Compressed Gas Stringing for DBS Cable Assembly
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Solution Overview
Problem
The existing methods for assembling drawn brazed strand (DBS) cables, which involve lubricating with alcohol, lead to kinking, safety concerns, and contamination issues, necessitating an improved method that does not require alcohol.
Innovation Solution
A method using compressed gas to propel the conductive element through a tubular sheath, facilitated by a system with a housing, clamp, and vacuum pump, forming an air bearing to reduce friction and prevent kinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If alcohol is used to lubricate the interior of the sheath, then the conductive element can be inserted more easily, but the conductive element becomes kinked and the alcohol poses safety hazards and contamination risks
Solution Approach 1:
The patent removes alcohol entirely from the stringing process. Instead of using alcohol to lubricate the sheath interior, the invention uses compressed gas to propel the conductive element through the sheath, extracting the harmful lubricant while maintaining the insertion function through a different mechanism
Solution Approach 2:
The patent employs compressed gas (pneumatics) to propel the conductive element through the sheath. The gas is introduced into a chamber containing both the sheath and conductive element, creating pressure that forces the element through the sheath without requiring manual pushing or chemical lubrication
2Ease of operation
If alcohol is used for lubrication, then insertion is facilitated, but residual alcohol must be removed through heating which adds process complexity
Solution Approach 1:
The patent eliminates the alcohol removal step entirely by not using alcohol in the first place. The compressed gas propulsion method leaves no residual lubricant that would require evaporation or removal, simplifying the overall process
Solution Approach 2:
The patent replaces the chemical lubrication system (alcohol) with a mechanical propulsion system (compressed gas). This substitution eliminates the need for subsequent thermal processing to remove alcohol residues
3Device complexity
If manual pushing is used to insert the conductive element, then the process is simple, but the element becomes kinked and strength is degraded
Solution Approach 1:
The patent uses compressed gas to propel the conductive element through the sheath, replacing manual pushing. The gas pressure provides uniform force that advances the element smoothly without the localized stress and kinking that occurs with manual insertion
Solution Approach 2:
The patent changes the insertion mechanism from mechanical contact (manual pushing) to pneumatic propulsion. This parameter change in the insertion method prevents kinking while maintaining process simplicity
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
This method effectively prevents kinking and eliminates the need for alcohol, enhancing the safety and quality of the cable assembly process by using compressed gas to propel the conductive element through the sheath without lubrication.
Implementation Method 1
Compressed gas is injected into the channel towards the first end such that the conductive element is propelled through the channel into the sheath
Implementation Method 2
An air bearing is formed on an inner surface of the sheath and the conductive element is propelled through the needle, over the air bearing and into the sheath
Data Source
AI summary
A method for stringing a first elongate element through a second elongate element is provided by placing the first elongate element in a channel and injecting compressed gas into the channel to propel the first elongate element therethrough. The channel has a first open end, and the second elongate element is sealed around the first open end. Compressed gas is injected into the channel towards the second elongate element, propelling the first elongate element through the second elongate element. Also disclosed is a system for performing such a method, including a source of compressed gas and a housing having a channel with a first end and a second open end. The first end is in fluid communication with the source of compressed gas. The channel has a tapered portion adjacent the open end of the channel, and the channel defines a straight longitudinal axis between the first end and the second open end.