Tool-Free Cable Tray Segments with Resilient Locking
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Solution Overview
Problem
Existing cable tray systems face difficulties in connecting cable tray segments, particularly with wider segments and at high installation locations, due to threading challenges, irregularities from hot-dip galvanizing, and thickened wall thickness from coatings, leading to installation complications.
Innovation Solution
The system employs complementary mechanical connecting elements with resilient locking elements and counter-receptacles that allow cable tray segments to be connected tool-free by bending ends relative to each other until a desired orientation is achieved, using loop-shaped locking elements with ramp-shaped parts for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bolted or tab-based connections are used to connect cable tray segments, then the connection is secure and reliable, but the installation process becomes complex and time-consuming, especially at high installation locations
Solution Approach 1:
The cable tray segments are equipped with self-aligning features including guide ribs that automatically align segments during installation, and resilient locking elements that automatically engage with counter-receptacles without requiring manual alignment or additional tools. The system performs its own alignment and locking functions, eliminating the need for complex bolted connections or manual tab engagement.
Solution Approach 2:
The locking elements are designed to be resilient and movable, allowing them to flex during the insertion process and then snap into the locked position. This dynamic behavior enables easy installation while maintaining secure connection, as the locking elements can accommodate minor misalignments and then firmly engage the segments together.
2Area of moving object
If cable tray segments are made wider to accommodate more cables, then the cable capacity increases, but the threading and connection difficulty increases significantly
Solution Approach 1:
The cable tray system is divided into modular segments that can be easily connected end-to-end. Each segment maintains standardized connection interfaces with locking elements and counter-receptacles positioned to facilitate easy engagement regardless of the overall tray width. This segmentation allows wide cable trays to be assembled from manageable sections without increasing connection complexity.
3Reliability
If hot-dip galvanizing is applied to protect against corrosion, then corrosion protection is improved, but irregularities and blocked openings occur at the edges
Solution Approach 1:
The cable tray segments are designed with pre-formed connecting sections and locking elements that are positioned and shaped before galvanizing. This preliminary preparation ensures that the connection features maintain their geometric integrity and functionality even after the galvanizing process creates surface irregularities. The locking elements are designed with sufficient tolerance to accommodate the zinc coating variations.
4Reliability
If thick coatings are applied for corrosion protection, then corrosion resistance is enhanced, but the wall thickness increases making installation more difficult
Solution Approach 1:
The locking elements are designed with adjustable geometric parameters that accommodate variations in wall thickness caused by different coating applications. The resilient nature of the locking elements allows them to flex and engage properly even when the base material thickness varies, maintaining installation ease while preserving enhanced corrosion protection from thick coatings.
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
Enables simple, ergonomic, and cost-effective installation of cable tray segments both horizontally and vertically, allowing for retrofitting without tools and preventing accidental jamming, while ensuring a secure connection.
Implementation Method 1
the complementary mechanical connecting elements are configured to resiliently bend the ends relative to each other when two corresponding ends of the cable tray segments are joined together
Implementation Method 2
The locking elements each have a ramp-shaped part. The end of the cable tray segment with the counter-receptacles is guided over the locking elements by the ramp-shaped parts
Data Source
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AI summary
The invention relates to a cable tray system (1), comprising two or more cable tray segments (2, 3), the cable tray segments each having a cable tray bottom and two cable tray side walls laterally delimiting the cable tray bottom, which cable tray bottom and cable tray side walls form a substantially U-shaped cross-section. The cable tray segments are designed such that two cable tray segments can be overlappingly interconnected, and for this purpose a connecting portion is provided at one end of the one cable tray segment and an end of another cable tray segment can be connected, in a clamping or detent connection, in or on said connecting portion by means of complementary mechanical connecting elements. In order to allow simplified and flexible assembly, the complementary mechanical connecting elements are designed such that, when two corresponding ends of the cable tray segments are being fit together in the longitudinal direction of the cable tray segments and in the vertical direction of the cable segments, the complementary mechanical connecting elements resiliently bend the ends, until the ends reach a target connection position relative to each other, and the complementary mechanical connecting elements form a detent connection blocking movement in the longitudinal direction and in the vertical direction. The assembly can be carried out without tools and without screwing.