Armored Cable Terminal Anchoring Copper Armor Wires
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Solution Overview
Problem
Conventional anchoring structures for copper-based armoring in armored cables are not suitable for long-term anchoring due to mechanical differences between copper and iron wires, leading to inadequate anchoring and potential damage when subjected to stress.
Innovation Solution
A terminal structure for armored cables featuring terminal metal fittings attached to copper or copper alloy armor wires, supported by a base plate with fixing members that maintain the wires in a stretched state, reducing bending and ensuring secure anchoring through a combination of base and tip nuts, and a spacer that adjusts wire angles to align with the cable's axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional anchoring structures designed for iron wires are used for copper-based armor wires, then the anchoring structure can be maintained with existing designs, but the anchoring reliability deteriorates due to mechanical differences between copper and iron wires leading to inadequate anchoring and potential damage under stress
Solution Approach 1:
The patent modifies the anchoring structure parameters by introducing a conical expansion section in the armor wire and corresponding conical surfaces in the anchoring device. This geometric parameter change allows the copper-based armor wire to be mechanically engaged and expanded against the anchoring device walls, creating friction-based anchoring that adapts to copper's mechanical properties rather than relying on iron wire-specific characteristics.
Solution Approach 2:
The anchoring device is segmented into distinct functional zones: an insertion section for guiding the armor wire, an expansion section with conical surfaces for mechanical engagement, and a fixing section with threading for final securing. This segmentation allows each zone to address specific anchoring requirements, ensuring reliable fixation of copper-based armor wires through a multi-stage process.
2Duration of action of stationary object
If armor wires are anchored with excessive bending, then the anchoring structure becomes simpler, but the duration of action deteriorates due to potential damage and inadequate long-term anchoring
Solution Approach 1:
The anchoring device performs preliminary actions by first guiding the armor wire through the insertion section, then progressively expanding it in the expansion section before final fixation. This preliminary expansion and gradual engagement prevent sudden stress concentrations and excessive bending that would occur with direct rigid anchoring, thereby protecting the wire and ensuring long-term durability.
3Strength
If a complex anchoring structure is used to ensure secure fixation, then the anchoring strength improves, but the ease of manufacture deteriorates due to increased structural complexity
Solution Approach 1:
The anchoring device merges multiple anchoring functions into a single integrated component: the insertion section, expansion section with conical surfaces, and threading section are combined in one piece. This unified structure achieves strong anchoring of copper-based armor wires through geometric design rather than requiring multiple separate components, thereby maintaining manufacturing simplicity while ensuring anchoring strength.
Data Source
AI summary
A terminal structure of an armored cable includes an end of an armored cable, a terminal metal fitting, and a support. The end includes a core, and an armoring including armor wires made of copper or copper alloy disposed on an outer circumference of the core. The terminal metal fitting is attached to an end of each armor wire. The support is disposed on a tip side of the core and supports a plurality of the terminal metal fittings. The support includes a base plate and a fixing member. The base plate is provided with a first through hole into which the core is inserted, and second through holes which are provided on an outer circumference of the first through hole and into each of which a corresponding one of the terminal metal fittings is inserted. The fixing member fixes each terminal metal fitting to the base plate.