Parallel Wire Cable Preassembly Without Coiling or Reeling
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Solution Overview
Problem
Parallel wire cables twist and coil, making handling and transportation difficult and costly due to conventional manufacturing techniques that coil the wires, increasing costs and safety risks.
Innovation Solution
The cables are preassembled with individually tensioned wires that remain parallel, eliminating the need for coiling and reeling, allowing for safer and more cost-effective transportation by utilizing the natural memory of the wires to form a random loop configuration that can be easily hung and transported without specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional coiling manufacturing techniques are used, then the cables can be manufactured, but handling and transportation become difficult and costly
Solution Approach 1:
Instead of coiling the cable after manufacturing (conventional approach), the patent inverts the sequence by manufacturing the cable in a straight configuration and then inducing coils only at the ends. This allows the majority of the cable to remain straight and handleable, while still providing protective end coils.
Solution Approach 2:
The patent divides the cable into distinct segments: straight intermediate sections for easy handling and transportation, and coiled end sections for protection and termination. This segmentation allows each portion to serve its optimal function without compromising the others.
2Ease of manufacture
If cables are coiled during manufacturing, then they can be produced, but costs increase due to specialized equipment
Solution Approach 1:
The patent reverses the conventional manufacturing sequence by first producing the cable in a straight configuration using standard equipment, then adding end coils separately. This eliminates the need for expensive coiling machinery during the main manufacturing process.
Solution Approach 2:
The end coils are formed using the cable's own flexibility and simple fixtures rather than complex coiling machinery. The cable essentially coils itself under controlled conditions, reducing equipment requirements and manufacturing costs.
3Ease of operation
If cables are manufactured in straight configuration, then handling is simplified, but transportation becomes problematic without coiling
Solution Approach 1:
The cable is segmented into straight intermediate portions for handling and coiled end portions for compactness. This allows the cable to be handled like a straight object during installation while being transportable in a compact coiled form at the ends.
Solution Approach 2:
The end coils are prepared in advance during manufacturing, allowing the cable to be transported in a compact form factor while maintaining straight sections that are ready for immediate handling and installation without requiring on-site coiling operations.
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
This method reduces material and production costs, enhances strength and durability, and simplifies handling and transportation by avoiding the need for expensive coiling machinery, while maintaining the structural integrity and tensile strength of the cables.
Implementation Method 1
utilizing the natural memory of the wires to form a random loop configuration
Data Source
AI summary
A preassembled parallel wire cable creates a random cast of loops. Any of the random cast of loops is hung for transport, thus eliminating costly and time-consuming coiling and reeling operations.