WO2025104547A1

WO2025104547A1 - Cutting apparatus for cutting a cable jacket, and related methods

Info

Publication number: WO2025104547A1
Application number: PCT/IB2024/060973
Authority: WO
Inventors: Patrick LESSARD; Fajar Setio ADRI PUTRO
Original assignee: GSI Electronique Inc
Current assignee: GSI Electronique Inc
Priority date: 2023-11-15
Filing date: 2024-11-06
Publication date: 2025-05-22
Anticipated expiration: 2026-05-15

Abstract

A cutting apparatus may include a base supporting a base cutting element defining a cutout area. A device may include a middle plate movably connected to the base in a longitudinal direction, the middle plate supporting a middle plate cutting element aligned with the base cutting element. A device may include a pusher movably connected to at least one of the base and the middle plate and configured to move longitudinally at least partially through the cutout area in the longitudinal direction.

Description

TITLE

CUTTING APPARATUS FOR CUTTING A CABLE JACKET, AND RELATED METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 63/599,081, filed November 15, 2023, the disclosure of which is hereby incorporated herein in its entirety by this reference.

FIELD

[0002] Embodiments of the present disclosure relate generally to a cutting apparatus for providing a cutout through a cable jacket to suspend a sensor therein, and to related methods.

BACKGROUND

[0003] Commodity monitoring systems include sensors suspended within a container of the commodity to measure one or more properties of the commodity and/or a storage environment of the commodity. Reliable and robust support of the sensors in the container volume is needed to ensure precise and accurate measurements.

BRIEF SUMMARY

[0004] In some embodiments, a cutting apparatus for cutting a cable jacket, includes a base supporting a base cutting element defining a cutout area; a middle plate movably connected to the base in a longitudinal direction, the middle plate supporting a middle plate cutting element aligned with the base cutting element; and a pusher movably connected to at least one of the base and the middle plate and configured to move longitudinally at least partially through the cutout area in the longitudinal direction.

[0005] In some embodiments, the pusher has a transverse area that is complementary to the cutout area.

[0006] In some embodiments, the pusher is at least partially concave in the longitudinal direction. [0007] In some embodiments, the pusher is peaked in a transverse direction perpendicular to the longitudinal direction.

[0008] In some embodiments, an edge of the pusher is at least partially peaked in a transverse direction.

[0009] In some embodiments, the cutting apparatus further includes a handle configured to release a top plate supporting the pusher wherein the pusher is released and moveable in the longitudinal direction relative to the middle plate when the handle is in an unlocked position.

[0010] In some embodiments, at least one of the base cutting element and the middle plate cutting element includes a plurality of knives.

[0011] In some embodiments, the plurality of knives has a plurality of leading-edge heights in the longitudinal direction.

[0012] In some embodiments, the cutout area is rectangular.

[0013] In some embodiments, at least one of the base cutting element and the middle plate cutting element has a flat inner surface and a beveled outer surface.

[0014] In some embodiments, the flat inner surface is substantially parallel to the longitudinal direction.

[0015] In some embodiments, a method of cutting a cutout in a cable jacket includes positioning a cable assembly including a first cable core and a second cable core encased in a cable jacket in a cutting apparatus; moving a middle plate cutting element toward a base cutting element in a longitudinal direction; at least partially cutting the cutout through the cable jacket and between the first cable core and the second cable core; pushing a cutout blank in the longitudinal direction out of the cutout; and after pushing the cutout blank, moving the cable assembly relative to the cutting apparatus.

[0016] In some embodiments, cutting the cutout through the cable jacket exposes at least one of the first cable core and the second cable core.

[0017] In some embodiments, cutting the cutout through the cable jacket exposes the first cable core and the second cable core. [0018] In some embodiments, moving the middle plate cutting element toward the base cutting element includes moving a pusher toward the base cutting element.

[0019] In some embodiments, a method of configuring a sensor array includes positioning a cable assembly including a first cable core and a second cable core encased in a cable jacket in a cutting apparatus; moving a middle plate cutting element toward a base cutting element in a longitudinal direction; at least partially cutting a cutout through the cable jacket and between the first cable core and the second cable core; pushing a cutout blank in the longitudinal direction out of the cutout; and installing a sensor in the cutout.

[0020] In some embodiments, installing a sensor in the cutout includes installing the sensor in the cutout such that an exterior surface of the sensor is flush with an outer surface of the cable jacket.

[0021] In some embodiments, installing the sensor in the cutout includes contacting the first cable core with the sensor.

[0022] In some embodiments, installing the sensor in the cutout includes contacting the second cable core with the sensor.

[0023] In some embodiments, installing the sensor in the cutout includes installing one or more of a level sensor, a gas sensor, a temperature sensor, and a humidity sensor in the cutout.

[0024] In some embodiments, installing the sensor in the cutout includes installing a level sensor in the cutout.

[0025] Some embodiments include a cutting apparatus for forming an aperture within a cable and between two conductors within the cable, the apparatus comprising: a base cutting element defining a cutout area and comprising a first plurality of knives; a middle cutting element vertically aligned with the base cutting element and comprising a second plurality of knives; and a pusher operably coupled to at least one of the base cutting element or the middle cutting element and comprising a cross-sectional area within a horizontal plane at least substantially equal to or smaller than a cross-sectional area of the cutout area within the horizontal plane.

[0026] The pusher may include a transverse area that is complementary to the cutout area.

[0027] The pusher may include an at least partially concave longitudinal tip. [0028] The pusher may include a peaked tip.

[0029] The cutting apparatus may include a handle configured to release a top plate supporting the pusher wherein the pusher is released and moveable vertical direction relative to the middle cutting element when the handle is in an unlocked position.

[0030] The first plurality of knives may include a plurality of leading-edge heights in a vertical direction.

[0031] The second plurality of knives may include a plurality of leading-edge heights in the vertical direction.

[0032] At least one of the base cutting element and the middle plate cutting element may include a flat inner surface and a beveled outer surface.

[0033] One or more embodiments include a cutting apparatus for forming an aperture within a cable and between two conductors within the cable, the apparatus comprising: a first cutting element defining a first interior channel and comprising a first plurality of knives; a second cutting element defining a second interior channel and comprising a second plurality of knives; and a pusher oriented within the first interior channel of the first cutting element and configured to extend out of the first interior channel of the first cutting element and into the second interior channel of the second cutting element during a cutting process.

[0034] Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.

[0035] Within the scope of this application, it should be understood that the various aspects, embodiments, examples and alternatives set out herein, and individual features thereof may be taken independently or in any possible and compatible combination. Where features are described with reference to a single aspect or embodiment, it should be understood that such features are applicable to all aspects and embodiments unless otherwise stated or where such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages may be more readily ascertained from the following description of example embodiments when read in conjunction with the accompanying drawings, in which:

[0037] FIG. 1 is a schematic diagram of an environment in which a commodity monitoring system may operate, according to one or more embodiments of the present disclosure.

[0038] FIG. 2A is a perspective view of a cutting apparatus that may be used to cut a cutout in a cable, according to one or more embodiments of the present disclosure.

[0039] FIG. 2B is a side cross-sectional view of a cutting apparatus, according to one or more embodiments of the present disclosure.

[0040] FIG. 2C is a perspective view of a cutting element including a plurality of knives, according to one or more embodiments of the present disclosure.

[0041] FIG. 2D is a side view of a pusher, according to one or more embodiments of the present disclosure.

[0042] FIG. 3A through FIG. 3D illustrate a process of cutting a cutout in a cable jacket, according to one or more embodiments of the present disclosure.

[0043] FIG. 4A through FIG. 4C illustrate pushing a cutout blank from a cutout, according to one or more embodiments of the present disclosure.

[0044] FIG. 5 is a flowchart illustrating a method of cutting a cutout in a cable jacket, according to one or more embodiments of the present disclosure.

[0045] FIG. 6 is a perspective view of a sensor positioned in a cutout, according to one or more embodiments of the present disclosure.

[0046] FIG. 7 is a cross-sectional perspective view of a sensor positioned through a cutout and protruding from the outer surface of the jacket and/or cable assembly, according to one or more embodiments of the present disclosure.

[0047] FIG. 8 is a flowchart illustrating a method of configuring a sensor array, according to one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

[0048] The illustrations presented herein are not actual views of any agricultural machine or portion thereof, but are merely idealized representations to describe example embodiments of the present disclosure. Additionally, elements common between figures may retain the same numerical designation.

[0049] The following description provides specific details of embodiments. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing many such specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional techniques employed in the industry. In addition, the description provided below does not include all elements to form a complete structure or assembly. Only those process acts and structures necessary to understand the embodiments of the disclosure are described in detail below. Additional conventional acts and structures may be used. The drawings accompanying the application are for illustrative purposes only, and are thus not drawn to scale.

[0050] As used herein, the terms "comprising," "including," "containing," "characterized by," and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps, but also include the more restrictive terms "consisting of" and "consisting essentially of" and grammatical equivalents thereof.

[0051] As used herein, the term "may" with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term "is" so as to avoid any implication that other, compatible materials, structures, features, and methods usable in combination therewith should or must be excluded.

[0052] As used herein, the term "configured" refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a predetermined way.

[0053] As used herein, the singular forms following "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0054] As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. [0055] As used herein, spatially relative terms, such as "beneath," "below," "lower," "bottom," "above," "upper," "top," "front," "rear," "left," "right," "vertical," and "horizontal," and the like, may be used for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Unless otherwise specified, the spatially relative terms are intended to encompass different orientations of the materials in addition to the orientation depicted in the figures.

[0056] As used herein, the term "substantially" in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, or even at least 99.9% met.

[0057] As used herein, the term "about" used in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter).

[0058] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[0059] From reading the following description it should be understood that the terms "longitudinal" and "transverse" are made in relation to a machine's normal direction of travel. In other words, the term "longitudinal" equates to the fore-and-aft direction, whereas the term "transverse" equates to the crosswise direction, or left and right. Furthermore, the terms "axial" and "radial" are made in relation to a rotating body or cylindrical such as a shaft or cable, wherein axial relates to a direction along the rotation axis and radial equates to a direction perpendicular to the rotation axis.

[0060] FIG. 1 is a schematic diagram of an environment 100 in which a commodity monitoring system 114 may operate according to one or more embodiments of the present disclosure. As shown in FIG. 1, the environment 100 may include a sensor array 104 having a plurality of sensors 106 in communication with a sensor controller 116, at least one client device 112, at least one server 110 including the commodity monitoring system 114, and a network 118. The commodity monitoring system 114, the client device 112, and the sensor controller 116 may communicate via the network 118. Although FIG. 1 illustrates a particular arrangement of the client device 112, the server 110, the sensor controller 116, and the network 118, various additional arrangements are possible. For example, the server 110 and, accordingly, the commodity monitoring system 114, can communicate directly with the client device 112 and/or the sensor controller 116, thereby bypassing the network 118.

[0061] As shown in FIG. 1, the plurality of sensors 106 of the sensor array 104 may be positioned (e.g., attached) at various locations (e.g., hung from a ceiling or other support) within a container 108 and may be utilized to monitor contents (e.g., a commodity) within the container 108. The plurality of sensors 106 of the sensor array 104 may be mounted to a cable 124 hung from a ceiling of the container 108 in a manner such the plurality of sensors 106 are located within the volume of the contents within the container 108. Furthermore, the plurality of sensors 106 of the sensor array 104 may be mounted at varying known elevations (e.g., heights) within the container 108. In at least one example, multiple sensors 106 are positioned on a single cable 124 suspended from the ceiling of the container 108.

[0062] In some embodiments, the plurality of sensors 106 are configured to transmit signals/energy (e.g., pulses) into the contents within the container 108 and/or to receive (e.g., collect) resulting signals that have passed through and/or been reflected from the contents. For example, each of the plurality of sensors 106 is polarized to provide excitement signals and collect resulting signals scattered by the contents. Furthermore, the plurality of sensors 106 may be utilized in electromagnetic imaging processes using at least some of the sensors 106 as active transmitters of electromagnetic radiation and at least some of the sensors 106 as receivers of electromagnetic radiation. In some embodiments, at least some of the sensors 106 may be utilized as both transmitters and receivers. Moreover, based on the transmitted and received electromagnetic radiation, quantitative and qualitative images of a dielectric profile of the contents of the container 108 may be generated. For example, the commodity monitoring system 114 may generate images of the contents of the container 108 via any of the manners described in U.S. Patent No. 11,125,796 B2, to Gilmore et al., issued September 21, 2021, WO 2021/001796 Al, to Jeffrey et al., filed July 3, 2020, WO 2021/070101 Al, to Jeffrey et al., filed October 8, 2020, WO 2022/200909 Al, to Asefi et al., filed March 14, 2022, WO 2022/200931 Al, to Lovetri et al., filed March 16, 2022, and/or WO 2022/200932 Al, to Asefi et al., filed March 16, 2022.

[0063] In some embodiments, the sensors 106 measure other or additional properties of the interior of the container 108 and the contents therein. For example, the sensors 106 may include temperature sensors, humidity sensors, gas sensors (methane sensors, carbon dioxide sensors, ammonia sensors, etc.), airflow sensors, pressure sensors, or other sensors. In such embodiments, the sensors 106 are positioned throughout the container 108 to collect information related to the air or contents of the container 108 in a volume surrounding the sensor 106. Distribution of the sensors 106 through the volume of the container 108 and/or the contents thereof may facilitate one or more of volumetric measurements, level detection of the commodity, temperature measurements, humidity measurements, and/or gas concentration measurements in the container 108.

[0064] The container 108 may include a grain storage bin. Furthermore, while a particular geometry is depicted in FIG. 1, it will be understood that the container 108 may include one or more containers of other geometries, for the same contents (e.g., grain) or other contents, with a different arrangement and/or quantity of inlet, outlet, and/or side ports.

[0065] The plurality of sensors 106 may be operably coupled to the sensor controller 116 via one or more wired connections (e.g., the cables 124, which may comprise, for example, coaxial cables). The sensor controller 116 may include a vector network analyzer and may include one or more of a radio frequency (RF) switch matrix (e.g., an array of RF switches arranged to route RF signals between multiple inputs and multiple outputs) and/or an RF multiplexor 120 for routing signals to and from the plurality of sensors 106. Additionally, the sensor controller 116 may include an electromagnetic transceiver (TCVR) 122. In some examples, the RF switch/MUX 120 of the sensor controller 116 enables each of the sensor 106 to deliver RF energy and/or collect RF energy provided by other sensors 106 and scattered by the contents of the container 108. In at least one example, the TCVR 122 of the sensor controller 116 generates the RF signals (e.g., RF wave) for providing to the contents of the container 108 via the plurality of sensor 106 and receives the resulting RF signals measured (e.g., acquired) by the plurality of sensor 106. In some embodiments, sensor data, such as temperature, humidity, gas concentration, are measured by the sensors 106 and transmitted to the sensor controller 116, such as through the cables 124. In some embodiments, each sensor 106 individually measures the same properties (e.g., temperature, pressure, humidity, etc.) and level of the commodity in the container 108.

[0066] In some embodiments, a user can interface with the client device 112, for example, to communicate with the server 110 and to utilize the commodity monitoring system 114 to monitor contents of the container 108. The user may include one or more operators of the container 108. Although FIG. 1 only shows a single client device 112, the environment 100 can include any number of client devices 112 in communication with the network 118, server 110, and/or sensor controller 116.

[0067] In some embodiments, the client device 112 may include a client application installed thereon. In one or more embodiments, the client application can be associated with the commodity monitoring system 114. For example, the client application may allow the client device 112 to directly or indirectly interface with the commodity monitoring system 114 of the server 110. The client application also enables a user (e.g., an operator) to initiate measurements via the commodity monitoring system 114 and observe any results of the measurements (e.g., generated images representing the contents of the container 108).

[0068] Both the client device 112 and the server 110 (and the commodity monitoring system 114) can represent various types of computing devices with which operators can interact. For example, the client device 112 and/or the server 110 may include a mobile device (e.g., a cell phone, a smartphone, a PDA, a tablet, a laptop, a watch, a wearable device, etc.). In some embodiments, however, the client device 112 and/or server 110 can be a non-mobile device (e.g., a desktop or server). In some embodiments, the server 110 may include a cloud computing platform and may be configured to perform processing required to implement the commodity monitoring system 114. In one or more embodiments, the server 110 may include a web server that provides a web site that can be used by operators monitoring the contents of the container 108 via a remote client device 112. [0069] Referring still to FIG. 1, while the commodity monitoring system 114 is depicted as being a portion of (e.g., implemented by) the server 110, the disclosure is not so limited. Rather, in some embodiments, the commodity monitoring system 114 may be implemented at one or more of the client device 112, the sensor controller 116, or the server 110. In some embodiments, the commodity monitoring system 114 may be implemented at a computing device that is local to the container 108 (e.g., edge computing). In some embodiments, the commodity monitoring system 114 may be implemented at different devices of the environment 100 operating according to a primary-secondary configuration or peer-to-peer configuration. For purposes of illustration and convenience, implementation of the commodity monitoring system 114 is described herein as being implemented by the server 110, with the understanding that functionality may be implemented in other and/or additional devices.

[0070] The network 118 may include one or more networks, such as the Internet, and can use one or more communications platforms or technologies suitable for transmitting data and/or communication signals. As a non-limiting example, the network 118 may utilize one or more of near field communication (NFC), BLUETOOTH ©, wireless/cellular networks, wide area networks (WAN), wired communications, or any other conventional network for transmitting data and/or communication signals between the sensor controller 116, client device 112, server 110, and commodity monitoring system 114.

[0071] In some embodiments, the sensors 106 of the sensor array 104 are positioned in the container 108 at various locations and heights by suspending at least some of the sensors 106 from cables 124. The weight of the commodity surrounding and/or above the sensor 106 can exert a large force on the sensor 106 and/or cable 124. In some embodiments, the sensors 106 are positioned in or through a portion of the cable 124 to provide sufficient strength and support retain the sensor 106 at the intended location in the container 108. In some embodiments, the cable 124 further provides data communication to or from the sensor 106. For example, the cable 124 may provide electrical data communication between the sensor 106 and the sensor controller 116. In another example, the cable 124 may provide optical data communication (e.g., fiber optics) between the sensor 106 and the sensor controller 116. In some embodiments, the cable 124 provides electrical power to the sensor 106. For example, the cable 124 may provide electrical power to the sensor 106 to power the sensor 106 while the sensor 106 is in wireless data communication with another sensor 106 and/or the sensor controller 116.

[0072] FIG. 2A is a perspective view of a cutting apparatus 226 that may be used to form (e.g., cut) a cutout in a cable 224 (e.g., a cable 124), such as that described in relation to FIG. 1, according to one or more embodiments of the disclosure. The cutting apparatus 226 may cut through a jacket of the cable 224 to create a cutout (e.g., cavity, opening) through the cable jacket, such that the jacket is continuous around a perimeter of the cutout, as will be described in more detail herein. After forming the cutout, a sensor (e.g., sensor 106) can be positioned in or through the cutout.

[0073] In some embodiments, the cutting apparatus 226 includes a base 228. The cable 224 is received in the cutting apparatus 226 and positioned on the base 228 while a middle plate 230 is movably connected to the base 228 to move in a longitudinal direction 232 toward the base 228. The cable 224 may be received by the cutting apparatus 226 between the base 228 and the middle plate 230. In some embodiments, the longitudinal movement of the middle plate 230 relative to the base 228 is at least partially controlled by a lever 234. For example, the middle plate 230 and base 228 may be moved relative toward another by an arbor press actuated by the lever 234. Rotating the lever 234 may move the middle plate 230 downward (e.g., toward the base 228) and move cutting elements supported by the base 228 and the middle plate 230 toward one another. In other embodiments, the middle plate 230 received a force from a hydraulic, pneumatic, electromagnetic, mechanical, or other type of press.

[0074] The cutting apparatus 226 further includes a top plate 236 that includes a pusher (e.g., pusher 248 (FIG. 2B)) movably connected to at least one of the base 228 and the middle plate 230. The pusher may be aligned with the cutting elements of the base 228 and the middle plate 230. In some embodiments, the top plate 236 receives a force from the press in a longitudinal direction 232. When the handle 238 is in a locked position, movement of the top plate 236 relative to the middle plate 230 is limited and/or prevented, which results in the top plate 236 and middle plate 230 moving together relative to the base 228. The longitudinal force from the press is transmitted to the middle plate 230 and the middle plate cutting elements, as will be described in more detail herein. When the top plate 236 is released relative to the middle plate 230, such as via movement of the handle 238 into an unlocked position, at least a portion of the top plate 236 and the pusher 248 moves in the longitudinal direction 232 relative to the cutting elements of the base 228 and the middle plate 230 to push or otherwise displace a cutout blank from the cutout and form a hole in the jacket of the cable 224. The cutout is thereby cut, and the cutout blank is cleared from the cable 224 without moving the cable 224, reducing steps and increasing precision of forming the cutout in the cable 224. In addition, the cutout may be formed in the cable 224 without cutting or removing conductive materials within the cable 224.

[0075] FIG. 2B is a side cross-sectional view of an embodiment of the cutting apparatus 226. The base 228 includes a base cutting element 240 that complementarily aligns with a middle plate cutting element 242. In some embodiments, each of the base cutting element 240 and the middle plate cutting element 242 includes a plurality of knives. In other embodiments, each of the base cutting element 240 and the middle plate cutting element 242 includes a single, monolithic, and/or continuous knife.

[0076] In some embodiments, the cable 224 includes a cable jacket 244 and a plurality of cable cores 246 encased by the jacket 244. The cutting elements 240, 242 are positioned to cut into and/or through the jacket 244 without cutting the cable cores 246. In some examples, the cutting elements 240, 242 are positioned to cut into and/or through the jacket 244 to expose at least a portion of a core 246 of the cable 224. In some examples, the cutting elements 240, 242 are positioned to cut into and/or through at least a portion of a core 246.

[0077] The pusher 248 is operably connected to the top plate 236 or other motive force to move the pusher 248 in the longitudinal direction 232 (FIG. 2A) relative to the cutting elements 240, 242 when the top plate 236 is released relative to the middle plate 230, such as by movement of the handle 238 to an unlocked position. In some embodiments, the pusher 248 is configured between the knives or other components of the cutting elements 240, 242 and complementary to the cutout area of the cutting elements 240, 242. In other words, when the cutting elements 240, 242 cut out the cutout blank from the cable 224, the pusher 248 fills substantially the entire cutout area within the cutting elements 240, 242 to act on the cutout blank (e.g., to remove the cutout blank from the cable 224). In some instances, the pusher 248 and/or the middle plate cutting elements 242 urge the cable 224 downward onto or around the base cutting elements 240. In such examples, the cable 224 can become lodged on the base cutting elements 240 and unable to move axially relative to the cutting apparatus, even after the middle plate 230 and the top plate 236 are moved longitudinally (e.g., upward) to an original position. In some embodiments, a puller 249 is located below the cable 224 (i.e., opposite the pusher 248) and fixed in the longitudinal direction relative to the middle plate 230 and the top plate 236. When the middle plate 230 and/or top plate 236 move in the longitudinal direction away from the base 228, the puller 249 applied a longitudinal force to the cable 224 to lift the cable 224 from the base cutting elements 240 and release the cable 224.

[0078] FIG. 2C is a simplified perspective view of the cutting element 240, 242, according to one or more embodiments of the disclosure. The cutting element 240, 242 may include a plurality of knives, such as side knives 250 and end knives 252 positioned substantially orthogonally to one another and defining a rectangular cutout area 254. In other examples, the cutting elements 240, 242 define a cutout area 254 having other shapes, including but not limited to square, triangular, pentagonal, hexagonal, other regular polygonal, irregular polygonal, oval, circular, irregular curved, or partially curved and partially polygonal shapes.

[0079] In some embodiments, each of the cutting elements 240, 242 has a substantially flat (e.g., substantially planar) inner surface 256. The substantially flat inner surface 256 of each of the cutting elements 240, 242 of the base 228 (FIG. 2A) may face one another. Similarly, the flat inner surface 256 of each of the cutting elements 240, 242 of the middle plate 230 (FIG. 2A) face one another. For example, the inner surface 256 is substantially parallel to the longitudinal direction 232. In some embodiments, the inner surface 256 is angled relative to the longitudinal direction 232 such that a cross-sectional area of the cutout area 254 increases in the longitudinal direction 232 to facilitate the cutout blank being ejected from the cutting element 240, 242 and/or cutting apparatus 226 by the pusher 248.

[0080] The outer surface 258 of the cutting element 240, 242 is, in some embodiments, beveled to allow the inner surface 256 to be substantially flat. The beveled outer surface 258 may also deflect or deform a portion of the cable 224 outward (e.g., away from the cutout) allowing easier insertion of a sensor into the cutout, as will be described in more detail herein. For example, the cable jacket 244 (e.g., which may be formed of a rubber or polymer material) may be elastically deformed by the beveled outer surface 258 to stretch the cutout initially larger than the cutout area 254. The stretched cutout in the cable 224 may reduce friction between the sensor and the walls of the cutout during installation until the jacket 244 elastically restores the cutout size, applying a compressive force to the sensor to retain the sensor in the cutout.

[0081] In some embodiments, the cutting element 240, 242 includes at least one gap 260 between knives 250, 252. In some embodiments, the cutting element 240, 242 has a substantially continuous leading edge 262. For example, the leading edge 262 of the knives 250, 252 may be adjacent to and/or contacting one another to create a substantially continuous leading edge 262. In some embodiments, the cutting element 240, 242 includes a single, continuous knife around a perimeter of the cutout area 254 with one or more gaps 260 in the leading edge 262. In some embodiments, the cutting element 240, 242 includes a single, continuous knife around a perimeter of the cutout area 254 with a substantially continuous leading edge 262.

[0082] In embodiments with a plurality of knives 250, 252, the knives 250, 252 may have different leading-edge heights of leading edge 262 in the longitudinal direction 232 relative to one another. In other words, the leading edge 262 of at least some of the knives 250, 252 may be offset from one another in the longitudinal direction 232. As the initial insertion of the leading edge(s) 262 into the jacket 244 of the cable may require an increased compression force, varying the leading-edge heights of the leading edge(s) 262 may distribute the force and reduce the total force needed to pierce the jacket 244. In some embodiments, a cutting element 240, 242 with a substantially continuous single knife has a leading edge 262 that varies in leading-edge height around a perimeter of the cutout area 254. In some embodiments, an end knife 252 has a leading edge 262 that is curved or has a peak in a lateral center of the leading edge 262 of the end knife 252. For example, the end knife 252 may be a spike or spike-like in the lateral dimension to pierce the jacket 244 of the cable and urge the jacket 244 in the lateral direction, similar to the side knives 250. In some embodiments, the end knives 252 are omitted and the pusher 248 cuts at least a portion of the jacket 244, as will be described in more detail herein.

[0083] FIG. 2D is a side view of an embodiment of a pusher 248. The pusher 248 has a concave contact surface 270 in the longitudinal direction (e.g., away from the cutout blank 266) and relative to an axial direction 272 of the cable 224. The concave contact surface 270 may be substantially V-shaped and include two linear surfaces, a continuously curved surface, or combinations thereof. A first end 271-1 and a second end 271-2 at an opposite end of the contact surface 270 in the axial direction 272 contact the cutout blank 266 first to limit and/or prevent the cutout blank 266 turning in the cutout.

[0084] FIG. 3A through FIG. 3C are side views of side knives 250 cutting a cutout in a cable 224 during a cutting process, in accordance with one or more embodiments of the disclosure. The end knives (such as described in relation to FIG. 2B and FIG. 2C) are not shown in FIG. 3A through FIG. 3C. In some embodiments, the cutout area of the base cutting element 240 and the middle plate cutting element 242 have a cutout width 259 that is less a distance between the cores 246 of the cable 224. In other embodiments, the cutout width 259 is greater than the distance between the cores 246 of the cable 224 and the cutting elements 240, 242 cut at least a portion of a core 246. In other embodiments, the cutout width 259 is greater than the distance between the cores 246 of the cable 224 and the cutting elements 240, 242 cut through the jacket 244 to the cores 246, at which point the portion of the jacket 244 between the cores 246 is no longer connected to the cores 246.

[0085] In some embodiments, the pusher 248 has a peaked edge in the transverse direction, such as a semi-convex edge or a double-bevel edge. For example, when the cutout width 259 is less than a distance between the cores 246, a peaked edge in the transverse direction urges the cores 246 apart without damaging the cores 246, in the event the pusher 248 contacts the cores 246 while moving the longitudinal direction. In some embodiments, the pusher 248 has an edge that is substantially linear in the transverse direction. In some embodiments, the pusher 248 has a concave edge in the transverse direction.

[0086] During the cutting operation, the cable 224 is centered in a transverse direction of the cutting elements 240, 242, and the middle plate cutting element 242 and base cutting element 240 are moved toward one another in the longitudinal direction 232 to pierce the cable jacket 244. Referring now to FIG. 3B, the middle plate cutting element 242 and pusher 248 move toward the base cutting element 240. The leading edge 262 of the middle plate cutting element 242 approaches the leading edge 262 of the base cutting element 240 to at least partially form the cutout blank 266 (FIG. 3C). In some embodiments, the leading edge 262 of the middle plate cutting element 242 contacts the leading edge 262 of the base cutting element 240 to complete the cutout and form cutout blank 266. In some embodiments, the leading edge 262 of the middle plate cutting element 242 does not contact the leading edge 262 of the base cutting element 240, and the cutting elements 240, 242 leave a tab 264 on at least one side of the cutout blank 266. Stopping the cutting elements 240, 242 before the leading edges 262 contact one another may limit and/or prevent damage to the leading edge of cutting elements 240, 242 and/or to the cores 246. In some embodiments, the leading edge 262 of the middle plate cutting element 242 does not contact the leading edge 262 of the base cutting element 240, and the cutting elements 240, 242 stop at the cores 246, severing the jacket 244, while leaving a portion of the jacket 244 between the cores 246 as illustrated in FIG. 3C. In such embodiments, a tab 264 may be left on an axial end, as will be described in relation to FIG. 4A through FIG. 4C.

[0087] FIG. 3C is a side view of the pusher 248 pushing the cutout blank 266 longitudinally from the cutout 268. In some embodiments, when the cutting elements 240, 242 leave a tab (such as the tab 264 described in relation to FIG. 3B), the pusher 248 finishes the cut by acting against the base cutting element 240, as shown in FIG. 3C. The pusher 248, therefore, pushes the cutout blank 266 in the longitudinal direction 232 to complete the cut of the tab 264 (FIG. 3C) and eject the cutout blank 266. In some embodiments, the tab 264 retains the cutout blank 266 at a known position between the knives 250 and/or cutting elements 240, 242 to facilitate the pusher 248 contacting a surface of the cutout blank 266 in a repeatable and desired orientation.

[0088] FIG. 3D is a perspective view of the cable 224 with a cutout 268 cut through the jacket 244 between the cores 246. The cutout 268 may define a cavity and may expose portions of the cores 246 within the cavity. As described herein, in some embodiments, the cutout 268 includes at least a portion of a core 246 and/or exposes a core 246 through the jacket 244 via the cutout 268 such that one or more sensors (e.g., sensors 106) may be placed within the cutout 268 and in contact (e.g., in electrical contact) with the core 246.

[0089] FIG. 4A through FIG. 4C illustrate another example of cutting a cutout in a cable jacket, according to one or more embodiments of the disclosure. FIG. 4A illustrates cutting the jacket 244 with the cutting elements 240, 242. In some embodiments, the process illustrated in FIG. 4A through FIG. 4C is a version of the pusher 248 ejecting the cutout blank described in relation to FIG. 3C. In some embodiments, the tabs are fully cut by the base cutting element 240 and the cutout blank 266 is disconnected from the jacket 244 before the pusher 248 engages and applies a force to the cutout blank 266.

[0090] Referring now to FIG. 4B, the concave pusher 248 contacts the axial ends 271-1, 271-2 of the cutout blank 266 and applies a downward force thereto. The concave contact surface 270 thereby applies an equal and/or concentrated force to the axial ends 271-1, 271-2 to urge the cutout blank 266 from the cutout 268.

[0091] FIG. 4C illustrates the cutout blank 266 ejected from the cutting apparatus downward in the longitudinal direction 232 and the pusher 248 returned to an initial position. In some embodiments, the pusher 248 returns to an initial position before the middle plate cutting element 242 returns to an initial position. In some embodiments, the pusher 248 and the middle plate cutting element 242 move upward in the longitudinal direction 232 toward the respective initial positions at the same time.

[0092] FIG. 5 is a flowchart illustrating a method 374 of cutting a cutout in a cable jacket. Though depicted as a flowchart, the actions in FIG. 5 may be performed concurrently, and in some embodiments, some actions may be omitted. As described herein, cutting a cutout in a cable jacket includes positioning a cable assembly including a first cable core and a second cable core encased in a cable jacket in a cutting apparatus, as shown at act 376. In some embodiments, the cutting apparatus is or includes any embodiment described in relation to FIG. 2A through FIG. 4C. In some embodiments, the cable assembly is any embodiment of a cable described in relation to FIG. 2A through FIG. 4C.

[0093] The method 374 further includes moving a middle plate cutting element toward a base cutting element in a longitudinal direction, as shown at act 378. For example, moving the middle plate cutting element towards the base cutting element includes applying a force with a press (e.g., lever 234 (FIG. 2A)), such as an arbor press, to move the middle plate cutting element. In some examples, moving the middle plate cutting element includes actuating a hydraulic press, a pneumatic press, or an electrical motor to apply a force to the middle plate cutting element. In some embodiments, moving the middle plate cutting element includes moving a middle plate assembly that supports a top plate assembly. In such examples, moving the middle plate cutting element includes moving a pusher simultaneously with the middle plate cutting element.

[0094] The method 374 further includes at least partially cutting a cutout through the cable jacket and between the first cable core and the second cable core, as shown at act 380. In some embodiments, cutting the cutout through the cable jacket includes cutting the cutout with the middle plate cutting element and the base cutting element. In some embodiments, the cutout is positioned between the cable cores of the cable assembly with at least a portion of the jacket remaining between the cable cores and the cutout. For example, the cable cores remain encased in the jacket after the cutout is cut through the jacket. In other embodiments, the cutout includes a portion of at least one of the cable cores. For example, the cutout may include the jacket material between the cable cores and a portion of both cable cores, exposing the cable cores through the cutout. In some embodiments, the cutout is proximate to the cable cores such that the jacket is removed from the cable cores, creating a window in the jacket material proximate to the cutout to expose the cable cores, but without cutting or removing material from the cable core(s). In some embodiments, the cable core is electrically conductive, and exposure of the electrically conductive cable core provides data communication to or from a sensor (e.g., sensor 106). In one example, the sensor has a terminal that contacts the cable core and allows electrical communication between the sensor and the cable core. In a particular example, the cable may provide electrical data communication between the sensor and the sensor controller (e.g., sensor controller 116). In some embodiments, the cable provides electrical power to the sensor. For example, the cable may provide electrical power to the sensor to power the sensor while the sensor is in wireless data communication with another sensor and/or the sensor controller. In another embodiment, the cable core is an optically transmissive material, and the cable provides optical data communication (e.g., fiber optics) between the sensor and the sensor controller or other component of a sensor array.

[0095] In some embodiments, the method 374 further includes pushing a cutout blank in the longitudinal direction out of the cutout, as shown at act 382. For example, pushing the cutout blank in the longitudinal direction includes applying a force to the cutout blank with a pusher, such as any embodiment described herein. In some embodiments, the movement of the middle plate cutting element cuts a portion of the cutout through the jacket and leaves a tab of jacket material (such as described in FIG. 3B and FIG. 3C) connecting the cutout blank to the cable jacket. Pushing of the cutout blank with the pusher may complete the cutting of the of the cutout by severing the tab(s) and releasing the cutout blank from the cable assembly.

[0096] Pushing the cutout blank out of the cutout, in some embodiments, includes deforming the cutout blank with the pusher. For example, a concave pusher interacts with the axial ends of the cutout blank to deform the cutout blank axially inward. Deforming the cutout blank axially inward may reduce or remove friction between the cutout blank and the cutting element(s), allowing the cutout blank to be ejected from the cutout.

[0097] After pushing the cutout blank out of the cutout, the method 374 includes moving the cable assembly relative to the cutting apparatus, as shown at act 384. In some embodiments, the cable assembly is moved relative to the cutting apparatus after pushing the cutout blank out of the cutout. The pusher may push the cutout blank from the cutout without moving the cable assembly in an axial direction of the cable. In some embodiments, the pusher and the cutting elements are released from the cable assembly at least partially simultaneously. In some embodiments, the pusher and the cutting elements are released from the cable assembly at different times.

[0098] After cutting the cutout, in some embodiments, a sensor is inserted into the cutout, for example, to be installed as part of a sensor array. FIG. 6 is a perspective view of a sensor 486 positioned in a cutout 468, according to one or more embodiments of the disclosure. In some embodiments, the cutout 468 is cut through the cable jacket 444 between the first core 446 and the second core 446. The sensor 486 is positioned in the cutout 468 with an outer surface of the sensor 486 flush with an outer surface 487 of jacket 444 and/or the cable assembly 424. In some embodiments, the sensor 486 includes one or more probes or sampling locations 488 on the exterior of the sensor 486. In some embodiments, the accuracy, precision, or speed of the data collection of the sensor 486 is based at least partially on a surface area of the probe or sampling location 488. It may be beneficial to have a surface area that is larger than a cutout area allows. [0099] FIG. 7 is a cross-sectional perspective view of a sensor 586 positioned through a cutout 568 and protruding from the outer surface 587 of the jacket 544 and/or cable assembly 524, according to one or more embodiments of the disclosure. The sensor 586 has one or more probes or sampling locations 588 that are positioned outside of the jacket 544 to increase a surface area of the probes or sampling locations 588. In some embodiments, the increased dimensions of the sensor 586 may allow directional RF antennas to provide more precise and/or accurate positional information of the sensor 586 in the sensor array (such as described in relation to FIG. 1).

[0100] In some embodiments, the sensor 586 includes one or more terminals 590 in contact with a cable core 546 through a window 592 in the cutout 568. As described herein, the window 592 may be through the jacket 544 without any material of the cable core 546 having been removed. In some examples, forming the window 592 removes a portion of the core 546 during cutting of the cutout 568. The terminal 590 may provide electrical communication with an electrically conductive core 546 for data communication and/or power delivery. The terminal 590 may provide optical communication with an optically transmissive core 546 for data communication. In some embodiments, one cable core 546 is electrically conductive and another cable core 546 is optically transmissive.

[0101] FIG. 8 is a flowchart illustrating a method 694 of configuring a sensor array, according to one or more embodiments of the disclosure. In some embodiments, the method 694 shares at least some actions with the previously described embodiments of methods of cutting a cutout in a cable assembly described above with reference to FIG. 5. For example, the method 694 includes positioning a cable assembly including a first cable core and a second cable core encased in a cable jacket in a cutting apparatus, as shown at act 676. In some embodiments, the cutting apparatus is or includes any embodiment described in relation to FIG. 2A through FIG. 4C. In some embodiments, the cable assembly is any embodiment of a cable described in relation to FIG. 2A through FIG. 4C.

[0102] The method 694 further includes moving a middle plate cutting element toward a base cutting element in a longitudinal direction, as shown at act 678. For example, moving the middle plate cutting element toward the base cutting element includes applying a force with a press, such as an arbor press, to move the middle plate cutting element. In some examples, moving the middle plate cutting element includes actuating a hydraulic press, a pneumatic press, or an electrical motor to apply a force to the middle plate cutting element. In some embodiments, moving the middle plate cutting element includes moving a middle plate assembly that supports a top plate assembly. In such examples, moving the middle plate cutting element includes moving a pusher simultaneously with the middle plate cutting element.

[0103] The method 694 further includes cutting a cutout through the cable jacket and between the first cable core and the second cable core, as shown at act 680. In some embodiments, cutting the cutout through the cable jacket includes cutting the cutout with the middle plate cutting element and the base cutting element. In some embodiments, the cutout is positioned between the cable cores of the cable assembly with at least a portion of the jacket remaining between the cable cores and the cutout. For example, the cable cores remain encased in the jacket after the cutout is cut through the jacket. In other embodiments, the cutout includes a portion of at least one of the cable cores. For example, the cutout may include the jacket material between the cable cores and a portion of both cable cores, exposing the cable cores through the cutout. In some embodiments, the cutout is proximate to the cable cores such that the jacket is removed from the cable cores, creating a window in the jacket material proximate to the cutout to expose the cable cores, but without cutting or removing material from the cable core(s). In some embodiments, the cable core is electrically conductive, and exposure of the electrically conductive cable core provides data communication to or from a sensor. In one example, the sensor has a terminal that contacts the cable core and allows electrically communication between the sensor and the cable core. In a particular example, the cable may provide electrical data communication between the sensor and the sensor controller. In some embodiments, the cable provides electrical power to the sensor. For example, the cable may provide electrical power to the sensor to power the sensor while the sensor is in wireless data communication with another sensor and/or the sensor controller. In another embodiments, the cable core is an optically transmissive material, and the cable provides optical data communication (e.g., fiber optics) between the sensor and the sensor controller or other component of a sensor array. [0104] In some embodiments, the method 694 further includes pushing a cutout blank in the longitudinal direction out of the cutout, as shown at act 682. For example, pushing the cutout blank in the longitudinal direction includes applying a force to the cutout blank with a pusher, such as any embodiment described herein. In some embodiments, the movement of the middle plate cutting element cuts a portion of the cutout through the jacket and leaves a tab of jacket material (such as described in FIG. 3B and FIG. 3C) connecting the cutout blank to the cable jacket. The pushing of the cutout blank with the pusher may complete the cutting of the of the cutout by severing the tab(s) and releasing the cutout blank from the cable assembly.

[0105] The method 694 further includes installing a sensor in the cutout, as shown at act 696. In some embodiments, installing the sensor includes inserting the sensor into the cutout with at least one surface of the sensor flush with an outer surface of the cable jacket and/or cable assembly, such as described in relation to FIG. 6. In some embodiments, installing the sensor includes inserting the sensor into the cutout with at least one surface of the sensor protruding from an outer surface of the cable jacket and/or cable assembly, such as described in relation to FIG. 7. In some embodiments, installing the sensor includes creating a cradle in the cutout, such as by polymer injection or mechanically assembly, while allowing communication through the cradle to the cable core(s).

[0106] In some embodiments, instal ling the sensor includes contacting a terminal of the sensor with a cable core. For example, the terminal may provide electrical communication with an electrically conductive core or optical communication with an optically transmissive cable core.

[0107] All references cited herein are incorporated herein in their entireties. If there is a conflict between definitions herein and in an incorporated reference, the definition herein shall control.

[0108] While the present disclosure has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the disclosure as hereinafter claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope as contemplated by the inventors. Further, embodiments of the disclosure have utility with different and various machine types and configurations.

Claims

CLAIMS What is claimed is:

1. A cutting apparatus for cutting a cable jacket, the apparatus comprising: a base supporting a base cutting element defining a cutout area; a middle plate movably connected to the base in a longitudinal direction, the middle plate supporting a middle plate cutting element aligned with the base cutting element; and a pusher movably connected to at least one of the base and the middle plate and configured to move longitudinally at least partially through the cutout area in the longitudinal direction.

2. The apparatus of claim 1, wherein the pusher has a transverse area that is complementary to the cutout area.

3. The apparatus of claim 1 or 2, wherein the pusher is at least partially concave in the longitudinal direction.

4. The apparatus of any of claims 1 through 3, wherein the pusher is peaked in a transverse direction perpendicular to the longitudinal direction.

5. The apparatus of any of claims 1 through 4, further comprising a handle configured to release a top plate supporting the pusher wherein the pusher is released and moveable in the longitudinal direction relative to the middle plate when the handle is in an unlocked position.

6. The apparatus of any of claims 1 through 5, wherein at least one of the base cutting element and the middle plate cutting element includes a plurality of knives.

7. The apparatus of claim 6, wherein the plurality of knives has a plurality of leadingedge heights in the longitudinal direction.

8. The apparatus of any one of claims 1 through 7, wherein the cutout area is rectangular.

9. The apparatus of any one of claims 1 through 7, wherein at least one of the base cutting element and the middle plate cutting element has a flat inner surface and a beveled outer surface.

10. The apparatus of claim 9, wherein the flat inner surface is substantially parallel to the longitudinal direction.

11. A cutting apparatus for forming an aperture within a cable and between two conductors within the cable, the apparatus comprising: a base cutting element defining a cutout area and comprising a first plurality of knives; a middle cutting element vertically aligned with the base cutting element and comprising a second plurality of knives; and a pusher operably coupled to at least one of the base cutting element or the middle cutting element and comprising a cross-sectional area within a horizontal plane at least substantially equal to or smaller than a cross-sectional area of the cutout area within the horizontal plane.

12. The apparatus of claim 11, wherein the pusher has a transverse area that is complementary to the cutout area.

13. The apparatus of claim 11 or 12, wherein the pusher comprises an at least partially concave longitudinal tip.

14. The apparatus of any of claims 11 through 13, wherein the pusher comprises a peaked tip.

15. The apparatus of any of claims 11 through 14, further comprising a handle configured to release a top plate supporting the pusher wherein the pusher is released and moveable vertical direction relative to the middle cutting element when the handle is in an unlocked position.

16. The apparatus of claim 11, wherein the first plurality of knives has a plurality of leading-edge heights in a vertical direction.

17. The apparatus of claim 11, wherein the second plurality of knives has a plurality of leading-edge heights in the vertical direction.

18. The apparatus of any one of claims 11 through 18, wherein at least one of the base cutting element and the middle plate cutting element has a flat inner surface and a beveled outer surface.

19. A cutting apparatus for forming an aperture within a cable and between two conductors within the cable, the apparatus comprising: a first cutting element defining a first interior channel and comprising a first plurality of knives; a second cutting element defining a second interior channel and comprising a second plurality of knives; and a pusher oriented within the first interior channel of the first cutting element and configured to extend out of the first interior channel of the first cutting element and into the second interior channel of the second cutting element during a cutting process.

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