Parallel Wire Cable Manufacturing with Individual Wire Tensioning
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Solution Overview
Problem
Conventional manufacturing processes for parallel wire cables are costly and prone to twisting and coiling, making them difficult and unsafe to handle and transport, while existing designs lack the superior strength and stiffness desired for structural applications like suspension bridges.
Innovation Solution
A method of manufacturing parallel wire cables by individually tensioning each wire to an equal tension value, eliminating the need for winding and using a seizing force to maintain tension, resulting in a lighter, stronger, and more cost-effective cable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used for parallel wire cables, then the cables can be produced, but they tend to twist and coil, making handling and transportation difficult and unsafe
Solution Approach 1:
The patent applies preliminary action by tensioning each wire individually to a predetermined tension value before the wires are bundled together. This pre-tensioning prevents the wires from twisting and coiling during subsequent handling and transportation, as the wires are already in their final operational configuration. The wires are tensioned, secured with seizings, and maintained in this state throughout the manufacturing process, eliminating the need for post-manufacturing adjustments and ensuring safe handling.
2Ease of manufacture
If conventional designs for parallel wire cables are used, then cables can be manufactured, but they are far too costly to manufacture
Solution Approach 1:
The patent applies parameter changes by systematically varying the tension value applied to each wire during manufacturing. By tensioning each wire to an optimal predetermined value and maintaining this tension through the bundling process, the method achieves superior cable strength and stiffness. This parameter optimization allows for more efficient material utilization and reduced manufacturing costs compared to conventional designs that require over-engineering to compensate for manufacturing inconsistencies.
3Strength
If wires are individually tensioned to equal tension values, then the cable achieves superior strength and stiffness, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the cable manufacturing process into discrete steps for each wire. Each wire is individually tensioned, secured with a seizing, and then bundled with the others. This segmented approach simplifies the overall process by making each individual wire treatment straightforward and repeatable, rather than attempting to tension and secure the entire cable bundle at once. The segmentation enables systematic quality control and reduces manufacturing complexity.
4Reliability
If a seizing force is applied to maintain tension in the wires, then the cable maintains its structural integrity, but additional manufacturing steps are required
Solution Approach 1:
The patent applies merging by combining multiple functions into the seizing application step. The seizing simultaneously maintains the predetermined tension in each wire, secures the wire in its tensioned position, and prevents the wire from slipping or loosening during subsequent handling and installation. This multi-functional approach consolidates what would otherwise require separate operations, thereby maintaining structural integrity while improving manufacturing efficiency.
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 enables the production of parallel wire cables that are significantly lighter yet stronger than conventional designs, requiring less material and offering greater design flexibility with reduced manufacturing costs and improved handling and transportation safety.
Implementation Method 1
a seizing force to maintain tension
Data Source
AI summary
A parallel wire cable is produced from a plurality of wires arranged in a bundle for use as a structural cable. Each wire in the plurality of wires is parallel to every other wire in the bundle, and each wire in the plurality of wires is tensioned to a tension value.