Steel Cable Optical Waveguide Mechanical Clamping
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Solution Overview
Problem
Existing steel cables with optical waveguides for strain measurement face challenges in reliably and cost-effectively fixing the fiber optic cable along its length, leading to inconsistent and complex manufacturing processes.
Innovation Solution
The steel wires closest to the optical waveguide are pressed and compressed to create a frictional and positive clamp, ensuring the waveguide is continuously and firmly held without slipping, with a symmetrical arrangement for uniform loading and a flexible plastic jacket to protect the glass fiber, allowing precise strain measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the optical waveguide is glued into the core wire to firmly connect it, then the connection reliability is improved, but the manufacturing complexity and process difficulty increase
Solution Approach 1:
The patent replaces the chemical bonding method (gluing) with a mechanical compression system. Steel wires are compressed radially inward to press the optical waveguide firmly against the core wire, creating a secure mechanical connection without requiring adhesive materials or complex gluing processes. This substitution eliminates the complexity associated with glue application, curing, and quality control while maintaining reliable connection.
Solution Approach 2:
The patent utilizes changes in compression force parameters to achieve firm connection. By controlling the radial compression force applied to the steel wires, the optical waveguide is pressed with sufficient force to prevent slippage while maintaining the integrity of the components. This parameter-based approach simplifies manufacturing compared to gluing, as it relies on controllable mechanical forces rather than chemical bonding processes.
2Reliability
If additional cable braiding is added to compress and clamp the fiber optic cable, then the clamping reliability is improved, but the manufacturing effort and costs increase
Solution Approach 1:
The patent merges the clamping function into the existing cable structure by having the steel wires that make up the cable body itself perform the compression. Instead of adding a separate braided cable layer for clamping, the regular steel wires are arranged and compressed to simultaneously provide structural support and clamping force. This integration eliminates additional manufacturing steps and reduces production time and costs.
Solution Approach 2:
The steel wires in the cable serve multiple functions: they provide the structural strength of the cable, maintain its shape, and simultaneously compress the optical waveguide to prevent slippage. This multi-functionality eliminates the need for dedicated clamping components or additional braiding operations, thereby improving manufacturing efficiency while maintaining reliable clamping.
3Measurement precision
If the optical waveguide is stranded with steel wires and pressed together, then the strain measurement precision is improved, but the light signal attenuation increases
Solution Approach 1:
The patent applies local quality by ensuring that only the necessary portions of the optical waveguide are compressed by the steel wires - specifically at the ends and at intervals along the length where strain measurement is needed. The compression is localized to create frictional anchoring without excessively compressing the entire waveguide, thereby maintaining light transmission properties while achieving sufficient measurement precision.
Solution Approach 2:
The patent optimizes the compression force parameter to balance two competing requirements: sufficient compression to prevent slippage and enable accurate strain measurement, but not so much compression as to cause excessive light attenuation. By carefully controlling the compression force within an optimal range, the system achieves reliable strain measurement while minimizing energy loss in the optical signal.
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
This solution provides a reliable, cost-effective, and precise method for strain measurement along the cable length, enabling early detection of weak points and damage, while minimizing attenuation of light signals.
Implementation Method 1
the optical waveguide is continuously clamped frictionally and positively along at least part of its longitudinal extent without slip between the steel wires closest to it
Data Source
Figure 1~6
Figure 2~5
AI summary
The invention relates to a steel cable (1, 11) comprising steel wires (2, 12) and comprising at least one light wave guide (3, 13) which is surrounded by the steel wires (2, 12) and provided for detecting load-dependent cable strains, and having a glass fibre (4, 14) surrounded by a plastic casing (5, 15), wherein at least the steel wires (2", 12") closest to the light wave guide (3, 13) are crimped with the light wave guide (3, 13) and permanently pressed against the casing surface (M) thereof, whereby the cross-sectional shape of the casing surface (M) of the light wave guide (3, 13) deviates from an unloaded shape, in particular a circular shape, and the light wave guide (3, 13) is clamped continuously along at least one part of the longitudinal extension (Z) thereof, in a slip-free manner between the steel wires (2", 12") closest to same. The invention also relates to a method for producing a steel cable (1, 11) of this type.