Stackable Cable Trays with Orthogonal Positioning Racks
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Solution Overview
Problem
The construction of towed array electrical harnesses is labor-intensive and exposes sensitive components, leading to potential damage and significant rework due to their delicate nature and lengthy construction process.
Innovation Solution
A cable tray design featuring orthogonal positioning racks with cable support apertures and slots, along with foot bars for stacking, which organizes and protects wiring harnesses by preventing entanglement and damage, allowing for efficient assembly and storage of sensitive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wiring harnesses are constructed on open benches, then assembly can be performed, but sensitive components are exposed to potential damage and entanglement
Solution Approach 1:
The construction process is segmented by dividing the workspace into multiple modular cable trays, each providing a contained environment for specific sections of the wiring harness. This segmentation allows assembly to proceed in organized sections rather than on exposed open benches, reducing component vulnerability while maintaining assembly capability.
Solution Approach 2:
Cable trays serve as intermediary structures between the open bench environment and the sensitive wiring harness components. These trays provide a protected intermediate workspace that shields components from damage and entanglement while still allowing access for assembly operations.
2Productivity
If multiple long benches are used for construction, then wiring harness assembly can proceed, but components remain exposed during the lengthy construction process
Solution Approach 1:
The solution transitions from a horizontal arrangement of multiple long benches to a vertical stacking configuration of cable trays. This dimensional change allows multiple construction levels to be stacked vertically, maintaining high construction capacity while enclosing components in protected trays, thereby improving reliability during the assembly process.
Solution Approach 2:
Cable trays are designed to nest within each other in a vertical stacking configuration, with each tray containing and protecting a specific section of the wiring harness. This nesting arrangement allows multiple construction zones to be compacted vertically while maintaining component protection, addressing both productivity and reliability requirements.
3Ease of operation
If wiring harnesses are laid out on open benches, then assembly work can be performed, but labor and rework costs increase due to potential damage
Solution Approach 1:
Cable trays are prepared and positioned in advance with appropriate cable management features before the wiring harness assembly begins. This preliminary preparation ensures that components are immediately protected upon placement, preventing damage before it can occur and eliminating the need for rework, thereby reducing time loss while maintaining assembly accessibility.
Data Source
AI summary
A cable tray and method of use is provided with the cable tray having a bottom extending along a horizontal panel with two opposite side edges. A pair of side walls attaches to the two opposite side edges. A first positioning rack extends between the side walls. The first positioning rack is orthogonal to the tray bottom and the side walls. A second positioning rack extends between the side walls. The second positioning rack is orthogonal to the tray bottom and the side walls. A first foot bar affixes to an underside of the tray bottom. The first foot bar is vertically aligns with the first positioning rack. A second foot bar affixes to the underside of the tray bottom. The second foot bar vertically aligns with the second positioning rack. Each of the first positioning rack and second positioning rack includes cable support apertures.