Non-Metallic Cable Support Bracket for Confined Spaces
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Solution Overview
Problem
Existing cable support systems in underground environments, such as manholes and tunnels, face issues with corrosion, safety hazards, and inability to accommodate the expansion of high-strength electrical utility cables due to metal components, and existing non-metallic solutions are inadequate for secure, elevated positioning and movement accommodation.
Innovation Solution
A non-metallic, high-strength, compact cable support bracket made of 40% fiber-reinforced nylon or polypropylene, featuring a cantilevered design with I-beam sections, crossed trusses, and a tapered shape for secure attachment to a stanchion without screws or bolts, allowing for controlled cable movement and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used in cable support racks, then strength and structural integrity are improved, but galvanic and stray current corrosion occurs leading to damage or destruction
Solution Approach 1:
The cable support rack uses composite materials consisting of a polymer matrix (such as polyethylene, polypropylene, or polyester) reinforced with fibers (such as glass fibers, carbon fibers, or aramid fibers). This composite structure provides high strength and structural integrity comparable to metal while being immune to galvanic and stray current corrosion, thus resolving the contradiction between strength and corrosion resistance.
2Strength
If metal cable support racks are used, then load-bearing capacity is improved, but safety hazards are created for workers due to electrical conductivity
Solution Approach 1:
The composite material construction provides high load-bearing capacity through fiber reinforcement while the polymer matrix provides electrical insulation. This eliminates the electrical conductivity of metal racks, removing safety hazards for workers while maintaining the necessary mechanical strength to support heavy cables.
Solution Approach 2:
The rack design incorporates localized reinforcement features such as rib structures, truss configurations, or increased material density in high-stress areas to ensure adequate load-bearing capacity. This allows the use of non-conductive composite materials throughout the structure while maintaining metal-like strength where needed, without introducing electrical conductivity.
3Reliability
If conventional cable support systems are used, then cable positioning is achieved, but the systems are too bulky for enclosed spaces of limited size
Solution Approach 1:
The cable support system is divided into modular segments or individual support elements that can be independently positioned and attached to the enclosure walls. This segmentation allows for compact installation in limited spaces while maintaining proper cable positioning, as each module can be optimally placed without requiring large continuous structural elements.
Solution Approach 2:
The support rack utilizes the third dimension by mounting vertically on enclosure walls rather than occupying horizontal floor space. The design incorporates vertical support members and cable routing that exploit the vertical dimension, allowing cables to be organized and supported in a compact footprint suitable for enclosed spaces with limited horizontal area.
Data Source
AI summary
An electrical cable support system for use with large diameter, heavy electrical cables disposed in confined spaces includes as least one support structure-mounted stanchion coupled to a generally triangular support bracket adapted for receiving and supporting one or more electrical cables. The coupling between the stanchion and support bracket allows for pivoting displacement of the support bracket on the wall-mounted stanchion to accommodate movement of the cables during electrical load cycling. The support bracket includes a first upper generally horizontal linear arm adapted for receiving and supporting one or more electrical cables, a second lower, inclined arm having plural steps proceeding downward toward the stanchion to provide an increased space below the support bracket to accommodate increased numbers of electrical cables. The support bracket is tapered along its horizontal and vertical axes to better distribute cable weight over the support bracket's entire length and height, and includes an inner apertured portion comprised of crisscrossed trusses for reduced weight and increased strength.