Swageless Cable Terminal With Self-Actuating Wedge Grip
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Solution Overview
Problem
Existing swageless cable terminals face issues with initial engagement and long-term reliability, particularly in harsh environments, as they often rely on springs that deteriorate or require complex tooling for secure grip and release mechanisms.
Innovation Solution
A swageless cable terminal design featuring tapered wedges and a resilient pressing ring, where the pressing ring provides frictional force to initiate and maintain the wedges' gripping engagement with the cable, allowing self-actuation and progressive gripping force increase with tension, without the need for swaging tools or special cable preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring is used to press the wedges into the tapered bore for initial engagement, then the wedges can be forced into gripping relationship with the cable, but the spring can deteriorate and lose effectiveness over time, particularly in marine or harsh environments
Solution Approach 1:
The patent removes the spring component entirely from the terminal design. Instead of using a spring to press the wedges into the tapered bore, the design relies on the cable insertion force itself to drive the wedges into position. This extraction of the deteriorating spring element eliminates the reliability issue while maintaining the initial engagement function.
Solution Approach 2:
The cable insertion process itself serves to press the wedges into the tapered bore and establish the gripping relationship. The cable's own force during installation performs the function previously requiring a spring, making the system self-servicing and eliminating components that can deteriorate.
2Reliability
If a threaded plug is used to press the wedges into the taper for fixed grip, then the grip between wedges and cable is established and fixed, but the cable cannot be released until the threaded plug is unscrewed, reducing ease of operation
Solution Approach 1:
The terminal design uses dynamic wedges that can move axially within the tapered bore. When cable tension is applied in the restraining direction, the wedges are drawn into the taper to grip the cable. When tension is released and cable is pushed in the opposite direction, the wedges move outward to release the grip, enabling easy removal without unscrewing any components.
Solution Approach 2:
Instead of using a threaded plug that requires unscrewing to release, the design inverts the mechanism by using cable push force in the opposite direction to drive the wedges outward and release the grip. This allows removal by simple cable insertion rather than complex plug unscrewing.
3Reliability
If multiple components are used for cable gripping and release mechanisms, then the terminal can provide secure grip and release functionality, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into the wedge components themselves. The wedges simultaneously provide the gripping surface, the self-actuating mechanism through the tapered bore interaction, and the release mechanism through reverse cable insertion. This merging reduces the number of separate components needed while maintaining full functionality.
Solution Approach 2:
The wedge components serve multiple functions: they provide the gripping surface through friction and serrations, they self-actuate by being drawn into the tapered bore under cable tension, and they enable release when cable is pushed in the opposite direction. This multi-functionality reduces overall device complexity.
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 terminal securely grips cables in various environments, including marine conditions, without requiring tools or special cable preparation, and maintains reliability by using a urethane pressing ring that withstands abrasive contact and environmental challenges, ensuring consistent performance.
Implementation Method 1
the pressing ring provides frictional force to initiate and maintain the wedges' gripping engagement with the cable
Implementation Method 2
the wedges are self-actuating to establish gripping engagement with the cable when tension is applied to the cable in one direction
Implementation Method 3
A set of tapered wedges fit in the tapered portion of the hollow bore of the terminal housing
Data Source
AI summary
A swageless cable terminal for gripping a cable includes an elongated terminal housing with a hollow bore, one portion of which is tapered toward one end of the housing. A set of tapered wedges positioned in the bore of the housing define a central passageway that admits a cable inserted into the housing through the one end. An inserted cable causes the set of wedges to shift in the bore of the housing and expand the passageway within the set of wedges to admit the inserted cable. When an attempt is made to withdraw the inserted cable from the one end of the terminal housing, a compliant pressing ring captured on the inserted cable urges the set of wedges into the tapered portion of the bore in gripping relationship with the cable. The inserted cable can then be secured to another object by means of the housing.