Conductor Sleeve and Tag Assembly for Low-Force Wire Pulling
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Solution Overview
Problem
Conventional methods for installing wire require at least three electricians to manage reels, making the process labor-intensive and strenuous due to the need to overcome the inertia of multiple reels holding significant weight, typically 50 pounds each, resulting in a total force requirement of 3,500 pounds for seven reels.
Innovation Solution
A multiple conductor container assembly that allows easy payoff of wires without the need for reels, featuring a container with concentric surfaces to house multiple conductors in a circular pattern, a container tap wire guide for secure and efficient pulling, and a system for tension equalization and lubrication to reduce the force required for pulling wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional reel holders are used to store and pay off wire, then wire can be stored in large quantities, but the force required to pull the wire becomes extremely high due to the inertia of multiple heavy reels
Solution Approach 1:
The patent divides the wire storage system into multiple individual containers, each holding a single conductor, rather than using one large reel holder. This segmentation allows each container to be pulled independently with much less force, eliminating the need to overcome the combined inertia of multiple reels stacked together.
Solution Approach 2:
The patent transitions from horizontal reel storage to vertical container stacking. Multiple containers are stacked vertically and pulled together as a group, changing the dimensional arrangement from horizontal layers to vertical columns. This allows the wire payoff system to be pulled with minimal force while maintaining large storage capacity.
2Productivity
If multiple electricians are assigned to manage reel holders, then wire installation can proceed, but labor requirements and physical strain increase significantly
Solution Approach 1:
The patent divides the labor task by assigning each electrician a specific vertical stack of containers rather than having multiple workers share a single horizontal reel holder. This segmentation of both the storage system and the labor assignment reduces physical strain on each worker while maintaining installation productivity.
Solution Approach 2:
Instead of having multiple workers pull on a single heavy reel holder, the patent inverts the approach by having each worker pull their own lighter vertical stack. The system transitions from one heavy load shared by many workers to multiple lighter loads each handled by one worker, reducing individual physical strain.
3Ease of manufacture
If wire is pulled through conduits from stationary reel holders, then wire installation is achieved, but the process becomes labor intensive and time consuming
Solution Approach 1:
The patent merges multiple individual container pulls into a coordinated group pull where several vertical containers are pulled together simultaneously. This combining approach maintains the feasibility of wire installation through conduits while significantly reducing the time required compared to pulling from traditional reel holders.
Data Source
AI summary
Conductor identification may be provided. A first sleeve may be placed around a first conductor and a second sleeve around a second conductor. Next, a first tag may be placed on the first conductor and a second tag on the second conductor. Then, the first conductor and the second conductor may be pulled together through a conduit. The first conductor may slideably move through the first sleeve and the second conductor may slideably move through the second sleeve as the first conductor and the second conductor are pulled together through the conduit.