Flexible Endless Winding Cable With Bonded Thimble Layers
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Solution Overview
Problem
Existing endless winding cables made of high modulus synthetic or natural fibers like aramid, PBO, and basalt fibers suffer from premature failure due to unequal load distribution and micro abrasion between yarn layers in the end fittings, leading to reduced lifespan.
Innovation Solution
Applying an adhesive, such as epoxy resin, to connect at least two layers of yarn turns in the thimbles, maintaining a tangential orientation and preventing relative movement between layers, thereby reducing micro abrasion and unequal load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If an adhesive is applied to connect yarn layers in the thimbles, then the cable life span is significantly increased and micro abrasion is reduced, but the manufacturing complexity and production time are increased
Solution Approach 1:
The adhesive is applied to the yarn layers in the thimbles during the manufacturing process, before the cable is put into service. This preliminary action prevents micro abrasion and unequal load distribution from the outset, ensuring the yarn layers maintain their tangential orientation throughout the cable's operational life, thereby significantly extending cable life span without requiring additional maintenance interventions later.
Solution Approach 2:
An adhesive substance is introduced as an intermediary between the yarn layers and the thimble bearing surface. This adhesive mediator connects the yarn layers to each other and to the thimble, preventing direct friction and wear between moving parts while distributing loads more evenly across the yarn stack, thus reducing micro abrasion and extending cable life.
2Object-affected harmful factors
If an adhesive is applied to connect yarn layers in the thimbles, then micro abrasion between layers is reduced, but the production time and manufacturing cost are increased
Solution Approach 1:
The adhesive application is performed as a preliminary step during cable manufacturing, before the cable enters service. By applying the adhesive beforehand, the process prevents micro abrasion from occurring during operation, eliminating the need for future maintenance or replacement due to wear, thereby reducing the overall lifecycle time loss despite the additional manufacturing time required.
3Strength
If adhesive is used to connect yarn layers, then load distribution is equalized and cable strength is improved, but the cable flexibility and ease of operation are reduced
Solution Approach 1:
The adhesive is applied locally only in the thimble regions where yarn layers are stacked and subject to friction and unequal load distribution. The adhesive creates localized connections that equalize load distribution and prevent micro abrasion in these specific high-stress areas, while leaving the rest of the cable structure unchanged to maintain its overall flexibility and ease of operation throughout its length.
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 significantly increases the cable's life span by 10 to 20 times, with cables tested enduring over nine million load cycles without failure, demonstrating enhanced durability and load capacity.
Implementation Method 1
An adhesive is provided at at least one of the first and second thimble only and mutually connects at least two of the plurality of layers of turns of the yarn in the stack of the respective first or second thimble to retain a tangential orientation of the respective yarn layers with respect to each other when the flexible endless winding cable is subject to a load
Data Source
AI summary
A flexible cable 1 is produced by endless winding of at least one yarn 6 around two thimbles 2, 4. The yarn 6 comprises aramid or similar fibres. Each thimble 2, 4 holds a stack 9 of a plurality of layers 10 of turns of the yarn 6. The cable 1 comprises a resin 12 which is provided at at least one of the first and second thimble only, for mutually connecting the layers of turns of the yarn and to retain a tangential orientation of the respective yarn layers 10 with respect to each other when the flexible endless winding cable is subject to a load. The cable has optional carbon fibre sheets 18, 20 between preselected yarn layers at the thimbles.