Barrier Cable Coupler With Wedge Locking and Adjustable Tension
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Solution Overview
Problem
Existing barrier cable systems lack an efficient method to securely couple and tension multiple lengths of barrier cables, which is crucial for effective vehicle and pedestrian restraint systems.
Innovation Solution
A barrier cable coupler system that includes a coupler body with fixed and tensioning retaining collars, wedges, and nuts, allowing for secure engagement and tensioning of cable ends, utilizing tapered surfaces and springs to enhance frictional retention and adjustable tensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier cable coupler system is implemented to couple and tension multiple lengths of barrier cables, then the security and stability of the barrier cable assembly are improved, but the device complexity increases due to multiple components including collars, wedges, springs, and nuts
Solution Approach 1:
The coupler body is divided into distinct functional segments: a fixed retaining collar for securing the first cable length, and a tensioning retaining collar with adjustable nut for the second cable length. This segmentation allows each component to perform its specific function independently while contributing to the overall reliability of the assembly.
Solution Approach 2:
The retaining collars, wedges, and springs are nested within the coupler body in a compact arrangement. The fixed retaining collar and tensioning retaining collar are positioned end-to-end within the coupler body, with wedges and springs nested within the collars, creating a space-efficient design that reduces overall device complexity despite multiple components.
2Strength
If tapered surfaces and springs are used in the retaining collars to enhance frictional retention, then the resistance to cable removal is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The tapered surfaces in the retaining collars provide a gradual change in contact area and friction force as the wedges are driven home. This parameter change (from wide to narrow contact) creates a self-energizing effect that enhances cable retention strength. The springs provide variable force based on compression, allowing the system to accommodate manufacturing tolerances while maintaining strong retention.
Solution Approach 2:
The tapered surfaces and springs work together to create a self-adjusting mechanism. As the wedges are driven into the tapered collars, the springs compress and provide continuous pressure, automatically compensating for minor variations in wedge positioning or cable diameter without requiring high manufacturing precision.
3Adaptability or versatility
If a tensioning nut is used to provide adjustable tensioning of the barrier cable, then the adaptability of the system is improved, but the ease of operation decreases due to the additional adjustment mechanism
Solution Approach 1:
The tensioning nut serves multiple functions: it secures the second cable length in the tensioning retaining collar, provides adjustable tensioning capability, and acts as a locking mechanism. This multi-functionality reduces the need for separate components for each function, simplifying the overall operation despite the added adjustment capability.
Solution Approach 2:
The tensioning function is merged with the retaining function in the tensioning retaining collar assembly. The nut simultaneously performs tensioning and securing operations, combining what could have been separate steps into a single integrated action, thereby maintaining ease of operation while providing adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively couples and tensions barrier cables, providing enhanced security and stability by resisting removal and allowing adjustable tension, thus improving the overall performance of barrier cable assemblies.
Implementation Method 1
The outer surface of the fixed retaining collar is retained to the threaded inner surface of the coupler body at the first end. The fixed retaining collar includes a tapered inner surface. The barrier cable coupler also includes one or more fixed end wedges positioned within the tapered inner surface of the fixed retaining collar
Implementation Method 2
The barrier cable coupler also includes one or more fixed end wedges positioned within the tapered inner surface of the fixed retaining collar
Implementation Method 3
The barrier cable coupler further includes a first spring cap retained to the inner surface of the coupler body at the first end, a first spring positioned between the fixed end spring cap and the one or more fixed end wedges
Implementation Method 4
The barrier cable coupler also includes one or more tensioning end wedges positioned within the tapered inner surface of the tensioning retaining collar and a tensioning nut. The tensioning nut includes an outer surface, where the outer surface of the tensioning nut is retained to the inner surface of the coupler body
Data Source
AI summary
A barrier cable coupler for coupling two lengths of barrier cable comprises a coupler body including a threaded inner surface, a first end, and a second end; a fixed retaining collar having an outer surface and being retained to the first end of the coupler body, the fixed retaining collar including a tapered inner surface; one or more fixed end wedges positioned within the tapered inner surface of the fixed retaining collar; a tensioning retaining collar having an outer surface, the tensioning retaining collar positioned at least partially within the second end of the coupler body and including a tapered inner surface; one or more tensioning end wedges positioned within the tapered inner surface of the tensioning retaining collar; and a tensioning nut including a threaded outer surface engaging the threaded inner surface of the second end of the coupler body and retaining the tensioning retaining collar therein.