Armored Synthetic Cable Structure for Abrasion-Prone Draglines

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Solution Overview

Problem

Existing dragline and power shovel operations face challenges with steel chain and wire rope systems due to their weight, susceptibility to abrasion, and elongation, which affects performance and safety in hostile environments.

Innovation Solution

A novel armored cable construction using high-strength synthetic filament cables with a tough termination and external armoring, which provides protection and durability, allowing these cables to be used in harsh environments by preventing abrasion and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If steel chain and wire rope systems are used, then strength and toughness are sufficient for hostile environments, but weight is excessive and susceptibility to abrasion and elongation occurs

Engineering Contradiction:
ImprovestrengthVSAvoidweight
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

The invention uses composite materials by combining synthetic filament cable core with steel wire armoring layers. The synthetic filaments (such as Dyneema, Spectra, or Kevlar) provide high strength-to-weight ratio, while the steel wire armoring provides toughness and abrasion resistance. This composite structure resolves the contradiction by achieving sufficient strength with reduced weight compared to all-steel constructions.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The invention applies local quality by providing steel wire armoring only in specific locations where abrasion and cut damage are most likely to occur (such as near the bucket and along the cable path), rather than using steel throughout the entire cable length. This allows the cable to have sufficient toughness where needed while maintaining the weight advantages of synthetic materials in other sections.

Inventive Principle:
Principle #3Local quality

2Reliability

If steel chain and wire rope systems are used, then toughness and abrasion resistance are adequate, but elongation occurs affecting performance

Engineering Contradiction:
Improveabrasion resistanceVSAvoidelongation
Core Design Contradiction:
ReliabilityVSLength of moving object

Solution Approach 1:

The composite structure combines synthetic filaments with very low elongation characteristics with steel wire armoring that provides dimensional stability. The synthetic core materials (such as HMWPE or aramid filaments) inherently exhibit minimal elongation under load, and the steel armoring further constrains any potential stretching, resolving the contradiction between reliability and length stability.

Inventive Principle:
Principle #40Composite materials

3Weight of moving object

If synthetic filament cables are used, then weight is reduced and strength-to-weight ratio is improved, but susceptibility to abrasion and cut damage increases

Engineering Contradiction:
ImproveweightVSAvoidabrasion susceptibility
Core Design Contradiction:
Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The invention uses composite materials by combining synthetic filament cable core with steel wire armoring layers. The synthetic filaments (such as Dyneema, Spectra, or Kevlar) provide high strength-to-weight ratio, while the steel wire armoring provides toughness and abrasion resistance. This composite structure resolves the contradiction by achieving sufficient strength with reduced weight compared to all-steel constructions.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The invention applies local quality by providing steel wire armoring only in specific locations where abrasion and cut damage are most likely to occur (such as near the bucket and along the cable path), rather than using steel throughout the entire cable length. This allows the cable to have sufficient toughness where needed while maintaining the weight advantages of synthetic materials in other sections.

Inventive Principle:
Principle #3Local quality

4Weight of moving object

If synthetic filament cables are used, then strength-to-weight ratio is improved, but toughness and durability in hostile environments are insufficient

Engineering Contradiction:
ImproveweightVSAvoidtoughness
Core Design Contradiction:
Weight of moving objectVSStrength

Solution Approach 1:

The invention uses composite materials by combining synthetic filament cable core with steel wire armoring layers. The synthetic filaments (such as Dyneema, Spectra, or Kevlar) provide high strength-to-weight ratio, while the steel wire armoring provides toughness and abrasion resistance. This composite structure resolves the contradiction by achieving sufficient strength with reduced weight compared to all-steel constructions.

Inventive Principle:
Principle #40Composite materials

Data Source

PatentUS10961683B2Cable armoring system
Publication Date: 2021.03.30 CAMPBELL RICHARD V
  • US10961683B2 patent drawing
  • US10961683B2 patent drawing
  • US10961683B2 patent drawing

AI summary

A novel cable construction provides an armored covering over a cable containing high-strength synthetic filaments. The synthetic cable is provided with a strong and tough termination where it attaches to the prior art dragline or power shovel digging equipment. An external armoring is then provided from the termination for a specified distance up the cable. The armoring ceases prior to the point where the cable passes over a pulley. At that point the cable just carries a conventional encapsulating jacket. A collar is preferably provided to seal the end of the armoring portion to the jacket.