Automatic cable forming system

Abstract

An automatic cable forming system incorporating an X-Y positioner for automatically laying a plurality of individual wires in a predetermined pattern to form a complex cable and including an array of individual spools each including a tensioning device to produce a predetermined tension on a wire as it is unspooled and to take up any slack in the wire. The system also includes a plurality of individual capstan pulleys each receiving an individual wire from one of the spools and with a single capstan drive for engaging one capstan pulley at a time for individually feeding the plurality of wires from the spools. The wires pass to a plurality of individual clamps for clamping the plurality of individual wires except the wire fed from the capstan pulley engaged by the capstan drive, and with a wire feed mechanism intermediate the capstan drive and the clamps for feeding the wires to a single wire head. The head is coupled to the X-Y positioner for receiving the wire fed from the capstan pulley engaged by the capstan drive for laying the wire in a predetermined pattern and with a single wire head individually receiving each one of the plurality of wires as each wire is fed from its capstan pulley for laying the plurality of wires in the predetermined pattern to form the complex cable. The wire head includes a roller to engage the wire feed mechanism to feed the wire through the wire head to have its end clamped by end clamps before laying the wire. The wire head also includes an internal clamp, a cutter and a wire presence sensor. The wire head also has a feed tube mounted on a rocker assembly.