Multi-pass crimp collar for looped cable
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Solution Overview
Problem
Looped security cables often fail at the connection between the cable and the crimping collar, as the cable can withstand higher pull-test values than the connection, necessitating improvements in systems and methods for securing looped cables.
Innovation Solution
A cable assembly with a collar having three openings is crimped or swaged to securely engage with the cable segments, distributing tensile force through frictional forces between the collar and wire rope, enhancing the cable's holding capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-pass crimping collar is used to secure a looped cable, then the device complexity is reduced, but the connection strength is insufficient as the cable fails at the collar connection point
Solution Approach 1:
The collar is divided into multiple segments or passes, with each pass creating a separate crimping operation that engages different portions of the cable. This segmentation allows the tensile load to be distributed across multiple engagement points rather than concentrating stress at a single crimp location, thereby increasing overall connection strength without requiring a fundamentally different collar design
Solution Approach 2:
The invention transitions from a single-point crimping approach to a multi-dimensional engagement system where the cable passes through the collar multiple times, creating engagement points distributed along the collar's longitudinal axis. This dimensional transformation from one-dimensional single-point contact to multi-dimensional distributed contact enhances the connection's ability to withstand tensile forces
2Reliability
If the cable is passed through the collar multiple times, then the force distribution is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The cable is pre-formed into a looped configuration before being inserted into the collar, and the routing path is pre-planned to ensure proper engagement in each pass. This preliminary preparation simplifies the actual crimping process by eliminating the need for complex real-time adjustments during manufacturing, allowing the multi-pass engagement to be achieved through straightforward sequential crimping operations
Solution Approach 2:
The collar design incorporates multiple openings and engagement points that serve universal functions across different passes. Each opening and crimping location is designed to handle the cable in the same manner, regardless of which pass it is engaged in, simplifying the manufacturing process by using repeated, standardized engagement sequences rather than requiring unique procedures for each pass
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 increases the cable's ability to withstand tensile forces without collar failure, allowing for greater weight lifting or towing capacity and improved security by distributing force effectively across the collar's engagement points.
Implementation Method 1
distributing tensile force through frictional forces between the collar and wire rope
Data Source
AI summary
A cable assembly including a collar and a cable. The collar includes a first opening, a second opening and a third opening, each of which extends through the collar along a longitudinal dimension of the collar. The cable includes a looped end and a first cable segment extending through the first opening, a second cable segment extending through the second opening, a third cable segment extending into the third opening, and a fourth cable segment forming a loop between the first and second cable segments. The collar is crimped or swaged to the cable and is securely engaged with the first, second and third segments of the cable.