Modular Support Sleeve Assembly for Multi-Diameter Cable Shielding
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Solution Overview
Problem
Existing support sleeves for cable shields are costly and complex to produce, requiring high material and labor for different cable diameters, and are not easily adaptable for mass production.
Innovation Solution
A support sleeve assembly combining a metal sheet external element with a plastics adapter element, allowing for cost-effective production and adaptation to various cable diameters using a modular system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support sleeves are made as turned metallic parts for different cable diameters, then mechanical stability and electrical connection are improved, but production cost and complexity increase
Solution Approach 1:
The support sleeve is divided into two separate components: an external metallic element and an internal adapter element made of plastics material. This segmentation allows each component to be manufactured using different, more efficient processes (stamping for metal, injection molding for plastic) rather than complex turning operations, thereby reducing production complexity while maintaining the required mechanical and electrical properties
Solution Approach 2:
The support sleeve combines two different materials - a metallic external element and a plastics internal adapter element - into a composite structure. This composite design allows the metallic portion to provide electrical conductivity and structural strength, while the plastics portion provides mechanical adaptation to different cable diameters, achieving reliability without requiring complex metalworking for each size variation
2Strength
If support sleeves have large wall thickness for small cable diameters, then mechanical strength is improved, but material cost increases
Solution Approach 1:
The internal adapter element made of plastics material is designed with varying wall thicknesses optimized for different cable diameters. This local optimization allows the adapter to provide sufficient mechanical strength where needed while using minimal material, eliminating the need for uniformly thick-walled metal sleeves that would be required to accommodate the smallest cables
3Adaptability or versatility
If support sleeves are designed for different cable diameters with consistent external diameter, then adaptability is improved, but wall thickness must be very large, increasing cost
Solution Approach 1:
By segmenting the support sleeve into an external metallic element with consistent outer dimensions and an internal adapter element that varies in size, the design achieves adaptability to different cable diameters without requiring the external element to be oversized. The adapter element is inserted into the external element, allowing the same external element to accommodate multiple cable sizes
Solution Approach 2:
The internal adapter element is nested within the external metallic element, creating a telescopic or nested structure. This nesting allows the external element to maintain a consistent outer diameter while the internal adapter provides the necessary adaptation to different cable sizes, eliminating the need for large wall thicknesses
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 combination of a metal sheet and plastics adapter element reduces production complexity and cost, enabling efficient assembly and adaptation to different cable diameters while maintaining mechanical and electrical stability.
Implementation Method 1
The at least one adapter element (3) is received within the external element (2) and is captively fastened to the external element (2)
Implementation Method 2
the cable shield is typically fastened in a force-fitting and/or form-fitting manner, in particular clamped, between the support sleeve and the outer conductor contact element
Data Source
AI summary
A support sleeve assembly (1) for fastening on a cable (5), in particular on an electrical cable (5) for high-voltage engineering, has an external element (2) which is formed from a metal sheet, and at least one adapter element (3) comprising a plastics material. The external element (2) is formed so as to be at least partially annular. The at least one adapter element (3) is received within the external element (2) and is captively fastened to the external element (2).