Terminating Stranded Synthetic Filament Cables with Binder Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Synthetic multi-stranded cables with non-parallel constructions pose challenges in cutting and terminating due to low stiffness and friction, leading to uneven load distribution and premature failure, as traditional methods fail to account for the unique properties of synthetic filaments.
Innovation Solution
A method involving straightening, applying a binder to maintain alignment, cutting, and securing terminations to each strand or strand group, with a collector that allows tension adjustment to ensure consistent and repeatable termination, breaking down the large cable into smaller components for uniform termination technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wire rope termination methods are used on synthetic filament cables, then the termination process is simple, but the load distribution becomes uneven and premature failure occurs due to low friction and stiffness of synthetic filaments
Solution Approach 1:
The cable is divided into individual strands that are terminated separately rather than as a single unit. Each strand receives its own termination device, allowing independent load path creation and ensuring even load distribution across all filaments despite the low friction characteristics of synthetic materials
Solution Approach 2:
The cable is straightened and bound before termination to pre-establish proper filament alignment. This preliminary action prevents filament dislocation during the termination process, compensating for the low stiffness of synthetic filaments that would otherwise allow excessive movement and uneven load distribution
2Productivity
If synthetic filament cables are cut and terminated without straightening and binding, then the process is faster, but filament dislocation occurs leading to wide variations in filament lengths and premature failure
Solution Approach 1:
The cable is straightened and bound before cutting and termination operations. This preliminary preparation ensures that filaments remain aligned and prevents dislocation during subsequent processing, maintaining consistent filament lengths without significantly extending the overall termination time
Solution Approach 2:
A binding element is introduced as an intermediary component to maintain filament alignment during processing. The binder acts as a temporary constraint that holds filaments in place during cutting and termination, preventing dislocation while allowing the process to proceed efficiently
3Device complexity
If non-parallel strands in synthetic cables are terminated without tension adjustment, then the termination process is simpler, but unequal load distribution occurs causing shorter filaments to fail prematurely
Solution Approach 1:
The termination devices incorporate adjustable tension mechanisms that allow dynamic adjustment of load distribution. This enables the termination system to compensate for variations in strand lengths and orientations, ensuring that load is evenly distributed across all filaments regardless of their initial configuration
Solution Approach 2:
The tension parameter of each strand is individually adjusted during termination to achieve uniform load distribution. By changing the tension parameter for each strand based on its specific characteristics (length, orientation), the system compensates for the non-parallel construction and prevents premature failure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for straightening, constraining, cutting and terminating a multi-stranded, non-parallel cable. The cable filaments are aligned. A binder is then applied to the cable to maintain the alignment. The cable is then cut to a desired length. Each strand or group of strands is then placed in an individual termination. Each individual termination is then attached - either directly or through intermediate devices - to a collector.