Overcoming the engineering challenges of stainless steel cable
While stainless steel has long been dismissed for being too costly and rigid of a material for automatic cover systems, many engineers have noticed its potential. The material is stronger, durable, and non-pliable—a superior option for outdoor pool environments. That said, the two major issues engineers had to face when designing an automated pool cover using stainless steel cable were:
1) How to keep the cable under constant tension; and
2) How to protect the entire system from getting damaged by the strong steel cable as the cover opens and closes.
These concerns are addressed when using pliable rope as it stretches like a rubber band. However, just a few inches of slack in a stainless steel cable line could tangle the cable, causing an entire pool cover system to fail.
To resolve these issues, a spring-loaded mechanism was built into the cable reels that maintains constant tension on the stainless steel cable regardless of unexpected movements within the pool cover system. This eliminates the risk of any slack in the cable line that could lead to system failure. Additionally, to prevent damage to the system from the rigid stainless steel cable itself, a mechanical slip clutch and electronic automatic shutoff sensors are integrated into the system. These mechanisms prevent the stainless steel cable from going past intended stopping points and causing damage as the pool cover is opened and closed.
As a result, the stainless steel cable accommodates a much smaller mechanism to operate, offering greater freedom and flexibility to designers to maintain the sleek, seamless lines of their pool designs.
Leveraging stainless steel cable for flexible pool designs
Pool design flexibility
A smaller mechanism creates a much smaller footprint. The reduced footprint for a stainless steel system requires only a 356-mm (14-in.) offset for most pools, compared to 813 mm (32 in.) commonly seen in standard, rope-based pool cover systems. With a smaller mechanism, designers can more easily incorporate a pool cover with no visible indication of an automated cover system positioned on one end.
Strong and durable
Stainless steel cable is water-resistant; therefore, it works better in a wet outdoor environment, as well as other weather conditions. The cable is even critter-proof and cannot be chewed or damaged by outdoor pests. Its strength alone means a small diameter cable can be used in automatic cover systems, increasing the ratio of the size of the cable to the size of the pulley. This increased size ratio leads to less mechanical wear and tear over time, meaning stainless steel systems have a long lifespan and require less maintenance.
Non-pliable
Unlike rope, stainless steel cable does not shrink or stretch; therefore, it does not change in length and the cover system does not need ongoing adjustments and repairs to function properly. This can be an incentive for those homeowners who do not wish to invest in the ongoing maintenance requirements of traditional pool cover systems.
Improved form and function
With advanced engineering in place, stainless steel cable is transforming automatic covers and pool designs. The smaller overall footprint of the cover system presents new design possibilities, while the strong, non-pliable material offers improved functionality and reduced maintenance over time. Due to its benefits, many pool builders have begun offering stainless steel cables to their clients as part of their ‘standard’ pool cover package instead of an upgrade. The technology has allowed many customers to view automatic pool covers as a necessity rather than an accessory, leading to greater opportunities for pool professionals and their ability to provide superior designs to clients.
LaMont Drechsel is an experienced operations executive with a strong background in product development and mechanical engineering for consumer goods and manufacturing. As the vice-president and general manager of specialty products at Fluidra North America, he oversees operations for various subsidiaries, including Cover-Pools Inc. Drechsel has overseen automated pool cover technology innovation and product development at Cover-Pools for more than 18 years. He holds an MBA in management and a bachelor of science degree in mechanical engineering from the University of Utah. For more information, visit coverpools.com/t4, or email cover-pools.sales@fluidra.com.
