Interlocked Armoured Cable Tube for High Pull Strength
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Solution Overview
Problem
Existing methods for manufacturing metal clad and interlocked armored cables face limitations in producing flexible tubes with optimal strength and efficiency, particularly in meeting high pull test standards with conventional production techniques.
Innovation Solution
The use of two interlocked metal strip parts with a common radius of curvature and specific helix angles, along with a specialized apparatus featuring roll-forming dies and tooling assemblies, allows for the production of flexible metal tubes with enhanced strength and efficiency, capable of passing high pull tests by forming a helical element that is interlocked throughout its length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single strip of metal is wrapped around a cable to define a flexible tube, then the manufacturing process is simple, but the production rate is limited and the tube strength is insufficient for high pull test standards
Solution Approach 1:
The metal strip is divided into two separate strip parts that are wrapped around the cable simultaneously. Each strip part is formed independently through its own roll-forming dies and tooling assembly, allowing parallel production that doubles the production rate while maintaining manufacturing simplicity through modular design
2Ease of manufacture
If a single strip of metal is wrapped around a cable, then the manufacturing process is simple, but the tube strength is insufficient to meet high pull test standards
Solution Approach 1:
The tube is constructed from two separate strip parts wrapped around the cable, providing redundant strength and meeting high pull test standards (150-pound and 300-pound tests) while maintaining relatively simple manufacturing through independent formation of each strip part
Solution Approach 2:
The tube combines two metal strip parts into a composite structure that provides enhanced strength and rigidity compared to a single strip, while the strips can be made from readily available materials such as aluminum or galvanized steel
3Productivity
If two strips of metal are wrapped around a cable to double production rates, then productivity increases, but the device complexity increases
Solution Approach 1:
The apparatus is segmented into two independent sets of roll-forming dies and tooling assemblies, each handling one strip part. This modular segmentation allows the complex task of forming two interlocked strips to be divided into manageable independent units that can be operated separately
Solution Approach 2:
Two independent strip formation systems are merged into a single production line that outputs one interlocked flexible tube. The tube itself merges the two strip parts into a unified protective covering that provides both strength and flexibility
4Ease of manufacture
If conventional production techniques are used, then capital costs are lower, but the ability to meet high pull test standards is compromised
Solution Approach 1:
The flexible tube uses a composite structure of two interlocked metal strip parts that provides enhanced strength and reliability to meet high pull test standards (150-pound and 300-pound tests) while using readily available strip materials to control capital costs
Data Source
AI summary
A product having a metal strip and a central longitudinal axis. The strip has two or more strip parts, each having a common radius of curvature defining a helix having an angle being offset from one another in the direction of the axis. A cross section of the strip parts causes them to be interlocked together throughout their lengths to define a flexible metal tube. The outside diameter of the tube is between ⅜″ and 1⅜″ and the helix angle of each strip part is between eight and thirty degrees.