Separable Cable Hanger Assembly for Multi-Cable Solar Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for improved cable hangers to manage the increased number of cables in solar panel mounting systems, particularly in utility-scale solar plants, to enhance cable management and structural integrity.
Innovation Solution
A cable hanger assembly comprising a frame with a separable hanger support that includes a unitary skeletal frame and a hanger support, which can be snap-fit or fastened to the frame, providing additional structural rigidity and multiple cable receptacle areas, and is made of materials like plastic or metallic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a traditional cable hanger is used, then the structure is simple, but it cannot effectively manage the increased number of cables in utility-scale solar plants
Solution Approach 1:
The cable hanger is divided into multiple functional segments including a main body portion, side wall portions extending from opposite sides, and multiple cable receptacles distributed across these segments. This segmentation allows the hanger to organize and manage multiple cables separately while maintaining overall structural simplicity.
Solution Approach 2:
The hanger structure serves multiple functions simultaneously: it suspends the hanger assembly from the messenger wire, organizes multiple cables in separate receptacles, provides structural support, and enables easy installation through the snap-fit mechanism. This multi-functionality increases cable management capacity without proportionally increasing complexity.
2Ease of operation
If the hanger support is permanently attached to the frame, then structural integrity is maximized, but installation and replacement of components becomes difficult
Solution Approach 1:
The attachment mechanism transitions from a permanent fixed connection to a dynamic snap-fit connection that allows both secure attachment during operation and easy detachment when needed. The resilient portion of the hanger support flexes during installation to engage with the frame, then maintains a firm hold during use, but can be released by applying sufficient force.
Solution Approach 2:
The attachment strength parameter is made variable through the snap-fit design. During installation, the resilient portion flexes to reduce attachment strength for easy engagement. During operation, the full attachment strength provides structural integrity. For replacement, sufficient force is applied to temporarily reduce attachment strength again, allowing removal without permanent damage to components.
3Object-affected harmful factors
If multiple cables are suspended from a single hanger, then cable management improves, but cable movement and interference between cables increases
Solution Approach 1:
The hanger structure is segmented into multiple separate cable receptacles positioned on the main body and side wall portions. Each receptacle provides a dedicated space for individual cables, preventing cables from moving freely against each other while maintaining an organized arrangement that reduces interference.
4Adaptability or versatility
If the frame is made as a single unitary structure, then manufacturing is simplified, but adaptability for different installation configurations is reduced
Solution Approach 1:
The hanger assembly is divided into separate components: the frame structure and the hanger support with resilient portion. This segmentation allows each component to be manufactured independently using optimized processes, then assembled through the snap-fit mechanism. The modular design provides adaptability for different installation configurations while maintaining manufacturing efficiency.
Data Source
AI summary
A cable hanger assembly comprises a frame including a base that comprises a first base surface and a second base surface separated by a channel open at a proximate channel end and closed at a distal channel end, where the channel is formed by a first channel support extending from the proximate end and a second channel support extending from the proximate end; a first support extending from a distal end of the first base surface; a second support extending from a distal end of the second base surface. A hanger support extends along the first base surface, the first channel support, the second channel support and the second base surface and attaches to the frame, and includes a radiused hanger surface at a distal end of the channel. The first channel support, the first base surface and the first support form a first cable receptacle area.