Nested Leaf Cable Retention for Sonobuoy Sensor Arrays
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Solution Overview
Problem
Conventional methods for packing and deploying hydrophone line arrays in sonobuoys face challenges due to the large diameter of hydrophones compared to the array cable, leading to stress on the cable and potential failure, and existing spiral interlocking packs are inadequate.
Innovation Solution
A packing module with a volumetrically efficient structure that includes a tray and a retaining leaf arrangement with nested leaves to separately accommodate sensors and cable, allowing for modular and flexible deployment without tangling or overstressing the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional cable packing and winding methods are used, then the cable can be accommodated, but the hydrophone cannot be properly retained due to its larger diameter
Solution Approach 1:
The packing module is divided into distinct functional zones: a cable retaining structure with spiral leaves for the cable, and a sensor retaining tray for hydrophones. This segmentation allows each component to be optimized for its specific function and diameter requirements, resolving the contradiction between accommodating different diameters and efficient space utilization.
Solution Approach 2:
The invention transitions from conventional two-dimensional winding to a three-dimensional nested arrangement where the cable spiral leaves are positioned radially inward from the sensor tray. This dimensional reorganization allows the larger-diameter hydrophones and smaller-diameter cable to coexist efficiently in the limited packing volume of small sonobuoys.
2Reliability
If spiral interlocking packs are used, then the array cable can be retained, but stress is imparted into the cable causing potential failure
Solution Approach 1:
The locking function is extracted from the cable itself and transferred to a dedicated tray interlock mechanism. The tray interlock comprises opposing engagement features that mechanically lock adjacent trays together, eliminating the need for the cable to act as a locking mechanism and thereby preventing stress-induced cable failure.
Solution Approach 2:
The tray interlock mechanism serves as an intermediary between adjacent trays, providing a dedicated locking interface that prevents relative motion without transmitting stress to the cable. This intermediary structure resolves the contradiction by maintaining cable retention while protecting cable integrity.
3Volume of moving object
If small-size sonobuoys are used, then deployment size is reduced, but packing challenges increase due to space constraints
Solution Approach 1:
The cable retaining structure features nested spiral leaves that wrap around the cable in a compact configuration. This nested arrangement maximizes space utilization within the small sonobuoy volume while maintaining cable retention, resolving the contradiction between reduced size and increased packing complexity.
Solution Approach 2:
Multiple functional elements are merged into integrated components: the tray both supports sensors and provides interlocking features for modular assembly, while the spiral leaves simultaneously retain the cable and define the modular sub-assembly boundaries. This merging reduces the number of separate parts needed in the constrained sonobuoy environment.
Data Source
AI summary
A packing module includes a volumetrically efficient structure for separately retaining sensors and a cable of a sensor array. The packing module includes a tray that supports the sensors and a retaining leaf arrangement that extends outwardly from the tray to retain the cable on the tray. The retaining leaf arrangement includes a plurality of nested leaves that are spaced relative to each other. Packing the module includes placing the sensors separately and in succession on the tray and inserting a portion of the cable in the retaining leaf arrangement in between each placing of a sensor. The placement of a sensor and insertion of a portion of the cable occurs alternately until the entire sensor array is accommodated. Deployment of the sensor array may occur by alternately removing a sensor and a portion of the cable until the sensor array is displaced from the module.