Continuous Cable Recycling System for Power Line Reconductoring
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Solution Overview
Problem
The existing methods for reconductoring or restringing high voltage power lines require frequent interruptions to replace full reels, leading to reduced productivity and lower recycling value due to the bundling of aluminum and steel materials, which are not efficiently separated.
Innovation Solution
A continuous processing system that simultaneously cuts and separates aluminum strands from the steel core during the pulling process, allowing for continuous operation without reel swaps, using counter-rotating cutter wheels and a passive splitter head to process the cable on-the-fly, enhancing recycling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a take-up reel is used to wind the old wire during reconductoring, then the wire can be pulled continuously, but the process must be stopped when the reel is full, causing productivity loss
Solution Approach 1:
The invention extracts the aluminum strands from the cable by cutting them at closely spaced intervals while leaving the steel core intact. This allows the steel core to be wound on the take-up reel without the aluminum strands, eliminating the need to stop for reel replacement and enabling continuous operation.
Solution Approach 2:
The cable is segmented into small aluminum strand segments that are cut from the continuous cable. These segments are removed while the steel core continues to be pulled and wound on the reel, allowing the process to continue without interruption for reel replacement.
2Loss of substance
If the old wire is wound on a reel for disposal, then it can be removed from the pull zone, but the recycling value is significantly lower because aluminum and steel are not separated
Solution Approach 1:
The cable is cut into small segments along its length, separating the aluminum strands from the steel core. This segmentation enables the aluminum to be recovered as valuable material while the steel core is wound on the reel, maximizing recycling value without requiring complex post-processing separation equipment.
Solution Approach 2:
The aluminum strands are cut and removed from the cable before the cable is fully pulled from the pull zone. This preliminary separation action ensures that only the steel core is wound on the take-up reel, preparing the materials for optimal recycling value before disposal or further processing.
3Loss of substance
If the cable is cut into segments to separate aluminum from steel, then recycling value increases, but the process requires stopping the pull to change reels
Solution Approach 1:
The aluminum strands are extracted from the cable by cutting them at closely spaced intervals while the cable is being pulled. The steel core continues to be wound on the take-up reel without interruption, maintaining continuous operation while achieving material separation for recycling.
Solution Approach 2:
The cutting and separation process operates continuously as the cable is pulled through the system. The take-up reel continuously winds the steel core while the aluminum strands are simultaneously cut and removed, eliminating the need to stop for reel replacement and maintaining continuous productive action throughout the process.
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
This system enables continuous operation during reconductoring or restringing, minimizing downtime and increasing recycling value by efficiently separating and processing aluminum and steel materials, thus improving operational efficiency and productivity.
Implementation Method 1
The first stage cutter includes at least one pair of counter-rotating wheels having circumcising cutter blades positioned about the wheels so that the cutter blades close at a bight between the wheels so as to cut through the aluminum strands of the cable-to-be-recycled while leaving the core intact
Implementation Method 2
A passive splitter head is provided downstream of the first stage cutter to remove any of the segments of the aluminum strands which remain adhered to the core of the cable
Data Source
AI summary
A continuous processing system and method for the continuous processing of an electrical conductor cable having aluminum strands encasing a steel core directly from a puller or from a puller and reel, simultaneously or on-the-fly during substantially the entirety of a reconductoring or re-stringing of the cable, wherein such cables are used for power lines or for static wires. The system is adapted to cooperate with a pulling machine. The pulling machine may be formed integrally within the system or may be a conventional pulling machine which cooperates with the system. The processing system runs continuously, substantially without interruption, during the pull of all of the cable from the pull zone of the reconductoring or restringing.