Cable Tray Bridge Over an Obstacle — Worked Layout
Calculate a four-fold cable tray bridge from obstacle height, clearance and slope angle. Inspect fold stations, notch widths and the editable 3D example.
Inspect the 3D example ↗Measure the obstacle from the incoming tray base
This route rises over an obstacle, crosses a raised plateau and returns to the incoming level. Measure obstacle height from the incoming tray base plane. Measure obstacle length along the incoming route. Choose clearance from the obstacle to the raised tray base and enter a slope angle measured above horizontal.
The example uses a 150 mm obstacle, 400 mm obstacle length, 50 mm clearance and 45° slopes. Tray base width is 200 mm and side height is 50 mm. The incoming and outgoing base-edge lengths are each 350 mm. The raised base level is obstacle height plus clearance, giving 200 mm.
Calculate both slopes and the plateau
For level change R and slope angle θ, the sloped base-edge length is S = R / sin θ and its horizontal projection is Q = R / tan θ. Here S = 282.84 mm and Q = 200 mm. The route has two equal sloped sections.
The model places the plateau fold axes beyond the obstacle ends. With obstacle length O, clearance c and side height h, the plateau is P = O + 2(c + h tan(θ/2)). Here P = 400 + 2(50 + 20.71) = 541.42 mm. This includes the side-wall fold setbacks at both ends. The original stock is the sum of the five base-edge segments.
Worked example dimensions
| Measurement | Value |
|---|---|
| Raised base above the incoming base | 200 mm |
| Each sloped base-edge length | 282.84 mm |
| Horizontal projection of each slope | 200 mm |
| Plateau between its fold axes | 541.42 mm |
| Straight-stock length | 1,807.11 mm |
| Closing V full width at folds 1 and 4 | 41.42 mm |
| Formed wall-top gap at folds 2 and 3 | 38.27 mm |
Mark all four stock stations and inspect the joints
Add the segment lengths cumulatively from the starting end. The four base-edge stock stations are 350, 632.84, 1174.26 and 1457.11 mm. Total straight stock is 1807.11 mm. The turn sequence is +45°, −45°, −45°, +45°.
Folds 1 and 4 close a side-wall V with full width 2h tan(θ/2) = 41.42 mm. Folds 2 and 3 open side-wall slits as the base folds downward. At full forming, their wall-top gap is 2h sin(θ/2) = 38.27 mm. Read the marked stock and formed views at their respective stages. Preserve the base connections shown in the model.
Review the fabrication detail
The model uses ideal sharp base folds. Verify the selected tray profile, thickness, rolled lips, cutting allowance and connections for opening joints. Review the cable route and required bending space with the actual product instructions.
Continue with a related layout
Centered Cable Tray Reducer — Panel Lengths and Assembly ↗