Helical Die Bending for Teardrop Cable Storage Brackets
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Solution Overview
Problem
Existing bending tools are inefficient in forming complex shapes like the teardrop-shaped cable storage brackets required for fiber optic cables, particularly all-dielectric self-supporting (ADSS) cables, which need precise bending without support wires, and often result in weld cracking and reduced rigidity.
Innovation Solution
A bending device with a rotating die and a roller system that creates a helical channel for the workpiece, allowing for overbending and securing the ends with cross-members to form a teardrop-shaped bracket without overlapping, enhancing rigidity and reducing weld cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing bending tools are used to form cable storage brackets, then the bending process can be completed, but the tools are inefficient in forming complex shapes and result in weld cracking and reduced rigidity
Solution Approach 1:
The patent employs a rotating die with a helical channel that guides the workpiece through a curved path during bending. The helical geometry of the channel creates a teardrop-shaped bracket with smooth curved transitions, eliminating sharp corners that would cause stress concentration and weld cracking. The rotational motion of the die around the workpiece axis enables continuous curvature formation, improving both manufacturing efficiency and shape accuracy for complex bracket geometries.
2Ease of manufacture
If traditional bending methods are used, then the process is simpler, but the resulting brackets have reduced rigidity and are prone to weld cracking
Solution Approach 1:
The helical channel in the rotating die produces smooth curved surfaces on the bracket that distribute stress evenly throughout the structure. This eliminates stress concentration points that would lead to weld cracking and improves overall structural rigidity. The continuous curvature formed by the rotational bending process creates a more robust bracket design compared to traditional linear bending methods.
3Productivity
If the workpiece is bent using conventional tools, then the bending can be achieved, but the ends overlap and require additional support wires
Solution Approach 1:
The helical channel geometry in the rotating die creates a teardrop-shaped bracket where the ends converge to a point without overlapping. The helical path length and channel orientation are designed to produce the precise teardrop geometry in a single bending operation, eliminating the need for additional support wires or secondary operations. This maintains manufacturing efficiency while achieving the correct bracket shape.
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 enables efficient formation of teardrop-shaped cable storage brackets with improved rigidity and reduced weld cracking, allowing for secure storage and protection of fiber optic cables without the need for additional support wires.
Implementation Method 1
a shaft driven to rotate by a motor
Implementation Method 2
Rotation of the die about the axis causes the workpiece to bend along the channel
Implementation Method 3
the roller is configured to bias the workpiece against a wall of the channel as the die rotates
Data Source
AI summary
A bending device for forming a product from a workpiece includes a shaft driven to rotate by a motor, an actuator including an extendable end configured to secure a portion of the workpiece, and a die coupled to the shaft and driven about an axis. The die includes a peripheral portion including a channel configured to receive the workpiece. The channel includes a first end and a second end offset from the first end in a direction parallel to the axis. Rotation of the die about the axis causes the workpiece to bend along the channel.