Interchangeable Wire Tensioner With Wedge Grip for Multiple Cable Sizes
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Solution Overview
Problem
The manufacturing of various cable connections for deck cable railings is costly due to the need for unique attachments for different cable sizes, making it challenging to create interchangeable connections.
Innovation Solution
A tensioning wire attachment system featuring a collar with a gripping wedge that secures the wire, allowing for interchangeable connections across multiple wire sizes by using a threaded stud and tubular body assembly with adjustable collars and wedges, enabling secure attachment and tensioning of cables of varying diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unique attachments are manufactured for each cable size, then secure attachment is achieved, but manufacturing cost increases
Solution Approach 1:
The attachment device is designed with a universal collar and gripping wedge mechanism that can accommodate multiple cable diameters (e.g., 3/16 inch, 1/4 inch, 5/32 inch) through a single standardized interface. The collar accepts various cable sizes within its gripping range, and the gripping wedge can be adjusted or replaced to match different cable diameters, eliminating the need for separate attachment devices for each cable size while maintaining secure attachment.
Solution Approach 2:
The attachment device incorporates adjustable parameters including collar inner diameter, gripping wedge angle, and wedge position along the cable. These parameters can be modified to accommodate different cable sizes and tension requirements. The frustoconical shape of the gripping wedge allows it to grip cables of varying diameters by changing the contact surface area and pressure distribution, enabling one device to serve multiple cable sizes securely.
2Reliability
If multiple types of attachments are manufactured for various cable sizes, then cable security is improved, but device complexity increases
Solution Approach 1:
The attachment device is segmented into distinct functional components: a standardized collar, a gripping wedge, and a tensioning mechanism. The collar provides a universal mounting interface, while the gripping wedge is the only component that varies with cable size. This segmentation allows the majority of the device (collar and tensioning mechanism) to remain standardized, reducing overall complexity while maintaining cable security through the specialized wedge component.
Solution Approach 2:
The gripping wedge is designed to be movable or adjustable within the collar, allowing dynamic adaptation to different cable sizes. The wedge can be positioned at different locations along the cable or rotated to change its gripping angle, providing flexibility without requiring multiple fixed attachment devices. This dynamic capability reduces device complexity by using one adaptable component instead of multiple static ones.
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 system reduces manufacturing costs by allowing multiple wire sizes to be used within the same device, providing a cost-effective solution for interchangeable cable connections while ensuring secure attachment and tensioning.
Implementation Method 1
a gripping wedge secured within the collar... The gripping wedge secures a wire
Implementation Method 2
a first collar connectable to a threaded stud. The threaded stud is connectable to a mounting plate
Implementation Method 3
Tension is applied to one end of the cable to keep it taught
Data Source
AI summary
A tensioning wire attachment system includes a tensioning device, which includes a first collar connectable to a threaded stud. The threaded stud is connectable to a mounting plate via a tubular body. The assembly also includes a first gripping wedge secured within the first collar via an inside thread of the first collar. The first gripping wedge secures a first wire.