Non-Welded Cable Tray Redirector With Nesting Modular Parts
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Solution Overview
Problem
Current cable tray redirectors require welding, which is time-consuming and costly, and may not be suitable for facilities with seismic restrictions or where electrical grounding is a concern, and they often require bulky storage and shipping due to non-interchangeable components and excessive fastener types.
Innovation Solution
The development of non-welded cable tray redirectors using interchangeable fasteners and components that nest for efficient storage and shipping, allowing for 90-degree redirection in a horizontal plane without the need for welding, and maintaining electrical conductivity for easy grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to assemble cable tray redirectors, then structural strength and reliability are improved, but manufacturing time and cost increase, and electrical grounding becomes more difficult
Solution Approach 1:
The redirector is divided into multiple modular components (base, flange, connector sections) that can be assembled separately using mechanical fasteners instead of welding. Each component maintains structural integrity independently while connecting to others through bolted joints, eliminating the need for time-consuming welding operations.
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using bolts, nuts, and interlocking features. This substitution maintains structural strength while dramatically reducing manufacturing time and eliminating the need for specialized welding equipment and expertise.
2Reliability
If welding is used to assemble cable tray redirectors, then structural strength is improved, but manufacturing cost and complexity increase
Solution Approach 1:
By segmenting the redirector into standardizable modular components, the patent enables mass production of individual parts using conventional machining or forming processes. This reduces manufacturing cost compared to custom welding operations, while the modular design maintains structural strength through standardized connection interfaces.
Solution Approach 2:
The patent designs universal connection features and standardized fasteners that can be used across different redirector configurations and cable tray systems. This universality reduces manufacturing cost by eliminating the need for specialized welding procedures and reduces complexity by using the same fastening system throughout.
3Reliability
If welding is used to assemble cable tray redirectors, then structural integrity is improved, but electrical grounding and suitability for nuclear facilities deteriorates
Solution Approach 1:
The patent replaces welding with mechanical fasteners that maintain structural integrity while providing continuous metal-to-metal contact paths for electrical grounding. The bolted connections create reliable electrical continuity between components, which is essential for grounding in nuclear facilities and other environments where welding is prohibited.
4Manufacturing precision
If non-interchangeable fasteners and components are used in cable tray redirectors, then assembly precision is improved, but storage and shipping volume increase
Solution Approach 1:
The patent employs universal, interchangeable fasteners and standardized component interfaces that can accommodate various redirector configurations. This standardization reduces the number of unique parts that need to be stored and shipped, while maintaining assembly precision through consistent dimensional tolerances and mating features.
Solution Approach 2:
The patent designs components with nesting capabilities, where smaller parts can be stored within larger components or attached to their surfaces. This nesting approach minimizes storage and shipping volume by utilizing the existing component geometry rather than requiring separate packaging space for each part.
Data Source
AI summary
Improved design of cable tray redirector components speeds assembly and connection of cable trays. More efficiently manufactured, universal components needed throughout horizontal redirectors of a specific size and type cable tray run reduce the overall total items and cost of inventory. The improvement is in part the elimination of welding cable redirector components in favor of connecting the components with bolts and nuts in the field. The inventory and shipment of individual parts is substantially more efficient because the new components “nest” efficiently prior to assembly. Moreover, components are designed to minimize the number of bolts and nuts used without jeopardizing strength. The use of bolts and nuts to fasten the components also enables good electrical conductivity for effective electrical grounding of the assembled cable tray system.