Method and apparatus for producing a synthetic tensile member with a precise length and enhanced stability

Abstract

A method for producing a synthetic tensile member having a precisely known and stable length. The invention also comprises equipment configured to carry out the method. A tensile member is prepared by attaching terminations to an assembly of synthetic filaments. The tensile member is then attached to a loading apparatus that subjects the tensile member to a pre-defined loading process. The tensile member is thereby conditioned to a stable length. The length is then measured and a length adjusting component is incorporated into the tensile member to create a precise and stabilized length that is configured for the tensile member's particular application.

Claims

1. A method for producing a synthetic tensile member assembly having a precise and stable length for application across a known distance, comprising: (a) providing a synthetic tensile member having a first end and a second end; (b) providing a first termination on said first end, said first termination having a first attachment reference; (c) providing a second termination on said second end, said second termination having a second attachment reference; (d) whereby said synthetic tensile member, said first termination, and said second termination are united to form said synthetic tensile member assembly; (e) applying a predetermined tension profile to said synthetic tensile member assembly in order to produce a stable overall length between said first and second attachment references; (f) determining said stable overall length between said first and second attachment references; (g) determining an offset distance that is a difference between said known distance and said stable overall length between said first and second attachment references; and (h) adding an attachment feature to said second termination, wherein a position of said attachment feature on said second termination is configured to add said offset distance to said second termination so that an overall length of said synthetic tensile member assembly is equal to said known distance.

2. The method for producing a synthetic tensile member as recited in claim 1, further comprising: (a) providing a loading cross bore in said second termination, said loading cross bore configured for use in applying said predetermined tension profile; and (b) wherein said attachment feature is a cross bore offset from said loading cross bore.

3. The method for producing a synthetic tensile member as recited in claim 2, further comprising: (a) providing an extended tang on said second termination; and (b) wherein said cross bore passing laterally through said second termination passes through said extended tang.

4. The method for producing a synthetic tensile member as recited in claim 1, wherein: (a) said second termination includes a splice woven back on itself, wherein said splice passes around a thimble block; and (b) said step of adding an attachment feature to said second termination includes providing a passage passing laterally through said thimble block.

5. The method for producing a synthetic tensile member as recited in claim 4, wherein said passage is a cross bore.

6. The method for producing a synthetic tensile member as recited in claim 4, further comprising: (a) providing a loading cross bore in said thimble block, said loading cross bore configured for use in applying said predetermined tension profile; and (b) wherein said attachment feature is a cross bore in said thimble block offset from said loading cross bore.

7. The method for producing a synthetic tensile member as recited in claim 1, wherein said attachment feature is a passage passing laterally through said second termination.

8. The method for producing a synthetic tensile member as recited in claim 7, further comprising: (a) providing an extended tang on said second termination; and (b) wherein said passage passing laterally through said second termination passes through said extended tang.

9. The method for producing a synthetic tensile member as recited in claim 7, wherein said passage is a cross bore.

10. The method for producing a synthetic tensile member as recited in claim 9, further comprising: (a) providing an extended tang on said second termination; and (b) wherein said cross bore passing laterally through said second termination passes through said extended tang.

11. A method for producing a synthetic tensile member assembly having a precise and stable length for application across a known distance, comprising: (a) providing a synthetic tensile member having a first end and a second end; (b) providing a first termination on said first end; (c) providing a second termination on said second end, said second termination having an attachment reference; (d) whereby said synthetic tensile member, said first termination, and said second termination are united to form said synthetic tensile member assembly; (e) applying a predetermined tension profile to said synthetic tensile member assembly in order to produce a stable overall length between said first and second terminations; (f) determining said stable overall length between said first termination and said attachment reference; (g) determining an offset distance that is a difference between said known distance and said stable overall length between said first and second terminations; and (h) providing an attachment feature on said second termination, wherein a position of said attachment feature on said second termination is configured to add said offset distance to said attachment reference so that an overall length of said synthetic tensile member assembly is equal to said known distance.

12. The method for producing a synthetic tensile member as recited in claim 11, wherein: (a) said second termination includes a splice woven back on itself, wherein said splice passes around a thimble block; and (b) said step of providing an attachment feature to said second termination includes providing a passage passing laterally through said thimble block.

13. The method for producing a synthetic tensile member as recited in claim 12, wherein said passage is a cross bore.

14. The method for producing a synthetic tensile member as recited in claim 12, further comprising: (a) providing a loading cross bore in said thimble block, said loading cross bore configured for use in applying said predetermined tension profile; and (b) wherein said attachment feature is a cross bore in said thimble block offset from said loading cross bore.

15. The method for producing a synthetic tensile member as recited in claim 11, wherein said attachment feature is a passage passing laterally through said second termination.

16. The method for producing a synthetic tensile member as recited in claim 15, further comprising: (a) providing an extended tang on said second termination; and (b) wherein said passage passing laterally through said second termination passes through said extended tang.

17. The method for producing a synthetic tensile member as recited in claim 15, wherein said passage is a cross bore.

18. The method for producing a synthetic tensile member as recited in claim 17, further comprising: (a) providing an extended tang on said second termination; and (b) wherein said cross bore passing laterally through said second termination passes through said extended tang.

19. The method for producing a synthetic tensile member as recited in claim 15, further comprising: (a) providing a loading cross bore in said second termination, said loading cross bore configured for use in applying said predetermined tension profile; and (b) wherein said attachment feature is a cross bore offset from said loading cross bore.

20. The method for producing a synthetic tensile member as recited in claim 19, further comprising: (a) providing an extended tang on said second termination; and (b) wherein said cross bore passing laterally through said second termination passes through said extended tang.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is a perspective view, showing a prior art cable made of three wrapped strands.

(2) FIG. 2 is a sectional elevation view, showing one way in which a termination can be attached to a cable.

(3) FIG. 3 is a perspective view, showing a cable termination in which multiple anchors are attached to a collector.

(4) FIG. 4 is a perspective view, showing a parallel cable assembly.

(5) FIG. 5 is an elevation view, showing a tensioning rig employed in the present invention.

(6) FIG. 6 is a perspective view, showing the addition of an extension link.

(7) FIG. 7 is a perspective view, showing the use of an extended tang.

(8) FIG. 8 is an elevation view, showing a splice-based termination.

(9) FIG. 9 is a sectional view, showing the nature of the thimble used in the splice-based termination of FIG. 8.

(10) FIG. 10 is a perspective view, showing a thimble block.

(11) FIG. 11 is an elevation and perspective view, showing a termination having a threaded shaft and an extension bushing.

(12) FIG. 12 is an elevation view, showing the placement of the extension bushing on the threaded shaft.

(13) FIG. 13 is a perspective view, showing the use of a plug in a loading eye.

(14) FIG. 14 is a perspective view, showing the addition of an extension link to a spliced termination.

(15) FIG. 15 is a perspective view, showing the use of a compressive bushing.

(16) FIG. 16 is an elevation view, showing the use of a correction block.

(17) FIG. 17 is an elevation view, showing the use of an extension link in the middle of a cable assembly.

(18) FIG. 18 is a plot showing applied tension over time.

REFERENCE NUMERALS IN THE DRAWINGS

(19) 10 cable 12 strand 18 anchor 19 passage 20 potted region 22 collector 24 load transferring feature 26 receiver 28 jacket 30 cable assembly 32 loading block 34 parallel assembly 36 termination 38 loading fixture 40 static fixture 42 extension link 44 first cross bore 45 first attachment reference 46 second cross bore 47 second attachment reference 48 tang 50 pin 52 first clevis 54 second clevis 56 extended tang 58 reference axis 60 cross bore 62 thimble 64 strands 66 jacket 68 thimble block 70 threaded shaft 72 extension bushing 74 mating surface 76 bearing surface 78 through bore 80 fusion 82 eye 84 cross bore 86 plug 88 offset cross bore 90 spliced eye 92 bushing half 94 correction block 96 overhang

DETAILED DESCRIPTION OF THE INVENTION

(20) A cable made according to the present invention will generally have a first termination on its first end and a second termination on its second end. The first termination will have a first attachment reference—such as the center axis of a first cross bore through the first termination. The second termination will likewise have a second attachment reference—such as the center axis of a second cross bore through the second termination.

(21) Returning to FIG. 4, those skilled in the art will know that the parallel assembly of three cables will typically have a loading block 32 or analogous anchoring component on each end. The example shown uses a large transverse pin joint to connect the terminations 36 to the loading block 32. For this particular installation, there is a known distance between the pin joint axis on the loading block 32 shown and the pin joint axis on the loading block on the opposite end of the cables. The cables must match this known distance in order to be correctly installed. In other words, the distance between the first and second attachment references on the cables must be equal to the known distance.

(22) FIG. 5 shows a synthetic cable assembly created by adding a termination 36 to each end of cable 10. The first termination is connected to static fixture 40. First attachment reference 45 on the first termination is the center line of a pin joint used to attach the first termination to the static fixture (Note that the first attachment reference could be at some other point along the assembly and need not coincide with the attachment point).

(23) The second termination is attached to loading fixture 38. A predetermined tension profile is then applied through loading fixture 38. Second attachment reference 47 on the second termination is the center line of a pin joint used to attach the second termination to loading fixture 38 (Note that the second attachment reference could be at some other point along the assembly and need not coincide with the attachment point).

(24) This tension profile may assume many forms, but it is preferable to include a pull test to a higher load than is anticipated in the end-use application. Where practical, it is also preferable to include multiple pulls to better condition the cable.

(25) FIG. 18 depicts an exemplary tension profile. The “design load” represents the maximum tension the cable assembly is expected to see in its upcoming installation. In this example, two ramped “pulls” are made to a level exceeding the design load by 20%. A third pull is established with a sinusoidal component applied over an extended period. With some fiber types, it is also beneficial to hold a load for a defined period so that the fibers will permanently elongate and better distribute the load.

(26) The tension profile is configured to fully “bed” (“set”) both the terminations and the lay of the cable itself. The length of the overall assembly will tend to extend for some period and then stabilize. Once the length has stabilized, the distance between the first attachment reference on the first termination and the second attachment reference on the second termination is determined. Two carefully pre-cut and terminated cable assemblies may have lengths that are very nearly the same. However, the length variation will tend to grow with the bedding process.

(27) This step may be accomplished in many ways. As one example, if the first and second attachment references are simple cross bores through tangs on the terminations, then closely fitted dowels can be placed in these cross bores. The assembly can then be placed under a suitable tension level and the distance between the dowels can be measured.

(28) In many instances it will be desirable to design the cable and terminations so that the bedded cable assembly winds up being a bit short. A length-adjustment component may then be added to bring the overall assembly of the now-stabilized cable to the proper length. There are many ways to provide such a length-adjustment component. The following embodiments illustrate some of these ways.

(29) FIG. 6 shows a second termination 36 on the second end of cable 10. The termination includes tang 48. A cross bore through the tang is used to attach the termination. The central axis of this cross bore is the second attachment reference used to determine the overall length of the cable assembly.

(30) Extension link 42 is provided to increase the effective length of the cable assembly. The extension link includes first clevis 52 and second clevis 54. The extension link also includes first cross bore 44 and second cross bore 46. First cross bore 44 is aligned with the cross bore in tang 48 and pin 50 is inserted to connect the extension link to the second termination. Second cross bore 46 is offset a distance “D” from first cross bore 44. In this example the second cross bore 46 becomes a third attachment reference. If one then measures the distance from the first attachment reference (on the opposite end of the cable) and the new third attachment reference created by the presence of second cross bore 46, the overall length of the cable will be increased.

(31) To improve accuracy, it is preferable to take the length measurements while the cable assembly is under a fixed reference load. The reference load is preferably as close as possible to the load anticipated for the end-use application.

(32) The process as applied in this exemplary embodiment may then be summarized as follows:

(33) 1. A known distance is the target value needed for the cable's desired installation at the anticipated reference load;

(34) 2. The cable is created with an overall length that is marginally too short for the known distance and defined reference load;

(35) 3. The cable undergoes the setting process depicted in FIG. 5;

(36) 4. The distance between the first and second attachment references is accurately determined;

(37) 5. An offset distance between the second attachment reference and a desired third attachment reference is calculated; and

(38) 6. An extension link 42 of suitable length is manufactured (or possibly pulled from inventory) and attached to the second termination, where the extension link provides the additional distance needed for the cable to have the correct overall length.

(39) Using exemplary numbers, the known distance for a particular installation is 30.260 meters. Once manufactured and set (as depicted in FIG. 5), the distance between the first and second attachment references is carefully measured to be 29.900 meters. An extension link is manufactured where the distance “D” between the first and second cross bores 44, 46 is 0.360 meters. This extension link is then installed as shown in FIG. 6. The cable assembly thus made now has the exact length desired (30.260 meters). And, the length is stable as the cable assembly has already been properly set. In this way countless assemblies can be created to exacting specification with a length that is stable and predictable over time.

(40) FIG. 7 provides another embodiment in which the second termination 36 is provided with an extended tang 56. Loading cross bore 59 is provided so that the cable assembly can be attached to loading fixture 38 (as depicted in FIG. 5). Once the loading process has been used to set the cable and its terminations, a second cross bore 60 is created in extended tang 56. In this example, both loading cross bore 59 and cross bore 60 are located with respect to reference axis 58. The cable is again manufactured a bit short. Cross bore 60 is offset by a distance (D2−D1). Cross bore 60 then becomes the desired third attachment reference and provides the correct overall length for the cable.

(41) FIG. 8 shows a second termination 36 made using a splice. A splice involves passing a length of cable around a thimble 62 and then weaving it back on itself. Such a termination can be very strong. However, because the interweaving is a highly-skilled manual process, it introduces considerable uncertainty regarding the final length of the cable following the setting process depicted in FIG. 5. While generally improved, similar process variation challenges are also involved in round slings, grommets, reeved cable block tension members, or wound slings. These types of looped tensile members will commonly include a thimble of some sort for support of high loads.

(42) FIG. 9 depicts a cross section through thimble 62. The reader will note how the thimble in this example includes a concave channel configured to receive the cable strands 64 (and jacket 66 in this case). The inward facing surface of thimble 62 is planar. In many cases thimble 62 may simply be a pulley or sheave configuration with a central cross bore.

(43) FIG. 10 depicts thimble block 68, which is configured to slide laterally into the thimble. When the thimble block is installed within the middle portion of the thimble, loading cross bore 59 allows the cable assembly to be set as shown in FIG. 5. Once a stable length is achieved a distance between the first and second attachment references is determined. An additional length required for the cable is determined. Cross bore 60 is then created in the thimble block. The additional length needed will be equal to (D2−D1) in the depiction of FIG. 10. Cross bore 60 then becomes the desired third attachment reference.

(44) Up to this point the second and third attachment references have been the centerlines of cross bores. This will not always be the case, as there are many different components used to attach terminations to external components. FIGS. 11 and 12 illustrate a different approach.

(45) The second termination 36 in this example includes a long threaded shaft 70. The cable assembly is attached to an external object by passing threaded shaft 70 through a hole in a thick steel plate and then threading a nut onto the exposed end of the threaded shaft. The nut is then tightened. Bearing surface 76 on termination 36 provides the desired second attachment reference.

(46) In this example—once the cable assembly is set as shown in FIG. 5—the cable assembly's length is again too short. Extension bushing 72 is provided to address this problem. Extension bushing 72 has mating surface 74 and bearing surface 76 on its opposite end. It also includes through bore 78. Through bore 78 is slipped over threaded shaft 70 and mating surface 74 on extension bushing 72 is mated to bearing surface 76 on termination 26.

(47) The mated assembly is shown in FIG. 12. Bearing surface 76 has thereby been extended by the distance “D” to form the desired third attachment reference. The two mating surfaces may be joined by adhesives, welding, or some other suitable method to create fusion 80. The termination and the extension bushing thereafter behave as one integrated part. Where possible, it is desirable for the length adjustment part to be permanent. The purpose of the fusion is simply to provide this permanence.

(48) FIG. 13 shows a second termination incorporating eye 82 and an enlarged cross bore 84. Plug 86 is configured to slide laterally into cross bore 84. Offset cross bore 88 provides the desired third attachment reference. It is offset from the center of plug 86 an appropriate amount to produce the desired overall length for the cable assembly.

(49) FIG. 14 shows an embodiment where an extension link 42 is added to a spliced type of termination. A length of cable is wrapped around a thimble and woven back into itself to create spliced eye 90. The extension link is connected to this spliced eye by passing a lateral pin through the extension link and the spliced eye.

(50) In the prior examples a cable that was marginally too short was extended by the addition of a length-adjustment component. In other instances the cable will be made marginally too long and the length-adjustment component will need to shorten its effective length. FIG. 15 shows a second termination 36 that includes a planar posterior bearing surface where the cable exits the anchor. In this example two bushing halves 92 have been clamped around the cable up against this posterior bearing surface. The two bushing halves create bearing surface 76—effectively reducing the length of the cable. Bearing surface 76 then becomes the desired third attachment reference. The reader should note that this type of corrective bushing can be added to each of the individual anchors as shown in the example of FIG. 3 in order to apply a length correction to the entire cable (three bushing assemblies would be required for the example of FIG. 3).

(51) FIG. 16 shows a length-adjustment component used to increase or decrease the effective cable length for the type of anchor shown in FIG. 15. Correction block 94 includes a cavity to receive termination 36. Overhang 96 abuts the posterior bearing surface on the termination. Cross bore 60 is provided a distance “D” from the posterior bearing surface. Thus, cross bore 60 extends the effective length of the cable assembly and provides the third attachment reference.

(52) In the preceding examples the length-adjustment component has been added to an end of the cable assembly. It is also possible to add the length-adjustment component to an intermediate location. FIG. 17 shows an embodiment in which a third and fourth termination 36 have been added in the middle of the cable. These third and fourth terminations can simply be linked together for the tensioning process shown in FIG. 5. An extension link 42 can then be added between the third and fourth terminations to increase the length of the cable assembly to match the desired length.

(53) Cables have been used as the examples in this disclosure, but the reader should bear in mind the fact that the principles disclosed apply to many other types of tensile members. These include synthetic rope/cable/cord grommets, choked assemblies, reeved block assemblies, and looped slings or pendants where a loop of filaments, strands, or cables are wound around two end points, and the two end points thereby become terminations.

(54) Additionally, the inventive process is not specific to the termination type/method or length correction component. The examples are merely meant to represent a design based on certain termination configurations. These designs are not to be viewed as limiting, like that of the tensile member, they will vary broadly from application to application—and countless variations are possible.

(55) The invention includes many other functional variations that are assumed throughout the examples, such as:

(56) 1. An embodiment in which a length-adjustment component is added to both ends of the cable. In many applications this is preferable and should be assumed to be the case in all embodiments in this disclosure. The simplified depiction of a second termination receiving a length adjustment feature is simply meant to assume that at least one end, if not both ends receive such a component;

(57) 2. An embodiment in which multiple length-adjustment components are “stacked” or otherwise configured for use on at least one end of the cable;

(58) 3. An embodiment in which the length-adjustment component is simply a modification of a component already on the cable (such as milling away a final load bearing surface or drilling a cross bore hole on the termination body itself as examples);

(59) 4. An embodiment in which the length-adjustment component is tamper resistant so that it cannot be easily modified in the field;

(60) 5. An embodiment in which the length-adjustment component is made visibly out of alignment should it be out of factory setting;

(61) 6. A configuration in which adjustment is possible in both directions, such that a tensile member can be made at the target length, and length correction can be designed to be either shorter or longer. (For example, the cable length and bushing halves 92 in FIG. 15 can be configured to first target the nominal length, and adjustments can then be made to the cable by simply using shorter or longer bushing halves 92. It need not be only adjustable in one direction as simplified in this disclosure.)

(62) 7. An embodiment in which the inventive process and length adjustment component is made to the strand or sub-rope of a larger tensile member. In most cases this would include similar length adjustment components with all or most of the loaded subcomponents. This can be used to balance subcomponents within a large assembly, just as if they were individual tension members requiring matched and stable lengths.

(63) Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Those skilled in the art will be able to devise many other embodiments that carry out the present invention. Thus, the language used in the claims shall define the invention rather than the specific embodiments provided.