Challenge

An industrial product required a compact, manually adjustable cable-resistance mechanism capable of meeting demanding performance requirements:

• Force: 0-1000N

• Force Accuracy: ±20N over full operating range

• Range: 3.5m

• Design Life: Infinite fatigue life

• Load Adjustment: Manual

Engineering Approach

A concept was developed combining a high-efficiency braking mechanism with an integrated spring-return system. Mathematical analysis was used to establish the required braking characteristics and component loads, with stress and fatigue analysis used to develop the mechanism for the required life and operating range. The complete mechanism was subsequently detailed for manufacture, including full production drawings.

Outcome

The completed design achieved the specified 0–1000 N resistance range, ±20 N force accuracy, 3.5 m cable travel and fatigue-life requirement.