Multiple Conductor Barrel Assembly for Low-Force Wire Pulling
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Solution Overview
Problem
Conventional methods for installing wire require multiple electricians to manually pull and feed wire through conduits, which is labor-intensive and strenuous due to the need to overcome the inertia of heavy wire reels, often necessitating three electricians to manage reels holding 50 or more pounds of wire.
Innovation Solution
A multiple conductor barrel assembly that allows easy payoff of wire without reels, featuring a container with concentric surfaces to house multiple conductors in a circular pattern, a barrel tap wire guide for secure feeding, and a system for tension equalization and lubrication to reduce the force required for pulling, enabling single-person operation and efficient wire management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional manual wire installation methods are used with multiple electricians pulling wire from heavy reels, then the wire can be installed through conduits, but the labor intensity and physical effort required increases significantly
Solution Approach 1:
The patent replaces the manual mechanical pulling system with a motorized wire paying-out mechanism. The motor automatically feeds wire from the reel through the conduit at controlled speeds, eliminating the need for electricians to manually pull heavy wire and significantly reducing labor intensity while maintaining installation capability.
Solution Approach 2:
The wire reel assembly is designed to be self-serving through the automated motor mechanism that pays out wire on its own. The system includes sensors and controls that automatically manage the wire feeding process, reducing the need for human intervention and multiple workers while maintaining continuous installation productivity.
2Productivity
If multiple electricians are deployed to handle heavy wire reels, then wire installation can be completed, but the complexity of the installation process increases
Solution Approach 1:
The patent combines the wire reel mounting mechanism, motorized paying-out system, and wire guiding components into a single integrated assembly that attaches to the conduit. This unified device performs multiple functions (reel holding, motor-driven wire feeding, tension control) that previously required coordination among multiple electricians, thereby reducing process complexity while maintaining installation capacity.
3Ease of operation
If electricians manually pull wire to overcome the inertia of stationary reels, then wire can be fed into conduits, but the force required and physical strain on workers increases
Solution Approach 1:
The patent substitutes the manual pulling force with a motorized system that provides controlled tensile force to pay out wire. The motor generates the necessary force to overcome reel inertia and friction, feeding wire smoothly into the conduit without requiring electricians to exert significant physical force, thereby reducing strain while maintaining wire feeding capability.
Data Source
AI summary
A method for laying multiple conductors in a container may be provided. The method may comprise receiving the multiple conductors at a monitoring station; receiving the multiple conductors at a drive; and receiving the multiple conductors at the container.