Parallel Wire Cable Tensioning to Reduce Twisting and Handling Risk
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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
The method involves creating a structural cable with parallel wires of equal length and tension, eliminating the need for winding, and using a tensioning process to apply a consistent tension value to each wire, which is then secured to maintain stability and prevent corrosion, allowing for lighter, stronger, and more cost-effective cable designs.
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 become costly and prone to twisting and coiling
Solution Approach 1:
The patent applies preliminary action by pre-tensioning each wire individually before assembly into the final cable structure. This preliminary tensioning prevents twisting and coiling during subsequent handling and transportation, while the systematic approach to individual wire tensioning actually reduces overall manufacturing cost by eliminating the need for expensive corrective operations and material waste.
2Strength
If conventional designs are used, then manufacturing is simpler, but the cables lack superior strength and stiffness
Solution Approach 1:
The patent applies segmentation by dividing the cable into individual wire elements that are tensioned and assembled separately. This segmentation allows each wire to be precisely controlled and tensioned to optimal levels, achieving superior overall cable strength and stiffness. The modular approach, while appearing complex, actually simplifies quality control and enables standardized manufacturing processes.
Solution Approach 2:
The patent applies parameter changes by systematically varying the tension parameters of individual wires during assembly. By controlling tension parameters for each wire, the cable achieves optimal strength and stiffness characteristics that conventional uniform designs cannot attain, while the parameter control is achieved through automated processes.
3Strength
If parallel wire cables are manufactured with proper tension, then strength is improved, but handling and transportation become difficult and unsafe
Solution Approach 1:
The patent applies preliminary action by pre-tensioning all wires before final assembly and securing. This preliminary tensioning creates a stable, rigid cable structure that resists twisting and coiling during handling and transportation, making the cable safer and easier to operate with despite the high tension forces involved.
4Ease of operation
If conventional helically-wound strands are used, then handling is easier, but strength and stiffness are reduced
Solution Approach 1:
The patent applies inversion by reversing the conventional approach: instead of winding wires into helical strands and then tensioning, the method tensions individual wires first and then assembles them into a parallel configuration. This inverted sequence achieves superior strength and stiffness while the tensioned parallel structure actually improves handling characteristics by preventing the twisting and coiling problems of conventional helical designs.
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.