Cable Termination Winding Member Capstan Load Distribution

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Solution Overview

Problem

Existing cable termination systems face issues with uneven contact pressure and potential crushing of strength members due to tight packing, leading to integrity loss under high loads and resin migration causing sharp particles that can sever the strength members.

Innovation Solution

A cable termination assembly featuring a winding member to wrap and secure strength members around, utilizing the capstan effect to distribute tensile loads evenly and reduce clamping force, with a toroidal shape and clamping means to prevent overcrowding and crushing, and encased in a soft elastomeric resin to prevent resin-induced damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If strength members are tightly packed around the spike tip to secure them, then they are held in place, but they crush and sever each other under high loads

Engineering Contradiction:

Improveintegrity of terminationVSAvoidstrength members integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies different geometries to different parts of the termination structure. The spike has a conical shape with varying radius, while the winding member has a toroidal shape with specific curvature. This local differentiation in geometry ensures that strength members are distributed evenly without crushing, while still being securely held in place through the capstan effect on the winding member.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The winding member acts as an intermediary between the strength members and the spike. By wrapping strength members around the winding member, the system transfers loads through friction (capstan effect) rather than direct compression against the spike, preventing crushing while maintaining security.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the spike tip has a small radius of curvature to protect strength members, then they are protected from bending, but side load stresses increase when the cable is subjected to torque

Engineering Contradiction:

Improveprotection of strength membersVSAvoidside load stresses

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The winding member is designed with a toroidal shape and specific radius of curvature. This curved geometry allows strength members to wrap around smoothly, protecting them from bending stresses while distributing side loads more evenly compared to a sharp spike tip.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If resin is used to retain strength members at the spike tip, then they are held in place, but resin migration produces sharp crystal particles that can sever strength members

Engineering Contradiction:

Improveretention of strength membersVSAvoidsharp crystal particles from resin

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The winding member serves as an intermediary that provides the primary retention mechanism through friction. This reduces reliance on resin for holding strength members at the critical tip area, minimizing the risk of resin migration and crystal formation that could damage strength members.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent extracts the retention function from the resin and transfers it to the winding member through the capstan effect. This removes the harmful resin from the critical load-bearing zone where strength members are most vulnerable to damage.

Inventive Principle:

Principle #2Taking out (Extraction)

4Device complexity

If a hollow cone spike is used to allow central components through, then the structure is simple, but contact pressure over the spike surface is uneven

Engineering Contradiction:

Improvesimplicity of termination structureVSAvoidcontact pressure distribution

Core Design Contradiction:

Device complexityVSStress or pressure

Solution Approach 1:

The termination structure is segmented into distinct functional components: the spike for structural support, the winding member for load distribution and retention, and the resin for sealing. This segmentation allows each component to perform its specific function optimally, with the winding member specifically designed to distribute contact pressure evenly.

Inventive Principle:

Principle #1Segmentation

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 solution ensures even load distribution, reduces the risk of crushing and severance of strength members, maintains cable integrity under high loads, and prevents resin-induced damage, enhancing the reliability and strength of the termination.

Implementation Method 1

utilizing the capstan effect to distribute tensile loads evenly and reduce clamping force

Methodology Applied

Scientific EffectCapstan effect: Friction

Data Source

PatentUS8567015B2Cable termination system

Publication Date: 2013.10.29 JDR CABLE SYST

AI summary

A cable termination system and method of assembly is provided that clamps strength members of the cable after they have been wrapped around a winding member. The clamping force required is therefore reduced by the capstan effect of the winding member. The winding member is preferably a torus that encircles the cable, and the system may comprise a number of progressively larger tori arranged in sequence along the cable to provide sufficient room for wrapping all of the strength members around them.