Composite Cable Saddle With Tie Arrangement
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Solution Overview
Problem
Existing cable support systems in underground manholes are prone to damage and failure due to brittle porcelain saddles and inadequate securing methods, leading to cable joint damage and costly repairs, especially with increased electrical loads causing cable expansion and contraction.
Innovation Solution
High-strength, insulated cable saddles made of lightweight, electrically insulating plastic with a tie arrangement and a moveable slider for secure attachment to a support member, accommodating cable expansion and contraction while maintaining electrical insulation and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porcelain cable saddles are used to support electrical cables, then electrical insulation is provided, but the saddles are brittle and highly subject to impact damage or breakage
Solution Approach 1:
The patent uses composite materials by combining fiberglass reinforcement with plastic matrix to create a cable saddle that provides both electrical insulation and high impact resistance. The fiberglass strands are embedded within the plastic material to create a composite structure that leverages the insulating properties of the plastic and the strength properties of the fiberglass.
Solution Approach 2:
The patent changes the material parameters from brittle porcelain to a composite plastic-fiberglass material that maintains insulating properties while dramatically improving impact resistance. This parameter change transforms the mechanical properties of the support saddle from fragile to rugged.
2Power
If larger electrical cables carrying increased electrical load are used, then electrical power capacity is increased, but the cables apply upward and sideways pressure on the cable saddle causing contortion
Solution Approach 1:
The composite fiberglass-reinforced plastic material provides enhanced structural strength to support larger, heavier cables carrying increased electrical loads. The fiberglass reinforcement specifically addresses the load bearing requirements while the plastic matrix maintains electrical insulation properties.
Solution Approach 2:
The cable saddle features localized reinforcement with fiberglass strands positioned to handle specific stress points where cables apply upward and sideways pressure. The internal structure is designed with varying material distribution to address local loading conditions.
3Reliability
If cotter pins are used to secure the support saddle to a support bracket, then attachment is achieved, but the cotter pins are difficult to install and frequently not properly installed
Solution Approach 1:
The patent removes the complex cotter pin securing mechanism entirely and replaces it with a simpler attachment system. The support saddle is designed with integrated attachment features that eliminate the need for separate cotter pins, reducing installation complexity while maintaining secure attachment.
Solution Approach 2:
The attachment function is merged into the support saddle structure itself, with the securing mechanism integrated into the saddle body rather than being a separate component. This integration simplifies the overall assembly and improves installation ease.
4Ease of operation
If high molecular weight polyethylene cable joint support saddles are used, then installation is improved, but additional cable support is necessitated due to increased cable expansion and contraction
Solution Approach 1:
The fiberglass-reinforced plastic composite provides enhanced structural support capabilities compared to standard polyethylene, allowing the saddle to adequately support cables undergoing significant thermal expansion and contraction without requiring additional support structures.
Solution Approach 2:
The cable saddle is designed to dynamically accommodate cable movement during thermal expansion and contraction. The structure allows for controlled deformation and recovery, maintaining cable support adequacy throughout load cycles while preventing damage.
Data Source
AI summary
An electric cable saddle, or support, arrangement includes a housing having an upper recessed portion adapted to receive and support one or more electrical cables in a fixed, stable manner. Plural apertures disposed on upper portions of the housing on opposed sides of the cable(s) and aligned generally transverse to the length of the cable(s) are adapted to receive a flexible, high strength tie member, or strap, for securely attaching the cable(s) to an upper portion of the housing. A slot disposed in a lower portion of the housing and also aligned generally transverse to the length of the cables(s) is adapted to receive a structural support member for supporting the housing and cable(s). A retaining member also disposed in a lower portion of the housing is moveable adjacent to or into engagement with the support member for fixed positioning of the housing on the support member.