Grain Bin Sensor Cable End Cap Molding

Solution Overview

Problem

Existing grain bin sensor cables are prone to damage and displacement due to downward forces exerted by grain during loading, storage, and unloading, leading to costly repairs and inaccurate data transmission.

Innovation Solution

A method and apparatus for forming grain bin sensor cables involve positioning a pre-formed cable with wires in a mold cavity, heating the outer sheath to displace plastic material into end cap cavities, creating depressions to expose wires, and coupling a sensor package to the cable, with end caps designed to reduce shearing and downward force components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors are suspended from the roof structure of a grain bin using cables, then monitoring capability at various height and perimeter locations is improved, but sensor cables are subjected to substantial downward forces from grain that can damage or displace sensors

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidsensor durability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-forming end caps on the cable during the cable manufacturing process itself, rather than adding them separately later. The mold cavity includes end cap cavities that receive displaced plastic material to form integrated end caps, which are positioned in advance to protect sensors from downward grain forces before the sensors are even installed on the cable.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the cable formation process with end cap formation by integrating both operations into a single molding process. The mold cavity simultaneously forms the cable body and the end caps, creating a unified structure where the end caps are an integral part of the cable assembly, thereby improving sensor protection without adding separate components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If end caps are added to protect sensors from downward forces, then sensor displacement is reduced, but cable formation process becomes more complex

Engineering Contradiction:

Improvesensor protectionVSAvoidcable formation process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the cable formation process with end cap formation by integrating both operations into a single molding process. The mold cavity simultaneously forms the cable body and the end caps, creating a unified structure where the end caps are an integral part of the cable assembly, thereby improving sensor protection without adding separate components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold cavity serves multiple functions: it forms the cable body, creates the end cap cavities, and produces the end caps themselves. This multi-functional approach eliminates the need for separate end cap manufacturing and attachment steps, reducing overall process complexity despite the added protection features.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If plastic material is heated and compressed to form end caps, then end caps are integrated into the cable structure, but manufacturing process requires additional heating and molding steps

Engineering Contradiction:

Improveend cap integrationVSAvoidmanufacturing process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent merges the cable formation process with end cap formation by integrating both operations into a single molding process. The mold cavity simultaneously forms the cable body and the end caps, creating a unified structure where the end caps are an integral part of the cable assembly, thereby improving sensor protection without adding separate components.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances the durability and accuracy of sensor data transmission by preventing sensor displacement and damage, ensuring reliable monitoring of grain bin parameters like moisture content and temperature.

Implementation Method 1

heating the outer sheath of the pre-formed cable

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

compressing the mold cavity around the heated outer sheath causing a volume of the plastic material to be displaced

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentEP2774740B1Grain bin sensor cable forming method and apparatus

Publication Date: 2022.11.23 CTB INC

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Figure 6A~6B

AI summary

A method and apparatus for forming a grain bin sensor cable (10) including a plurality of mold members (62, 76) defining a mold cavity is disclosed. A pre-formed cable (12) with wires disposed therein is placed into the mold cavity, heated, and formed into a post-formed cable (26). The post-formed cable includes a recessed portion (28) and a pair of end caps (38). Apertures are created within the recessed portion (28) so as to expose a portion of the wires. The end caps (38) are generally cone-shaped and include vertical walls. The post-formed cable is removed from the mold cavity and a sensor package is coupled to the wires exposed in the recessed portion and captured between the vertical walls of the end caps. A housing is coupled about the sensor package.