Multi-angle adjustable modular as cable bridge transfer device and method thereof

Abstract

The application relates to the technical field of electrical installation and power distribution accessories, in particular to a multi-angle adjustable modular AS cable bridge switching device and a method thereof; the device comprises first and second injection-molded half frames, a fan-shaped smooth baffle, an optical strain scale, an injection-molded connecting plate and a fastening assembly; the device is combined with the center pivot and the pivot hole of the two half frames to form a rotating pair, and realizes multi-angle flexible adaptation and high-strength rigid engagement through trapezoidal shear-resistant teeth on an end face tooth disc; the core is that the main bodies are all formed by AS resin to maintain pure insulation characteristics, and when rotating relatively, the fan-shaped smooth baffles are overlapped and slid at the bottom to form a continuous inner wall shielding surface; the application replaces a traditional construction mode of cutting and destroying structures on site, solves the internal splicing gap problem by smooth baffle follow-up rotation, and effectively avoids the risk of cable insulation layer being scraped.

Description

Technical Field

[0001] This invention relates to the field of electrical installation and power distribution accessories technology, specifically to a multi-angle adjustable modular AS cable tray adapter and its method. Background Technology

[0002] In current power distribution and cable laying operations, standard cable trays often need to be repositioned at non-standard corner locations to adapt to complex wiring environments such as transformer racks. To achieve corner adaptation, existing construction solutions often involve on-site cutting and splicing of standard cable trays, or assembly using metal hinges and connecting pieces. While this approach can meet the need for flexible routing, on-site cutting easily damages the overall structural strength of the cable tray and creates internal splicing gaps and sharp edges, increasing the risk of scratching the cable insulation layer. Furthermore, the introduction of dissimilar materials such as metals not only compromises the pure insulation characteristics of the cable tray system but also, due to differences in thermal expansion coefficients, easily leads to node loosening when subjected to the cable's own weight and wind vibration loads in outdoor environments over long periods. Due to the lack of scientific shear resistance design and intuitive mechanical engagement verification methods, traditional solutions cannot guarantee the long-term stability of the connection status.

[0003] Therefore, how to achieve flexible multi-angle adaptation without on-site destructive cutting, while providing continuous internal insulation protection and high-strength mechanical connection, and achieving reliable verification of the connection status, has become an urgent technical problem to be solved. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a modular AS cable tray adapter with multi-angle adjustable properties and a method thereof. Specifically, the technical solution of the present invention is as follows:

[0005] A modular AS cable tray adapter with multi-angle adjustable features, comprising:

[0006] The first injection-molded half-frame has a hollow U-shaped groove inside, and its end is integrally injection-molded with a first end face toothed disc. The first end face toothed disc has a pivot hole in the center and trapezoidal anti-shear teeth distributed on its surface.

[0007] The second injection-molded half-frame has a hollow U-shaped groove inside. Its end is integrally injection-molded with a second end face toothed disk and a central pivot. The surface of the second end face toothed disk is distributed with matching trapezoidal anti-shear teeth. The central pivot has a through hole inside. The central pivot and the pivot hole cooperate to form a rotating pair.

[0008] A fan-shaped smooth baffle is integrally injection molded on the lower part of the inner side wall of the first injection molded half frame or the second injection molded half frame. When the first injection molded half frame and the second injection molded half frame rotate relative to each other around the central pivot, the fan-shaped smooth baffle overlaps and slides at the bottom of the hollow U-shaped groove of the other injection molded half frame.

[0009] Optical strain gauges are directly injection molded onto the outer circumferential sidewalls of the first and second end face toothed disks.

[0010] Injection-molded connecting plates symmetrically cover the outer sides of the first and second end face gear discs;

[0011] The fastening assembly passes through the internal through-holes of the two side injection-molded connecting plates and the central pivot, and presses together the first and second injection-molded half-frames.

[0012] Preferably, the trapezoidal anti-shear teeth number 72, and the fastening assembly presses the first injection-molded half-frame and the second injection-molded half-frame together, with the trapezoidal anti-shear teeth abutting against each other.

[0013] Preferably, the first injection-molded half-frame, the second injection-molded half-frame, the fan-shaped smooth baffle, and the injection-molded connecting plate are all integrally injection-molded using AS resin material.

[0014] Preferably, the optical strain gauge is a uniform array of protrusions arranged along the circumference.

[0015] Preferably, the fastening assembly includes a fastening bolt and a mating nut.

[0016] Preferably, the central pivot and the pivot hole of the first injection-molded half-frame are configured with a clearance fit.

[0017] Preferably, the optical strain gauge is a geometric array structure disposed on the outer edges of the first end face toothed disk and the second end face toothed disk.

[0018] A multi-angle adaptation and security lock verification method includes:

[0019] S1. Loosen the fastening assembly, rotate the first injection half frame and the second injection half frame to the target angle, and drive the fan-shaped smooth baffle to rotate to the target position. Initially tighten the fastening assembly so that the trapezoidal anti-shear teeth on the first end face toothed plate and the second end face toothed plate are engaged accordingly.

[0020] S2. Extract the optical strain gauge images of the outer sides of the first end face toothed disk and the second end face toothed disk using a handheld computing device, and identify and obtain the relative misalignment distance;

[0021] S3. Evaluate the ultimate torque value under the current occlusal state based on the relative misalignment distance;

[0022] S4. Determine the actual angle based on the optical strain gauge and obtain the radius of curvature of the internal cable trajectory at the transition position;

[0023] S5. Read the ambient temperature at the construction site and determine the amount of deformation compensation caused by temperature.

[0024] S6. Determine the torque compensation value based on the deformation compensation amount, and adjust the locking torque according to the torque compensation value to complete the fastening.

[0025] Preferably, the step between S3 and step S4 includes:

[0026] Obtain a preset load-bearing threshold, and compare the ultimate torque resistance value with the preset load-bearing threshold;

[0027] If the ultimate torque value is lower than the load threshold, a prompt to readjust the engagement gear will be output.

[0028] If the ultimate torque value is greater than or equal to the bearing threshold, proceed to step S4.

[0029] Preferably, the step between S4 and S5 includes:

[0030] Obtain a preset safe bending radius by comparing the radius of curvature of the internal cable's trajectory with the preset safe bending radius;

[0031] If the radius of curvature is lower than the preset safe bending radius, a prompt will be output to increase the transition of the straight section of the cable tray;

[0032] If the radius of curvature is greater than or equal to the preset safe bending radius, proceed to step S5.

[0033] The present invention has the following beneficial effects:

[0034] 1. The adapter of the present invention forms a rotating pair by engaging the central pivot and pivot hole of the first injection-molded half-frame and the second injection-molded half-frame. Combined with the trapezoidal anti-shear teeth on the end face gear plate, it achieves flexible multi-angle adaptation and high-strength rigid meshing, solving the problem of structural damage during on-site cutting. At the same time, the main components are all molded from AS resin material, maintaining pure insulation characteristics. Combined with the continuous inner wall shielding surface formed by the rotation of the fan-shaped smooth baffle, internal splicing gaps are eliminated, effectively avoiding the risk of cable insulation layer being scratched.

[0035] 2. The safety locking verification method of the present invention utilizes the relative misalignment of the optical strain gauge on the outer side of the end face toothed disc to intuitively map the micro-engagement state of the internal trapezoidal anti-shear teeth, and calculates the ultimate anti-torque value, thus achieving intuitive and reliable mechanical locking verification. In addition, by reading the ambient temperature and combining it with the standard injection molding temperature and the coefficient of linear expansion, the method converts the axial deformation compensation caused by temperature into a torque compensation value and superimposes it on the obtained preset basic locking torque, effectively preventing long-term node loosening caused by thermal expansion and contraction of materials. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings:

[0037] Figure 1 This is a schematic diagram of the overall structure of the device;

[0038] Figure 2 This is a partial schematic diagram of the mating structure of the first injection-molded half-frame and the second injection-molded half-frame of the device;

[0039] Figure 3 This is a schematic diagram of the device's fastening components.

[0040] Figure 4 This is a schematic diagram of the structure of the first and second injection molded half-frames of the device;

[0041] Figure 5 This is a flowchart of the method of the present invention.

[0042] In the figure: 1. First injection-molded half-frame; 2. Hollow U-shaped groove; 3. First end face toothed disc; 4. Pivot hole; 5. Trapezoidal anti-shear tooth; 6. Second injection-molded half-frame; 7. Second end face toothed disc; 8. Central pivot; 9. Fan-shaped smooth baffle; 10. Optical strain gauge; 11. Injection-molded connecting plate; 12. Fastening assembly; 13. Fastening bolt; 14. Nut. Detailed Implementation

[0043] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0044] Example 1:

[0045] A modular AS cable tray adapter with multi-angle adjustable features, such as... Figure 1 As shown, it includes:

[0046] First injection-molded half-frame 1, as shown Figure 2 and Figure 4 As shown, it has a hollow U-shaped groove 2 inside, and a first end face toothed disk 3 is integrally injection molded at its end. The first end face toothed disk 3 has a pivot hole 4 in the center and trapezoidal anti-shear teeth 5 distributed on its surface.

[0047] The second injection-molded half frame 6 has a hollow U-shaped groove 2 inside. Its end is integrally injection-molded with a second end face toothed disk 7 and a central pivot 8. The surface of the second end face toothed disk 7 is distributed with matching trapezoidal anti-shear teeth 5. The central pivot 8 has a through hole inside. The central pivot 8 and the pivot hole 4 cooperate to form a rotating pair.

[0048] The fan-shaped smooth baffle 9 is integrally injection molded on the lower part of the inner side wall of the first injection half frame 1 or the second injection half frame 6. When the first injection half frame 1 and the second injection half frame 6 rotate relative to each other around the central pivot 8, the fan-shaped smooth baffle 9 overlaps and slides at the bottom of the hollow U-shaped groove 2 of the other injection half frame.

[0049] Optical strain gauge 10 is directly injection molded onto the outer circumferential sidewall of the first end face toothed disk 3 and the second end face toothed disk 7.

[0050] Injection-molded connecting plate 11 symmetrically covers the outer sides of the first end face gear plate 3 and the second end face gear plate 7;

[0051] Fastening component 12, such as Figure 3 As shown, the first injection molded half frame 1 and the second injection molded half frame 6 are pressed together through the through holes of the two side injection molded connecting plates 11 and the central pivot 8.

[0052] To address the issues of standard transformer cable trays not being directly compatible with non-standard corner positions and the potential reduction in insulation and structural strength after on-site cutting and splicing, this device is equipped with a first injection-molded half-frame 1 and a second injection-molded half-frame 6 as the main body of the adapter joint. Both form a hollow U-shaped cable trough 2 to accommodate the cable. The width of the U-shaped cable trough can be set from 80mm to 300mm according to the cable tray specifications, and the depth can be set from 50mm to 150mm to adapt to common power distribution cable tray models.

[0053] The first end face toothed disc 3 is integrally formed with the first injection-molded half frame 1, the second end face toothed disc 7 and the central pivot 8 are integrally formed with the second injection-molded half frame 6, and the pivot hole 4 and the central pivot 8 form a rotating pair that can rotate relative to each other, so that the two half frames can adjust the included angle around the same axis when the fastening assembly 12 is loosened; the trapezoidal anti-shear teeth 5 are set on the opposite surfaces of the two end face toothed discs, and are used to bear the tangential shear load and limit the relative rotation after pressing;

[0054] The fan-shaped smooth baffle 9 is set at the junction of the inner side walls of the two halves of the frame. It slides along the bottom overlapping and continuously blocks the gap in the inner wall formed by the angle adjustment, so that the inner wall surface that the cable contacts during installation and operation remains continuous, reducing the possibility of the insulation layer being scratched by the edge.

[0055] The optical strain gauge 10 is directly formed on the outer circumferential sidewall of the two end face toothed disks, without the use of post-sticking or secondary spraying, thus avoiding detachment or identification deviation during long-term outdoor use; the symmetrically arranged injection molded connecting plate 11 covers the outer side of the toothed disk, and the fastening component 12 passing through the internal through hole of the central pivot 8 applies axial pressure to the two halves of the frame, so that the mechanical engagement and subsequent image verification have the same reference benchmark.

[0056] In this embodiment, the structural part provides angle adjustment, shear bearing and inner wall protection. The optical strain gauge 10 and the relative pose after fastening together provide collectable data for subsequent interlocking state calculation, thereby enabling mechanical connection and state verification to be completed in the same device.

[0057] The trapezoidal anti-shear teeth 5 number 72. The fastening assembly 12 presses the first injection molded half frame 1 and the second injection molded half frame 6 together, and the trapezoidal anti-shear teeth 5 abut against each other.

[0058] When there are 72 trapezoidal anti-shear teeth 5, the theoretical adjustment resolution between two adjacent tooth positions is 5°, which can control the complexity of mold processing while meeting the requirements of rapid on-site corner matching. Each trapezoidal anti-shear tooth 5 can extend 6mm to 15mm radially along the tooth disk, and the tooth height can be set to 2mm to 6mm. The tooth tip width and tooth root width are configured as 1:1.2 to 1:2 according to the anti-shear requirements, so that the tooth root area has a high load-bearing cross section.

[0059] The trapezoidal teeth adopt a relative inclined surface fit. When the fastening component 12 applies an axial clamping force, a rigid meshing with surface contact or near-surface contact is formed between the tooth surfaces. When the joint bears the torsional load caused by the weight of the cable and the vibration of the cable tray, the load is mainly transmitted through the tooth sides of multiple trapezoidal anti-shear teeth 5, rather than being borne solely by the central pivot 8, thereby reducing local stress concentration on the pivot.

[0060] In practical use, construction personnel select one of the two adjacent meshing positions according to the cable tray direction, so that the switching angle changes in 5° increments. After the fastening component 12 continues to tighten, the number of effective contact teeth participating in the load-bearing among the 72 teeth is usually greater than 12. The ultimate torque resistance increases with the increase of the number of contact teeth, which can meet the stable support requirements of the cable tray of the platform transformer under wind vibration and temperature change conditions.

[0061] The first injection-molded half-frame 1, the second injection-molded half-frame 6, the fan-shaped smooth baffle 9, and the injection-molded connecting plate 11 are all integrally injection-molded using AS resin material.

[0062] The first injection-molded half-frame 1, the second injection-molded half-frame 6, the fan-shaped smooth baffle 9, and the injection-molded connecting plate 11 are all integrally injection molded from AS resin material. AS resin is a copolymer of acrylonitrile and styrene, which has insulation, dimensional stability, and surface molding capability in outdoor environments. The integral molding method using the same resin can avoid long-term relaxation at the joint of dissimilar materials due to different coefficients of thermal expansion, and also avoid the damage to the pure insulation characteristics of the cable tray accessories by metal hinges or metal connecting pieces.

[0063] During manufacturing, the first injection-molded half-frame 1 and the first end face toothed disc 3 share the same cavity for molding, while the second injection-molded half-frame 6, the second end face toothed disc 7, and the central pivot 8 share another cavity for molding. The fan-shaped smooth baffle 9 is simultaneously molded on the half-frame body, and the injection-molded connecting plate 11 is used as an outer pressure plate after being molded independently. During overall assembly, axial clamping is achieved only through the fastening component 12, without the need for cutting or drilling correction on the resin body. This combination of materials and processes allows the optical strain gauge 10 on the outer circumference of the toothed disc to be directly replicated in the mold, ensuring a fixed correspondence between the feature point spacing and the tooth pitch, which facilitates subsequent image inversion calculations to extract angular displacement and misalignment based on a unified benchmark.

[0064] The optical strain gauge 10 is represented by a uniform array of raised lines arranged along the circumference.

[0065] The optical strain gauge 10 uses a uniform array of protrusions arranged along the circumference. Each protrusion in the array can be set as a hemispherical crown, a short prism, or a truncated cone, with a height of 0.2 mm to 1.2 mm, a bottom width of 0.3 mm to 1.5 mm, and a center-to-center distance between adjacent protrusions of 0.8 mm to 3 mm. The reason for using protrusions instead of grooves is that even after dust and dirt adhere to them outdoors, the protrusions can still easily form a stable shadow boundary through side lighting. When a handheld computing device acquires an image, it can simultaneously identify the grayscale gradient and geometric contour, which is beneficial to improving pixel-level positioning accuracy.

[0066] The array is evenly distributed along the circumference of the toothed disc, ensuring that a sufficient number of markings are present in the field of view at any installation angle. The calculation program can extract the corresponding upper and lower rows of markings from the same image to calculate the tangential relative misalignment and circumferential angular displacement. The protrusion array and the trapezoidal anti-shear tooth 5 are not independently set up; their arrangement in the circumferential direction has a fixed geometric relationship. This allows the externally visible features to represent the internal meshing geometry, reducing the reliance on disassembly and inspection at the construction site.

[0067] Fastening assembly 12 includes fastening bolt 13 and mating nut 14;

[0068] The fastening assembly 12 consists of a fastening bolt 13 and a mating nut 14. The fastening bolt 13 passes through the injection-molded connecting plate 11 on one side, the internal through hole of the central pivot 8, and the injection-molded connecting plate 11 on the other side. The nut 14 is located on the side opposite to the bolt head and is used to form an adjustable axial clamping force. The bolt specification can be selected from M6 to M12 according to the cable tray size. Fine thread is preferred to improve the clamping force adjustment accuracy. The nut 14 can be a hexagonal nut 14 or a nut 14 with an anti-loosening structure. The preset basic locking torque can be set from 4 N·m to 35 N·m according to the bolt specification.

[0069] Since the rigid engagement of the gear disc relies on a continuous and stable axial clamping force, the fastening bolt 13 provides clamping stroke and the nut 14 provides repeatable adjustment capability. Together, they enable the construction personnel to implement the final locking after angle adjustment, engagement verification, and thermal expansion pre-compensation. The use of detachable fastening components 12 instead of permanent welding or riveting facilitates readjustment during subsequent maintenance. Furthermore, the nominal diameter, comprehensive torque coefficient, effective clamping length, and stiffness coefficient of the fastening components 12 can all be used as quantifiable input parameters in the method steps, improving the consistency of locking verification.

[0070] The central pivot 8 and the pivot hole 4 of the first injection-molded half frame 1 are set with clearance fit;

[0071] The central pivot 8 and the pivot hole 4 are set with a clearance fit. The purpose is to provide smooth rotation capability for the two halves of the frame when the fastening component 12 is loosened, and to retain axial and radial self-adjustment space within a preset tolerance range before clamping, so that the trapezoidal anti-shear teeth 5 can self-align during meshing. The clearance value can be set to 0.05mm to 0.50mm according to the injection shrinkage tolerance and assembly tolerance, preferably 0.10mm to 0.25mm. Within this range, the half frame can maintain smooth relative rotation when rotating around the central pivot 8, and can limit the radial runout of the end face toothed disk in the initial state, so as to meet the self-aligning meshing requirements of the trapezoidal anti-shear teeth 5.

[0072] Since the final load is borne by the clamping engagement of the gear discs, the main function of the central pivot 8 is to provide a rotational guide for angle adjustment and a passage for fastening assembly 12. The clearance fit helps to eliminate the influence of individual size differences of injection molded parts on on-site angle adjustment. After clamping and locking, the axial clamping force presses the end faces of the two gear discs together, and the clearance fit no longer becomes the main force interface. Therefore, it can take into account both assembly flexibility and load-bearing stability.

[0073] The optical strain gauge 10 is a geometric array structure disposed on the outer edge of the first end face toothed disk 3 and the second end face toothed disk 7;

[0074] The three-dimensional spatial relative misalignment of the optical strain gauge 10 refers to the relative offset of the corresponding protrusion array on the outer circumferential sidewall of the two end face tooth disks in the circumferential tangential, axial projection and local height shadow boundary. This offset is not used as a general decorative pattern in this device, but as an external geometric quantity characterizing the micro-engagement state of the internal trapezoidal anti-shear tooth 5.

[0075] When the fastening assembly 12 has not applied sufficient clamping force, there is a normal separation distance between the two toothed discs. The trapezoidal anti-shear teeth 5 only approach each other in a state of partial contact or tooth tip suspension. Since the tooth surface is inclined, the same normal separation will be reflected as measurable tangential misalignment on the outer peripheral marking line, and the magnitude of tangential misalignment is related to the tooth surface angle.

[0076] When the clamping force increases, the normal separation decreases, and the effective contact area increases, the relative misalignment between the markings tends to the design reference value. Thus, the internal engagement can be judged by external images. This mapping relationship provides a basis for non-contact detection. Construction personnel do not need to disassemble the connecting parts or rely on their sense of touch to estimate the degree of tooth engagement and load-bearing capacity based on the relative position of the markings, thereby improving the consistency of locking status confirmation.

[0077] This mapping relationship essentially establishes a microscopic meshing state characterization model. The purpose of this model is to accurately estimate the actual contact area and load-bearing potential of the trapezoidal shear-resistant tooth 5 when the internal tooth surface cannot be directly measured. Logically, the model receives the tangential misalignment and axial projection offset of the optical strain gauge 10 as inputs, and calculates the normal separation distance between the tooth discs by combining the known geometric dimensions of the tooth discs. At the same time, the normal separation distance is used as an internal state variable to further derive the effective contact area.

[0078] The model as a whole characterizes the synchronous displacement law of internal and external structures with fixed geometric relationship under rigid stress, as well as the direct physical causal relationship between external deformation and internal mechanical meshing strength: because the internal and external structures are integrally formed and the geometric relationship is fixed, the spatial misalignment of the external markings directly reflects the normal separation of the internal tooth surface, which determines the size of the shear-resistant contact surface.

[0079] Example 2:

[0080] A multi-angle adaptation and security lock verification method, such as Figure 4 As shown, it includes:

[0081] S1. Loosen the fastening assembly 12, rotate the first injection half frame 1 and the second injection half frame 6 to the target angle, and drive the fan-shaped smooth baffle 9 to rotate to the target position, and initially tighten the fastening assembly 12 so that the trapezoidal anti-shear teeth 5 on the first end face toothed plate 3 and the second end face toothed plate 7 are engaged accordingly.

[0082] S2. Extract the images of the optical strain gauges 10 on the outer sides of the first end face toothed disk 3 and the second end face toothed disk 7 using a handheld computing device, and identify and obtain the relative misalignment distance.

[0083] S3. Evaluate the ultimate torque value under the current occlusal state based on the relative misalignment distance;

[0084] S4. Determine the actual angle based on the optical strain gauge 10, and obtain the radius of curvature of the internal cable trajectory at the transition position;

[0085] S5. Read the ambient temperature at the construction site and determine the amount of deformation compensation caused by temperature.

[0086] S6. Determine the torque compensation value based on the deformation compensation amount, and adjust the locking torque according to the torque compensation value to complete the fastening;

[0087] The method is executed by a handheld computing device, which can be an industrial tablet, a handheld terminal with a camera and computing program, or a mobile device with a dedicated program installed; in S1, the construction personnel loosen the fastening component 12 to the state where the toothed disc can be separated and rotated, adjust the included angle between the first injection molded half frame 1 and the second injection molded half frame 6 to adapt to the direction of the cable tray on site, and keep the fan-shaped smooth baffle 9 overlapping and covering the bottom of the two half frames to prevent the formation of through gaps. The fastening component 12 is initially tightened so that the trapezoidal anti-shear tooth 5 enters the corresponding tooth position;

[0088] In S2, the handheld computing device takes pictures of the outer circumferential sidewalls of the two end face toothed disks. The image acquisition distance can be 100mm to 500mm. The pixel size is converted into physical size by the known calibrated pitch or additional calibration scale, and the actual physical misalignment distance corresponding to the tangential pixel misalignment is obtained.

[0089] In S3, if the angle of the inclined plane of the trapezoidal shear-resistant tooth 5 is α, and the angle α is defined as the angle between the force-bearing inclined plane of the trapezoidal shear-resistant tooth 5 and the axis of the central pivot 8, then the normal separation distance can be calculated by dividing the actual physical misalignment distance by... Based on the effective contact radius of the toothed disc, the reduction ratio of the current contact area of ​​the trapezoidal shear-resistant tooth 5, and the allowable shear stress of the AS resin material, the load-bearing capacity of each contact tooth is estimated and summarized into the ultimate torque value of the entire joint; the specific evaluation formula is as follows: [Formula omitted for brevity] The initial design tooth height of the trapezoidal anti-shear tooth 5 is The current contact area reduction ratio According to the formula:

[0090]

[0091] Calculation; load-bearing capacity of a single shear tooth:

[0092]

[0093] in, The design reference force-bearing area for a single tooth. The allowable shear stress of the AS resin material; the ultimate torque resistance of the entire joint:

[0094]

[0095] in, The effective contact radius of the gear disc. This refers to the effective contact number of the toothed disc in effective engagement. The preset load-bearing threshold is determined based on the product of the cable's design self-weight load under the worst operating conditions, the preset maximum wind vibration load, and the safety factor, and is pre-entered into the handheld computing device.

[0096] In S4, the actual angle between the two halves of the frame is calculated based on the absolute angular displacement of the optical strain gauge 10 in the circumferential direction. After the angle is determined, the fixed radius of the fan-shaped smooth baffle 9 is used as the intermediate transition geometric constraint to obtain the continuous inscribed circular arc trajectory formed between the inner wall of the first injection-molded half frame 1, the edge of the baffle, and the inner wall of the second injection-molded half frame 6, and calculate its equivalent radius of curvature.

[0097] In S5, the ambient temperature at the construction location is read, and the difference between it and the standard injection molding temperature of AS resin is taken as the temperature difference value. The temperature difference value, the linear expansion coefficient of AS resin, and the effective clamping length of fastening component 12 are multiplied to obtain the axial deformation caused by temperature.

[0098] In S6, based on the nominal diameter, comprehensive torque coefficient, and stiffness coefficient parameters of the fastening component 12, the axial deformation is converted into a torque compensation value, which is then added to the preset basic locking torque as the setting value of the torque wrench. The specific conversion formula is as follows:

[0099]

[0100] in, This is the torque compensation value. The overall torque coefficient of fastening assembly 12, The nominal diameter of the bolt for fastening assembly 12 is... This represents the change in axial preload. The overall stiffness coefficient of fastening component 12 is given by This is the axial deformation compensation amount; the final torque wrench setting value:

[0101]

[0102] in, The preset base locking torque is used to ensure that the device maintains a relatively stable toothed disc clamping state even after seasonal temperature changes. The above conversion process essentially constitutes a thermal expansion pre-compensation torque conversion logic model. The purpose of this model is to compensate for the possible axial clamping force relaxation by adjusting the tightening torque in advance when the AS resin material undergoes thermal expansion and contraction due to seasonal temperature differences.

[0103] In terms of logic structure and data flow, the model receives the axial deformation compensation amount and the stiffness coefficient of the fastening component 12 as inputs to calculate the additional axial clamping force required to offset the deformation. It also receives the nominal diameter and the comprehensive torque coefficient as inputs to convert the additional axial clamping force into the corresponding torque compensation value.

[0104] The model as a whole characterizes the torque transmission law of the threaded pair under stress and deformation, as well as the dynamic mechanical balance relationship between material thermal expansion and mechanical clamping. The method enables angle adaptation, engagement verification, cable curvature verification and temperature compensation to be completed in the same process, and the relevant input quantities are all derived from the inherent geometric parameters of the device or measurable data on site.

[0105] To ensure that the above calculations have a consistent standard of reference on the construction site, the allowable shear stress refers to the upper limit of the shear stress that AS resin material can withstand for a long period of time under a predetermined safety factor. It can adopt the conservative value in the material sample, type test or enterprise design manual.

[0106] The contact area reduction ratio refers to the ratio of the actual tooth surface area currently involved in bearing load to the fully pressed design area. Its value is based on the degree of tooth surface contact corresponding to the normal separation distance. The smaller the normal separation distance, the closer the ratio is to 1. The larger the normal separation distance, the lower the ratio is according to the preset grading table. The preset basic locking torque refers to the reference torque value set in advance under standard temperature conditions, only to obtain the design clamping state. A reference table can be established in advance according to the bolt specifications and target axial clamping force.

[0107] The processing flow from S2 to S6 is executed sequentially according to the data flow direction, and the output of each step is used as the input of the next step. The input of S2 is the two end face tooth disk marking images, marking pitch and image calibration scale acquired at the same time. Its processing order is as follows: first, identify the center position of each row of protrusion array, then establish a one-to-one correspondence between the upper and lower rows of markings, calculate the tangential pixel offset, convert it into the actual physical misalignment distance, and output the actual physical misalignment distance in the tangential direction and the angular displacement in the circumferential direction.

[0108] The inputs to S3 are the output of S2, the tooth surface bevel angle, the effective contact radius, the allowable shear stress, and the contact area reduction ratio; its processing order is: first, based on:

[0109]

[0110] The actual physical misalignment distance will be tangential. Converted to normal separation distance ,in, The normal separation distance, The actual physical misalignment distance is tangential. The angle of the trapezoidal shear-resistant tooth is 5 on the inclined surface. The symbol represents the tangent operation. The effective contact radius refers to the radial distance between the geometric center of the trapezoidal shear-resistant tooth 5 and the rotation center of the central pivot 8. The reduction ratio of the current contact area is determined by looking up the table based on the normal separation distance. The ultimate torque value is obtained by summing the load-bearing capacity of each effective contact tooth. The output results are the normal separation distance and the ultimate torque value. This calculation process constructs a logical model for estimating shear bearing capacity. The purpose of this model is to accurately calculate the current ultimate torque of the internal tooth disk in a non-contact manner based on external displacement data.

[0111] In terms of logical structure and data flow, the model receives the normal separation distance and the contact area reduction ratio as inputs, calculates the current actual effective contact area, and calculates the single tooth bearing capacity by combining the input allowable shear stress and effective contact radius, and sums them up to obtain the ultimate torque value; the model characterizes the nonlinear physical attenuation causal relationship between tooth surface slope, normal clearance and actual bearing section under incomplete meshing state.

[0112] To ensure the above calculation process is feasible for software programming, a specific quantitative deduction example is provided: Assuming the inclined plane angle of the trapezoidal anti-shear tooth 5 is 45°, and the actual physical misalignment distance in the tangential direction received by the handheld computing device from the S2 output is 0.5mm, then the normal separation distance is calculated to be 0.5mm.

[0113] If the preset first separation threshold is 0.2mm and the second separation threshold is 0.8mm, and the current separation distance of 0.5mm is in the transition pressing zone, the program looks up the table to obtain the contact area reduction ratio of 0.6; given that the design area for complete pressing of a single tooth is 20mm², the allowable shear stress is 15MPa, and the effective contact radius is 50mm, then the current bearing capacity of a single tooth is 20×0.6×15=180N; if the number of effective contact teeth is 12, then the current ultimate torque value is calculated to be 180×12×50 / 1000=108N·m;

[0114] The input to S4 is the actual angle output by S2 and the fixed radius of the inherent fan-shaped smooth baffle 9 of the device; its processing sequence is as follows: first, determine the included angle between the two half-frames, then construct a continuous transition trajectory based on the junction of the inner wall of the first injection-molded half-frame 1, the edge of the baffle, and the inner wall of the second injection-molded half-frame 6, and obtain the equivalent radius of curvature of this trajectory. Specifically, the calculation model for the radius of curvature of the inscribed circular arc trajectory is as follows: let the actual angle between the first injection-molded half-frame 1 and the second injection-molded half-frame 6 be... The fixed radius of the edge of the fan-shaped smooth baffle 9 is The width of the hollow U-shaped wire groove 2 is Then the equivalent radius of curvature of the inscribed circular arc trajectory is:

[0115]

[0116] in, The equivalent radius of curvature of the inscribed circular arc trajectory; the output results are the actual angle and radius of curvature; the inputs to S5 are the ambient temperature, standard injection molding temperature, AS resin linear expansion coefficient, and effective clamping length of fastening component 12; the processing order is: first calculate the temperature difference value, then press:

[0117]

[0118] Calculate the axial deformation compensation, where, This is the axial deformation compensation amount. This is the temperature difference value. The coefficient of linear expansion is 1 / 3. For the effective clamping length, the output result is the axial deformation compensation amount; the input of S6 is the preset basic locking torque, axial deformation compensation amount, nominal diameter, comprehensive torque coefficient and stiffness coefficient; its processing order is as follows: first, the axial deformation compensation amount is converted into the required additional axial clamping force according to the stiffness coefficient, and then combined with the nominal diameter of the bolt of the fastening component 12 and the comprehensive torque coefficient, it is converted into a torque compensation value and superimposed on the preset basic locking torque, and the output result is the final locking torque setting value;

[0119] To further clarify the calculation rules and data flow of torque compensation, a quantitative simulation example is provided: assuming the ambient temperature read on-site is 20°C lower than the standard injection molding temperature, and the linear expansion coefficient of AS resin is 6×10⁻ 5 / ℃, the effective clamping length of fastening component 12 is 100mm, then the axial deformation compensation is -20×6×10⁻ 5 ×100=-0.12mm; The program receives this compensation amount. Given that the bolt stiffness coefficient is 50000N / mm, taking the absolute value of the deformation compensation amount, the required additional axial clamping force is calculated to be 0.12×50000=6000N; The required additional axial clamping force is calculated to be 0.12×50000=6000N;

[0120] The program obtains a preset comprehensive torque coefficient, which characterizes the friction and geometric constants of the threaded pair. Based on the standard formula for torque calculation, which states that torque equals the product of the comprehensive torque coefficient, the additional axial clamping force, and the nominal diameter of the bolt, and considering the nominal bolt diameter of 10mm and the comprehensive torque coefficient of 0.2, the torque compensation value is calculated to be 0.2×6000×10 / 1000=12N·m. The program then adds this 12N·m to the preset base locking torque output, thus providing a clear logical deduction path and traceable quantitative basis for the thermal expansion compensation calculation process.

[0121] To ensure that the judgment logic of the processing is clear and quantifiable, the contact area reduction ratio is preferably determined by a graded judgment method rather than a single fixed empirical value: when the normal separation distance is not greater than the preset first separation threshold, it is judged as a fully pressed area, and the first preset reduction ratio is applied accordingly; when the normal separation distance is greater than the first separation threshold but not greater than the second separation threshold, it is judged as a transitional pressed area, and the second preset reduction ratio is applied accordingly.

[0122] When the normal separation distance is greater than the second separation threshold, it is judged as an insufficient compression zone, and the corresponding third preset reduction ratio is adopted or it is directly judged as unqualified. Among them, the first preset reduction ratio is greater than the second preset reduction ratio, and the second preset reduction ratio is greater than the third preset reduction ratio. The first separation threshold and the second separation threshold can be pre-calibrated and stored in the handheld computing device based on the tooth height, tooth surface slope and prototype torque test results. The specific threshold setting logic is as follows: the maximum allowable normal clearance corresponding to the calculated single tooth ultimate torque just meeting the target load requirement is set as the first separation threshold; the normal clearance corresponding to the effective contact area decaying to 50% of the total design area is set as the second separation threshold, so that on-site personnel can complete the reproducibility judgment based on the unified threshold.

[0123] The steps between S3 and S4 include: obtaining a preset load threshold, comparing the ultimate torque value with the preset load threshold; if the ultimate torque value is lower than the load threshold, outputting a prompt to readjust the meshing gear; if the ultimate torque value is greater than or equal to the load threshold, proceeding to step S4.

[0124] A load-bearing threshold comparison step is set between S3 and S4 to convert the interlocking state obtained from image inversion into an executable construction criterion. The load-bearing threshold can be preset according to the cable tray model, cable self-weight, additional safety factor and platform transformer maintenance specifications. For example, it can be set to 20 N·m to 80 N·m for small and medium-sized cable trays and 80 N·m to 200 N·m for large-sized cable trays.

[0125] The handheld computing device compares the ultimate torque value obtained by S3 with the load threshold. When the ultimate torque value is lower than the load threshold, it indicates that the normal separation distance is too large, the effective contact area is insufficient, or the current tooth position is not sufficiently pressed. The program outputs a prompt to readjust the meshing position. The prompt may include suggestions to loosen the fastening component 12, back one tooth position, or continue to tighten and retest.

[0126] When the ultimate torque value is greater than or equal to the load-bearing threshold, it indicates that the current engagement state meets the predetermined load-bearing requirements, and the program allows entry into S4 to perform cable curvature verification. This comparison step ensures that subsequent curvature calculations are based solely on qualified mechanical locking, avoiding continued construction in a loose connection state, thereby reducing the risk of cable tray posture changes caused by joint loosening during long-term operation.

[0127] The physical meaning of the load-bearing threshold is the minimum torsional load requirement that the joint should meet at the current installation position. It is not an arbitrary empirical value, but a logical threshold used to determine whether the current engagement state is sufficient to withstand the self-weight of the cable tray, the weight of the cable, wind vibration disturbance, and the additional load of maintenance operations. The preferred method for determining it is to execute it in the following order: first, read the cable tray specifications, the total weight or unit length weight of the cable to be laid, the length of the transition section, and the preset safety factor; then, establish the target load-bearing requirement based on the design torque that may be generated in this installation scenario; convert the target load-bearing requirement into the minimum qualified value of the ultimate torque and write it into the handheld computing device.

[0128] This determination method essentially constructs a target load-bearing requirement assessment logic model. The purpose of this model is to dynamically set the minimum safe load-bearing threshold that the joint must meet for different construction scenarios. In terms of logical structure and data flow, the model receives cable weight, transition section length and cable tray specifications as inputs, calculates the maximum static load torque that the transition joint can withstand under extreme working conditions, multiplies the static load torque by a preset safety factor, and outputs the final load-bearing threshold.

[0129] This model characterizes the complex torque distribution physical relationship of a cable tray system at connection nodes under the combined action of external loads such as gravity, wind load, and mechanical vibration. To ensure that this evaluation model can be accurately programmed in software, its specific calculation rules are broken down as follows: Target load-bearing requirement = (Cable unit weight × Transfer section length + Cable tray self-weight) × Center of gravity offset distance + Wind load torque. A specific quantitative simulation example illustrates this: If the program receives data showing a heavy cable unit weight of 50 N / m, a transfer section length of 2 m, a cable tray self-weight of 100 N, and a center of gravity offset of 0.1 m from the central pivot, the static load torque is calculated to be (50 × 2 + 100) × 0.1 = 20 N·m. If the maximum additional torque from wind load is 15 N·m, then the target load-bearing requirement is calculated to be 35 N·m.

[0130] The program multiplies 35 N·m by a preset safety factor of 1.5, outputting a load-bearing threshold of 52.5 N·m. This deduction process transforms the abstract load-bearing requirement into a system judgment standard with clear data flow and quantitative basis. For situations where precise on-site weight data is lacking, the default load-bearing threshold table corresponding to the cable tray model can be directly called. The default load-bearing threshold table is pre-calculated and calibrated based on standard environmental wind load and the full load weight of cables under the maximum design volume ratio of each cable tray model, ensuring that different construction personnel use consistent judgment standards.

[0131] The processing flow of this comparison step is as follows: receive the ultimate torque value output by S3; read the load threshold corresponding to this device; perform a size comparison; if the comparison result is lower than the threshold, write the unqualified state into the current assembly record and trigger a rectification prompt, and the rectification prompt preferably provides three types of suggestions in sequence: continue to tighten and retest, reselect the adjacent meshing gear, and check the stress conditions of the cable tray; if the comparison result is greater than or equal to the threshold, write the load qualified state into the assembly record and allow the program to enter S4; thus, the load threshold is not only a numerical threshold, but also a logical trigger condition in the control flow that determines whether to enter the subsequent curvature verification step.

[0132] The steps between S4 and S5 include: obtaining the preset safe bending radius, comparing the curvature radius of the internal cable's trajectory with the preset safe bending radius; if the curvature radius is lower than the preset safe bending radius, outputting a prompt to add a straight section transition of the cable tray; if the curvature radius is greater than or equal to the preset safe bending radius, proceeding to step S5.

[0133] A curvature radius comparison step is set between S4 and S5 to establish a direct correspondence between the angle adjustment result and the cable insulation safety requirements. The preset safe bending radius can be set to not less than 12D to 20D based on the outer diameter D of the heavy cable to be laid, or it can be input into the handheld calculation device based on the minimum allowable bending radius given by the cable manufacturer.

[0134] The program compares the radius of curvature of the inscribed arc trajectory obtained by S4. When the radius of curvature is lower than the preset safe bending radius, it means that although the angle of the two halves of the frame matches the direction of the cable tray, the bending degree of the cable formed by the inner wall transition arc exceeds the allowable limit. The program determines that there is a risk of scratching the insulation layer or reducing the cable life, and outputs a prompt to add a straight section of the cable tray transition. The prompt may include adding a certain length of straight cable tray section before and after the current adapter, or reselecting the adjacent meshing position to reduce the degree of bend.

[0135] When the radius of curvature is greater than or equal to the preset safe bending radius, the program determines that the current angle combination meets the laying requirements and enters S5 to perform thermal expansion pre-compensation calculation; this step makes the geometric function of the fan-shaped smooth baffle 9 not only reflected in blocking gaps, but also calculates the continuous transition curvature of the cable when passing through the joint by linking with the actual angle, thereby transforming the inner wall smooth design into a quantifiable cable protection criterion.

[0136] The preset safe bending radius is the minimum permissible bending radius that prevents excessive stretching, wrinkling, or stress concentration of the insulation layer during long-term operation of the cable. Its physical significance lies in limiting the minimum transition curvature of the cable when passing through the transfer device. The preferred method for determining it is to follow the order below: first, read the outer diameter, structural type, and manufacturer's specifications of the cable to be laid; if the manufacturer provides a minimum permissible bending radius, then directly use that value as the preset safe bending radius; if the manufacturer does not provide one, then select it according to a preset multiple of the cable's outer diameter D, and for heavy or multi-core cables, use a higher preset multiple than that for single-core unarmored cables to form a protection standard with a higher safety margin.

[0137] Specifically, the selection logic and system data interaction process of the preset multiplier are as follows: The handheld computing device has a built-in multiplier reference table for common cable types, such as 15 times for single-core unarmored cables and 20 times for multi-core or steel tape armored cables; when the program receives an input that the outer diameter D of the heavy armored cable to be laid is 30mm, it automatically looks up the table to retrieve the multiplier of 20, calculates and outputs the preset safe bending radius of 600mm;

[0138] In subsequent comparisons, if the radius of curvature of the inscribed circular arc trajectory output by S4 is 500mm, the program performs numerical comparison and generates a Boolean trigger signal representing the curvature risk. This signal is directly transmitted to the user interface module through the internal data stream, driving the screen to pop up a warning message and providing specific rectification directions. This clear logical decomposition and data flow ensures that the protection criteria have both sufficient theoretical basis and can be accurately executed by the software system.

[0139] The input for this comparison step is the radius of curvature of the inscribed circular arc trajectory output by S4 and the pre-stored safe bending radius. The processing sequence is as follows: confirm whether the cable model has been selected; retrieve the corresponding safe bending radius; and compare the radius of curvature of the inscribed circular arc trajectory with it.

[0140] If the result is lower than the safe bending radius, the curvature risk status is output and the process is stopped from entering S5. At the same time, the rectification direction is given. The rectification direction includes at least one of the following: increasing the straight section transition of the cable tray, reselecting the engagement gear so that the curvature radius corresponding to the actual angle is greater than the safe bending radius, or adjusting the installation position of the adapter before and after.

[0141] If the result is greater than or equal to the safe bending radius, the curvature is output as qualified and S5 is allowed to be executed; thus, the safe bending radius is not only used for geometric verification, but also serves as a procedural threshold for deciding whether to continue the temperature compensation locking calculation.

[0142] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A modular AS cable tray adapter with multi-angle adjustable features, characterized in that, include: The first injection-molded half frame (1) has a hollow U-shaped groove (2) inside, and its end is integrally injection-molded with a first end face toothed disc (3). The first end face toothed disc (3) has a pivot hole (4) in the center and trapezoidal anti-shear teeth (5) distributed on its surface. The second injection-molded half frame (6) has a hollow U-shaped groove (2) inside. Its end is integrally injection-molded with a second end face toothed disc (7) and a central pivot (8). The surface of the second end face toothed disc (7) is distributed with matching trapezoidal anti-shear teeth (5). The central pivot (8) has a through hole inside. The central pivot (8) and the pivot hole (4) cooperate to form a rotating pair. The fan-shaped smooth baffle (9) is integrally injection molded on the lower part of the inner side wall of the first injection half frame (1) or the second injection half frame (6). When the first injection half frame (1) and the second injection half frame (6) rotate relative to each other around the central pivot (8), the fan-shaped smooth baffle (9) overlaps and slides at the bottom of the hollow U-shaped groove (2) of the other injection half frame. Optical strain gauges (10) are directly injection molded onto the outer circumferential sidewalls of the first end face toothed disk (3) and the second end face toothed disk (7); Injection-molded connecting plate (11) symmetrically covers the outer sides of the first end face gear plate (3) and the second end face gear plate (7); The fastening assembly (12) passes through the internal through holes of the two side injection molding connecting plates (11) and the central pivot (8) and presses together the first injection molding half frame (1) and the second injection molding half frame (6).

2. The multi-angle adjustable modular AS cable tray adapter according to claim 1, characterized in that, The trapezoidal anti-shear teeth (5) number 72, and the fastening assembly (12) presses the first injection-molded half frame (1) and the second injection-molded half frame (6) together, with the trapezoidal anti-shear teeth (5) abutting against each other.

3. The multi-angle adjustable modular AS cable tray adapter according to claim 1, characterized in that, The first injection-molded half frame (1), the second injection-molded half frame (6), the fan-shaped smooth baffle (9) and the injection-molded connecting plate (11) are all integrally injection molded from AS resin material.

4. The multi-angle adjustable modular AS cable tray adapter according to claim 1, characterized in that, The optical strain gauge (10) is represented by a uniform array of protrusions arranged along the circumference.

5. The multi-angle adjustable modular AS cable tray adapter according to claim 1, characterized in that, The fastening assembly (12) includes a fastening bolt (13) and a mating nut (14).

6. The multi-angle adjustable modular AS cable tray adapter according to claim 1, characterized in that, The central pivot (8) and the pivot hole (4) of the first injection-molded half frame (1) are configured with a clearance fit.

7. The multi-angle adjustable modular AS cable tray adapter according to claim 1, characterized in that, The optical strain gauge (10) is a geometric array structure arranged on the outer edge of the first end face toothed disk (3) and the second end face toothed disk (7).

8. A multi-angle adaptation and safety locking verification method, applied to the multi-angle adjustable modular AS cable tray adapter as described in claim 1, characterized in that, include: S1. Loosen the fastening assembly (12), rotate the first injection half frame (1) and the second injection half frame (6) to the target angle, and drive the fan-shaped smooth baffle (9) to rotate to the target position. Preliminarily tighten the fastening assembly (12) so that the trapezoidal anti-shear teeth (5) on the first end face toothed plate (3) and the second end face toothed plate (7) are engaged accordingly. S2. Extract the optical strain gauge (10) images of the outer sides of the first end face toothed disk (3) and the second end face toothed disk (7) using a handheld computing device, and identify and obtain the relative misalignment distance; S3. Evaluate the ultimate torque value under the current occlusal state based on the relative misalignment distance; S4. Determine the actual angle based on the optical strain gauge (10) and obtain the radius of curvature of the internal cable trajectory at the transition position; S5. Read the ambient temperature at the construction site and determine the amount of deformation compensation caused by temperature. S6. Determine the torque compensation value based on the deformation compensation amount, and adjust the locking torque according to the torque compensation value to complete the fastening.

9. The multi-angle adaptation and security lock verification method according to claim 8, characterized in that, The steps between S3 and S4 include: obtaining a preset load threshold, comparing the ultimate torque value with the preset load threshold; if the ultimate torque value is lower than the load threshold, outputting a prompt to readjust the engagement gear; if the ultimate torque value is greater than or equal to the load threshold, proceeding to step S4.

10. The multi-angle adaptation and security lock verification method according to claim 8, characterized in that, The steps between S4 and S5 include: obtaining a preset safe bending radius and comparing the curvature radius of the internal cable's trajectory with the preset safe bending radius; If the radius of curvature is lower than the preset safe bending radius, a prompt to increase the transition of the straight section of the cable tray is output; if the radius of curvature is greater than or equal to the preset safe bending radius, proceed to step S5.

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