Sliding Cable Tray Supports for Fast Reconfigurable Assembly
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Solution Overview
Problem
Conventional cable tray systems require complex fastening methods and are rigidly fixed, making them difficult to assemble, disassemble, and reconfigure, which can compromise structural integrity and increase installation time.
Innovation Solution
A cable tray system with paired side rails and support members featuring elongate tabs and recesses that allow for sliding engagement, eliminating the need for additional fastening means and enabling adjustable positioning of support members along the rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fastening methods (fasteners, rivets, welds) are used to join support members to side rails, then structural strength is improved, but device complexity and installation time increase
Solution Approach 1:
The connection system is segmented into discrete components: side rails with integrated tabs and support members with corresponding recesses. This segmentation eliminates the need for separate fasteners or welding operations, as each component has its connection feature built-in, reducing overall assembly complexity while maintaining structural integrity
Solution Approach 2:
The connection features (tabs and recesses) are merged directly into the side rails and support members during manufacturing. This integration eliminates the need for separate fastening hardware or welding procedures, simplifying the assembly process while ensuring strong mechanical connections through the interlocking tab-recess geometry
2Stability of the object's composition
If support members are rigidly fixed to side rails using conventional methods, then structural stability is improved, but adaptability and ease of reconfiguration deteriorate
Solution Approach 1:
The connection system transitions from a static, permanent connection (welding or rigid fastening) to a dynamic, adjustable connection. The tab-recess design allows support members to be easily inserted, positioned, and removed along the side rails, enabling the cable tray system to be reconfigured as needed while maintaining structural stability during use
Solution Approach 2:
The side rails are pre-formed with tabs during manufacturing, and support members are pre-formed with corresponding recesses. This preliminary preparation of connection features eliminates the need for on-site welding or complex fastening operations, allowing for quick assembly and future reconfiguration without compromising structural integrity
3Strength
If welding is used to join support members to side rails, then structural strength is improved, but installation time and skill requirements increase
Solution Approach 1:
The welding process is segmented out and replaced with mechanical interlocking components. The side rails contain pre-formed tabs and support members contain corresponding recesses, creating a mechanical connection that achieves joint strength without requiring welding operations, thereby eliminating the time and skill constraints associated with welding
Solution Approach 2:
The tab-recess connection system is designed to be self-assembling without requiring specialized welding equipment or skilled welders. The components simply need to be aligned and inserted, allowing unskilled or minimally trained personnel to assemble the cable tray system quickly and efficiently while maintaining strong joints
4Ease of manufacture
If pre-punched holes and fasteners are used to connect support members to side rails, then ease of assembly is improved, but structural reliability deteriorates due to potential fastener failure
Solution Approach 1:
The connection features are merged into the structural members themselves: tabs are formed as integral parts of the side rails, and recesses are formed as integral parts of the support members. This eliminates the need for separate fasteners that could fail, while maintaining ease of assembly through the simple tab-recess insertion mechanism
Solution Approach 2:
The fasteners and pre-punched holes are extracted from the connection system and replaced with integrated tab-recess features. This removal of separate fastening components eliminates the reliability issues associated with fastener failure (shearing, cross-threading, improper torqueing) while preserving the simplicity of assembly through direct mechanical interlocking
Data Source
AI summary
Provided herein is a cable tray apparatus including a first side rail, a second side rail spaced from the first side rail, and at least one support member having a first end and a second end. The second side rail includes a support wall and first and second tabs extending from the support wall. The support member includes side walls extending between the ends, and first and second recesses formed within each of the two side walls at each end. The support member is located between the side rails, and the tabs of the side rails are configured to engage and be located within the respective first and second recesses at the respective ends of the support member. The support member is slidable relative to the side rails along the tabs.