Spool Line Retention System for Synthetic Rope Wear Reduction

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Solution Overview

Problem

Cables used in mining machines, such as power shovels, have limited bending fatigue resistance due to corrosion and abrasion, leading to frequent replacements that are difficult, time-consuming, and expensive, and pose snag hazards due to broken strands, requiring large drums and sheaves for their handling.

Innovation Solution

A line retention system featuring a line termination coupling with a hook mechanism and removable retention component that securely engages and retains the end loop of a trip line on a spool, reducing friction and wear through coatings and rounded surfaces, allowing for easier installation and use of synthetic ropes with improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If steel cables are used for mining operations, then strength and durability are improved, but bending fatigue resistance deteriorates due to corrosion and abrasion requiring frequent replacement

Engineering Contradiction:

Improvecable strengthVSAvoidbending fatigue resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the material parameter from steel cable to synthetic rope, fundamentally altering the physical and chemical properties of the line. Synthetic ropes exhibit superior resistance to corrosion and abrasion while maintaining adequate strength, eliminating the bending fatigue issues that plague steel cables in mining applications

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs synthetic rope construction using composite material structures (such as braided or twisted synthetic fibers) that combine flexibility with strength. This composite approach provides both the required mechanical properties and resistance to environmental degradation from corrosion and abrasion

Inventive Principle:

Principle #40Composite materials

2Strength

If steel cables with large bending radius are used, then cable strength is maintained, but device size increases requiring large drums and sheaves

Engineering Contradiction:

Improvecable strengthVSAvoiddrum and sheave size

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The patent changes the flexibility parameter by switching from rigid steel cable to flexible synthetic rope. This parameter change allows the use of smaller bending radii, enabling compact drum and sheave designs while maintaining adequate strength through proper synthetic rope selection and routing configurations

Inventive Principle:

Principle #35Parameter changes

3Force

If steel cables are used, then load-bearing capacity is improved, but ease of replacement deteriorates due to heavy weight and stiffness

Engineering Contradiction:

Improveload-bearing capacityVSAvoidease of replacement

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent changes the weight and flexibility parameters by replacing steel cable with synthetic rope. Synthetic ropes provide adequate load-bearing capacity while being significantly lighter and more flexible, enabling easy manual handling, routing, and replacement by operators without specialized equipment

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If synthetic rope is used instead of steel cable, then ease of installation is improved, but retention security worsens due to difficulty in securing the line end

Engineering Contradiction:

Improveease of installationVSAvoidretention security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent segments the retention function into separate components: a fixed retention element (such as an eye or loop at the line end) and a corresponding retention feature (such as a cleat, clamp, or locking mechanism on the drum). This segmentation allows for simple line termination while providing secure retention through the interaction of dedicated retention components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces intermediary retention components (such as eyes, loops, cleats, or clamps) that mediate between the synthetic rope end and the drum. These intermediaries provide reliable mechanical retention while maintaining ease of installation and removal of the line

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11708250B2Retention system for a line on a spool

Publication Date: 2023.07.25 CATERPILLAR INC

AI summary

A retention system for a line on a spool is disclosed. The retention system may include a base component that includes a retention receiving element within a line-side surface of the base component. The retention system may include a line engagement component that includes an engagement surface, wherein the engagement surface includes a portion that is perpendicular to the base component to engage a line, wherein the engagement surface abuts the line-side surface. The retention system may include a removable retention component that is configured to retain the line between the engagement surface and the removable retention component when the removable retention component is installed within the retention receiving element.