Clam-shell Weld Cable Housing for Stress Transfer
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Solution Overview
Problem
Welding system cabling, particularly control cables, are susceptible to damage due to harsh environmental conditions and physical stresses, leading to reliability issues and increased maintenance needs.
Innovation Solution
A cable management system with a clam-shell housing and cable engagement features that protect and secure the weld cable, transferring stress to it rather than weaker cables, while allowing easy access for maintenance by separating the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding system cabling is used in harsh environments with physical stresses, then the system can operate and connect components, but the cables are susceptible to damage and reliability decreases
Solution Approach 1:
The housing is divided into a first shell and a second shell that can be separated from each other, allowing the housing to be opened for cable installation and maintenance, then closed to provide protection. This segmentation enables both easy access and protective enclosure.
Solution Approach 2:
The housing acts as an intermediary structure between the cables and the harsh external environment. It provides a protective barrier that isolates the cables from environmental damage and physical stresses while allowing the system to function.
2Reliability
If the housing is designed to protect cables, then cable durability improves, but access to cables for maintenance becomes difficult
Solution Approach 1:
The housing is segmented into separable first and second shells that can be easily opened and closed. This allows cables to be accessed for installation and maintenance by separating the shells, then the housing can be reassembled to restore protective enclosure.
Solution Approach 2:
The housing transitions from a static enclosed structure to a dynamic structure that can be opened and closed. The separable shells allow the housing to change state between protected enclosure and accessible configuration, facilitating maintenance while maintaining protection during operation.
3Strength
If stress is distributed across all cables, then all cables share the load, but weaker cables like control cables are more likely to fail
Solution Approach 1:
The housing provides localized protection and stress management at specific cable positions. The cradle and cable clamp create designated areas where the weld cable is secured, allowing it to bear stress while protecting the control cable from excessive load through its routing and positioning within the housing.
Data Source
AI summary
Embodiments of the present disclosure include a cable management system with a housing comprising a first shell and a second shell configured to couple together about welding system cabling such that a portion of the welding system cabling is contained by the housing. The first and second shells form openings at ends of the housing such that the welding system cabling is capable of extending through the openings and such that edges of the openings enclose a perimeter of the welding system cabling when the first and second shells are coupled together about the welding system cabling. A cradle receives a weld cable of the welding system cabling. A cable clamp engages the weld cable and cooperates with the cradle to restrict movement of the weld cable when the weld cable is disposed in the cradle and the cable clamp is engaged.