Cable Insertion Tool With Support Means For Corrugated Pipe
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Solution Overview
Problem
The increased hardness of modern Monoflex corrugated pipes makes existing cable insertion tools wear out quickly due to high spring forces, which can damage cables and lead to assembly errors, as the pipes tend to close and apply sharp edges against the tool, causing increased wear and potential cutting of wires.
Innovation Solution
A cable insertion tool with a quadrilateral body and guiding ribs that reduce the force exerted by the pipe's spring action by widening the slot and providing a protection tongue to keep cables inside, featuring a smooth inner surface, handle, and flexible guiding fins to manage the pipe's edges and prevent misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the slot of the slashed corrugated pipe is extended to allow cable insertion, then the cable can be fed into the pipe, but the pipe acts like a spring and generates high spring force that presses sharp edges against the tool, causing increased wear and potential cable damage
Solution Approach 1:
A support means is introduced as an intermediary element between the tool and the pipe edges. This support means absorbs and distributes the spring force generated by the pipe, preventing the sharp edges from pressing directly against the tool body. The support means acts as a mediator that protects both the tool and cable from the harmful spring action of the pipe.
Solution Approach 2:
The support means is positioned in advance within the tool structure to preemptively counteract the spring force before it can damage the tool or cable. By having the support means ready in position, the tool is pre-prepared to handle the spring action of the pipe during the insertion process.
2Strength
If modern Monoflex corrugated pipes with increased hardness are used to meet environmental temperature and robustness requirements, then the wiring harness robustness is improved, but the tool life time is significantly decreased due to increased wear from high spring forces
Solution Approach 1:
The support means serves as a protective intermediary that reduces the direct contact and wear between the tool and the hard pipe edges. By distributing the spring force, the support means prevents the high hardness of modern pipes from causing rapid tool wear, thereby extending tool lifetime while maintaining the use of robust modern pipes.
Solution Approach 2:
The support means changes the force distribution parameters by converting concentrated spring force into distributed pressure across a larger area. This parameter change reduces the contact stress and wear rate on the tool, allowing it to withstand the increased hardness of modern Monoflex pipes.
3Stability of the object's composition
If the sharp edges of the slot are pressed hard against the tool due to spring force, then the pipe maintains its structural integrity, but any derailing can easily lead to cutting wires
Solution Approach 1:
The support means acts as a protective barrier between the sharp pipe edges and the cable. Even if derailing occurs, the support means prevents the sharp edges from directly contacting and cutting the wires, thereby reducing the harmful effects while maintaining pipe structural integrity.
Solution Approach 2:
The support means provides beforehand cushioning protection by being positioned to absorb and distribute spring forces before they can cause cable damage. This pre-positioned protection cushioning reduces the risk of wire cutting from derailing events.
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
The tool extends the lifespan of the insertion tool, protects cables from damage, and ensures accurate assembly by distributing the spring force and providing audible and tactile feedback for quality control, reducing wear and misalignment issues.
Implementation Method 1
the slashed corrugated pipe acts like a spring and tries to close the increased slot. A high spring force is generated while spreading the slashed corrugated pipe to feed in the wire
Data Source
Figure 1~2
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AI summary
A cable insertion tool (10) for supporting manually insertion of at least one electrical cable (200) into a slashed corrugated pipe (100), whereby the insertion tool (10) comprises, a body (20) formed by bending a quadrilateral sheet around an inlet axis (I) defining an arc, having a first radius (32) whereby the body (20) has a u-shaped cross section perpendicular to the inlet axis (I) and an outer surface (21), the quadrilateral sheet comprises a first corner (24), a third corner (28) located opposite the first corner, a body edge (40) starting from a second corner (26) continuing to the third corner (28) and further to a fourth corner (30), whereby the inlet axis (I) extends from the first corner (24) towards the third corner (28), the body edge (40) is angled with respect to a plane spanned by the body edge (40) between the third corner (28) and the second corner (26) and the third corner and the fourth corner (30), a first guiding rib (42) extends from the body edge (40) outwards, a support means, supporting the widening of a slot (110) of the slashed corrugated pipe (100) by urging against the inner surface of the slashed corrugated pipe (100), when the tool is positioned to be pulled along the slashed corrugated pipe (100).