Stranded Rope Coupler with Conical Cavities for Tension Distribution
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Solution Overview
Problem
Existing couplers for stranded ropes in the oil industry fail to provide a secure and efficient termination or splicing method, leading to uneven tension distribution and potential strand breakage under dynamic loads.
Innovation Solution
A coupler design featuring a combination of cylindrical and truncated conical cavities with optimized angles and a splay device to evenly distribute tension, paired with a resin filling process to enhance bonding between the rope strands and a low-friction inner cavity coating for easy release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional coupler design is used for stranded rope, then the structure is simple, but the tension distribution is uneven leading to strand breakage under dynamic loads
Solution Approach 1:
The coupler cavity is segmented into multiple functional zones: a cylindrical cavity for initial rope insertion, a first truncated conical cavity for strand separation, and a second truncated conical cavity for resin distribution. This segmentation allows each zone to perform a specific function in the tension distribution process, preventing strand breakage through systematic force distribution.
Solution Approach 2:
Different regions of the coupler cavity have different geometric properties optimized for specific functions. The cylindrical portion provides alignment, the first conical portion with its specific angle range (15-45 degrees) optimizes strand separation, and the second conical portion with a smaller angle range (5-20 degrees) optimizes resin distribution. Each local region is tailored to its specific function to achieve overall reliability.
2Reliability
If a secure bonding method is used to prevent strand breakage, then the rope strands adhere strongly to the coupler, but the strands cannot be easily detached for maintenance
Solution Approach 1:
The coupler employs a dynamic bonding system where resin is injected under pressure to create strong bonds during operation, but the system allows for controlled detachment when needed. The truncated conical geometry creates a progressive bonding pattern that secures strands under load while maintaining release capability through the structured cavity design that prevents permanent deformation.
3Strength
If resin is used to enhance bonding between rope strands, then the bonding strength increases, but the resin may cause adhesion to the coupler cavity making release difficult
Solution Approach 1:
The coupler features asymmetric truncated conical cavities with specific angle ranges that create a directional bonding pattern. The first conical cavity (15-45 degrees) and second conical cavity (5-20 degrees) have different geometries that promote resin distribution toward the rope strands while minimizing contact and adhesion to the coupler cavity walls, enabling strong bonding without permanent adhesion.
4Strength
If the coupler cavity has a large surface area for resin bonding, then the bonding strength increases, but the resin coating process becomes more complex
Solution Approach 1:
The coupler utilizes curved conical surfaces instead of flat or complex geometries. The truncated conical cavities provide smooth, continuous surfaces that facilitate uniform resin coating through gravity and pressure-driven flow. The curved geometry naturally guides resin distribution across the bonding surfaces without requiring complex coating equipment or multi-step processes.
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
The solution ensures a strong, even tension distribution across the stranded rope strands, enhancing the coupler's ability to withstand both static and dynamic loads while allowing for easy detachment without adhering to the coupler, thus preventing strand breakage and improving operational reliability.
Implementation Method 1
a low-friction inner cavity coating for easy release
Data Source
AI summary
A coupler may be provided. The coupler may comprise a first cylindrical cavity, a first truncated conical cavity, and a second truncated conical cavity. The first truncated conical cavity may be adjacent to and concentric with the first cylindrical cavity. The first truncated conical cavity may have a first angle. The second truncated conical cavity may be adjacent to and concentric with the first truncated conical cavity. The second truncated conical cavity may have a second angle less than the first angle.