold the flared section of the cable braid <NUM> is the mandrel <NUM> is loaded into the gap <NUM>. Optionally, the cable <NUM> may additionally or alternatively be moved relative to the mandrel <NUM> and the braid blades <NUM>, such as in a rearward direction (<FIG>). Rearward movement of the cable <NUM> has the same effect as moving the mandrel <NUM> forward to further pack the mandrel <NUM> into the gap <NUM>.

Once the mandrel <NUM> is positioned relative to the cable <NUM>, the cable cutting device <NUM> is used to cut the cable braid <NUM>. The braid blades <NUM> are closed around the cable braid <NUM> to cutting positions (<FIG>). For example, the arms <NUM> are pivoted to the advanced positions to close the braid blades <NUM> around the cable braid <NUM>. In the cutting positions, the braid blades <NUM> press against the cable braid <NUM> such that the cable braid <NUM> may be cut against the mandrel <NUM>. The shear feature <NUM> cooperates with the braid blades <NUM> to cut the cable braid <NUM>. The arms <NUM> may be moved between the retracted positions and the advanced positions by rotating the blade assembly <NUM> about the cable axis <NUM> onto the cable braid <NUM>. Optionally, the positioning of the arms <NUM> is electronically controlled to control a depth of cutting of the braid blades <NUM> on the cable braid <NUM>. For example, the drive assembly <NUM> may be used to electronically control the pulley assembly <NUM> to control the positions of the arms <NUM>, and thus the depth of cutting of the braid blades <NUM>. In other various embodiments, the positioning of the arms <NUM> may be controlled based on cutting force of the braid blades <NUM> against the cable braid <NUM>. For example, sensors may be provided within the system to measure the force of the braid blades <NUM> on the cable braid <NUM>. The arms <NUM> may be advanced until a predetermined force of the braid blades <NUM> against the cable braid <NUM> is achieved. The blade assembly <NUM> is configured to cut the cable braids <NUM> of different diameter cables <NUM> by controlling the depths of the braid blades <NUM> at the advanced positions. In an exemplary embodiment, different diameter mandrels correspond to the different diameter cables. When a different diameter cable is used, the mandrel <NUM> may be replaced with a different diameter mandrel <NUM> for loading onto the end of the different diameter cable.

After the cable braid <NUM> is cut, the end <NUM> of the cable braid <NUM> forms a removable slug <NUM> configured to be removed from the end of the cable <NUM> (<FIG>). The cable <NUM> may be moved forward to separate the slug <NUM> from the cable braid <NUM>. Optionally, the mandrel <NUM> may be moved forward with the cable <NUM> to position the removable slug <NUM> relative to the mandrel <NUM>. In various embodiments, the braid blades <NUM> may be held in pinching positions (<FIG>) on the removable slug <NUM> to hold the removable slug as the cable <NUM> is moved forward. For example, in the removable slug <NUM> may be pinched against the mandrel <NUM> as the cable <NUM> is moved forward.

Claim 1:
A cable preparation machine (<NUM>) comprising:
a frame (<NUM>) forming a cable preparation zone (<NUM>), the frame having a cable opening (<NUM>) configured to receive an end (<NUM>) of a cable (<NUM>) therein along a cable axis (<NUM>) wherein the cable (<NUM>) comprises a cable insulator (<NUM>, <NUM>) and a cable braid (<NUM>);
a drive assembly (<NUM>) operable in a first drive configuration and a second drive configuration; and
a blade assembly (<NUM>) comprising a plurality of arms (<NUM>) and cutting blades mounted to the corresponding arms (<NUM>), the blade assembly being operably coupled to the drive assembly (<NUM>) and such that the blade assembly (<NUM>) is rotated about the cable axis (<NUM>); and
a mandrel (<NUM>) coupleable to the end (<NUM>) of the cable between the cable braid (<NUM>) and an inner insulator (<NUM>) of the cable to provide a hard surface for supporting the cable braid during the cutting operation, the mandrel (<NUM>) is operably coupled to a carriage (<NUM>) that moves the mandrel (<NUM>) relative to the cable opening; the carriage (<NUM>) slides the mandrel (<NUM>) forward and rearward along the cable axis (<NUM>) during operation and the mandrel (<NUM>) includes a shear feature (<NUM>) defined by an outer surface of the mandrel;
wherein each arm (<NUM>) comprises an insulation blade (<NUM>) configured to cut the insulation (<NUM>, <NUM>) of cable (<NUM>) and a braid blade (<NUM>) configured to cut the braid (<NUM>) of cable (<NUM>) wherein when the cable is positioned in the cable opening and the drive assembly (<NUM>) is operated in a first drive configuration, the insulation
blades (<NUM>) are actuated thereby to cut the insulation (<NUM>, <NUM>) from the cable (<NUM>) and when the drive assembly (<NUM>) is operated in a second drive configuration, the braid blades (<NUM>) are actuated thereby to cut braid (<NUM>) from the cable (<NUM>) wherein the braid blades (<NUM>) have edges configured to engage a cable braid (<NUM>) of the cable to cut the cable braid, and wherein when the drive assembly (<NUM>) is operated in a second drive configuration the edges (<NUM>) of the braid blades (<NUM>) are configured to close towards the shear feature (<NUM>) to cut the cable braid (<NUM>) between the braid blade (<NUM>) and the shear feature (<NUM>).