Signal Body Half-Shell Stop for Safe Overhead Cable Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing signal bodies for overhead cables are difficult to install and lack sufficient safety features, particularly in high-altitude installations, as they require constant force to maintain an open position during assembly and are not secure against falling.
Innovation Solution
A signal body design featuring a stop mechanism to prevent further opening of half-shells, balanced weight distribution for self-balancing on the cable, and quick-release fasteners for easy assembly, combined with hinges allowing controlled pivoting and frictional engagement for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring load is used to provide automatic closing force, then the signal body can be secured against falling, but the assembly becomes more difficult because the holding device cannot open the half-shells sufficiently
Solution Approach 1:
The installer opens the half-shells manually before positioning the signal body on the cable, then the spring load automatically closes them. The stop prevents over-opening while the pre-positioning of the signal body on the cable allows easy closing without requiring the holding device to maintain an open position against spring force during the entire assembly process
Solution Approach 2:
The spring load mechanism is extracted from the holding device function. The holding device only needs to temporarily hold the half-shells open during positioning, while the spring load provides the closing force separately. The stop is introduced to limit the opening angle, preventing the half-shells from opening too wide while still allowing sufficient opening for cable insertion
2Ease of operation
If the holding device maintains half-shells in open position against spring load, then the signal body remains open during assembly, but the open position is not open enough to allow cable insertion
Solution Approach 1:
The installer manually opens the half-shells to the required angle before positioning the signal body on the cable. The holding device then maintains this pre-opened position, which is sufficient for cable insertion. This separates the opening action from the holding action, allowing the holding device to maintain a fixed, adequate opening angle without requiring complex adjustment mechanisms
Solution Approach 2:
The holding device is designed to hold the half-shells at a specific open angle that is sufficient for cable insertion. The stop prevents over-opening while the holding device maintains the optimal opening angle. This dynamic control allows the half-shells to be held open just enough for assembly without requiring the holding device to counteract the full spring load throughout the entire opening range
3Ease of operation
If the installer must actively hold the signal body on the cable, then positioning is possible, but the installation process becomes more difficult and time-consuming
Solution Approach 1:
The signal body is designed to self-balance on the cable when opened, with the center of gravity positioned so that the body naturally stabilizes in the open position on the cable. This eliminates the need for the installer to continuously hold the signal body in position, allowing hands-free positioning and reducing installation time
Solution Approach 2:
The weight distribution is designed so that the signal body achieves gravitational equilibrium when positioned on the open cable. The center of gravity is positioned such that the body naturally balances in the open position, creating a stable equilibrium state that requires no active holding by the installer
4Quantity of substance
If the half-shells are delivered separately, then transport is easier, but pre-assembly of hinges is required which adds complexity
Solution Approach 1:
The signal body is divided into two separate half-shells that can be transported independently. The hinges are designed to connect these half-shells, allowing pre-assembly of the hinge mechanism on one half-shell before final assembly. This segmentation enables efficient transport while the standardized hinge design simplifies the pre-assembly process
Solution Approach 2:
The hinges are designed as universal connecting elements that can be pre-assembled on one half-shell and then used to connect to the other half-shell. The same hinge design allows for both pre-assembly during manufacturing and final assembly during installation, providing multi-functionality that simplifies both transport and assembly processes
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
Enables quick and safe installation by allowing the signal body to balance on the cable without constant force, simplifying assembly and ensuring secure attachment, while maintaining visibility even after damage.
Implementation Method 1
A central, surprising finding of the invention is that these seemingly contradictory requirements are met with a good compromise thanks to the normal friction present in the hinges.
Implementation Method 2
This object is achieved by the features of claim 1, namely by providing at least one stop which inhibits a further opening movement of the half-shells starting from the open position.
Implementation Method 3
According to the invention, the weight distribution of the signal body is designed so that it can be placed on the open cable in the open position, where it balances itself
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3~4
AI summary
Signal body, in particular signal ball, for attachment to a free rope with two half-shells (2) and two hinges (3), wherein the half-shells (2) are connected or connectable to the hinges (3) such that the half-shells (2) are partially pivoted into each other in an open position and enclose the free rope, preferably substantially axially symmetrically, wherein at least one stop (4) is provided which, starting from the open position, inhibits a further opening movement of the half-shells (2).