Slotted Reducer for Luminaire Cable Routing
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Solution Overview
Problem
Existing reducers for light masts complicate the assembly process and risk damaging electrical cables during connection, as they require threading the cable through a solid cylindrical element.
Innovation Solution
A reducer with a recess allowing the electrical cable to be inserted between the lamp post and mast flange after the cable is already connected, featuring a longitudinal slot or cutout that extends over the entire length, enabling easier assembly and reducing cable damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a solid cylindrical reducer is used to fill the space between the mast flange and the light mast, then the structural stability is improved, but the assembly process becomes complicated and the cable may be damaged during threading
Solution Approach 1:
The patent removes material from the solid cylindrical reducer to create a longitudinal slot, extracting the problematic threading path while maintaining the reducer's structural function. This allows the cable to pass through the slot rather than being forced through the solid cylinder, eliminating damage risk while preserving clamp stability.
Solution Approach 2:
The reducer is segmented by introducing a longitudinal slot that divides the cylindrical structure into two half-cylindrical sections. This segmentation creates a cable passage without compromising the overall structural integrity, allowing simultaneous cable installation and stable clamping.
2Strength
If a solid cylindrical reducer is used, then the structural integrity is maintained, but the cable threading process risks damaging the cable edges
Solution Approach 1:
A longitudinal slot is extracted from the solid cylindrical reducer, creating a dedicated cable passage. This removes the harmful friction and edge contact that would otherwise damage the cable during threading, while the remaining reducer structure maintains sufficient structural integrity for clamping.
Solution Approach 2:
The longitudinal slot acts as an intermediary element that facilitates cable passage through the reducer. Instead of forcing the cable through solid material, the slot provides a guided pathway that protects the cable from edge damage while allowing it to pass through the reducer body.
3Ease of manufacture
If the reducer is made as a solid cylindrical element, then the manufacturing is simple, but the assembly process requires threading the cable through the reducer which complicates the procedure
Solution Approach 1:
The longitudinal slot is created by removing material from the solid cylinder, a process that adds minimal manufacturing complexity (e.g., a single cutting operation). This small increase in manufacturing steps eliminates the need for complex cable threading procedures during assembly, significantly simplifying the installation process.
Solution Approach 2:
The reducer structure is segmented by the longitudinal slot, creating a design that is still simple to manufacture (using standard cutting or forming operations) but fundamentally changes the assembly process by providing a built-in cable pathway, thereby reducing assembly complexity.
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a reducer for arrangement between a lighting mast (10) and a mast flange (12) of a luminaire mounted on the lighting mast (10), wherein the reducer has a hollow shape with openings at opposite ends and is configured to encompass an outer circumference of the lighting mast (10) with an inner side and to abut an inner circumference of the mast flange (12) with an outer side in order to fill a gap between the lighting mast (10) and the mast flange (12), wherein the hollow shape of the reducer has a recess (8) which continuously connects the openings at the opposite ends of the reducer, wherein the recess (8) is dimensioned to allow an electrical cable to be inserted into the hollow shape between the openings of the reducer.