Conductor Identification Sleeves for Low-Force Conduit 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 controlled wire extraction, and a system for tension equalization and lubrication to reduce the force required for pulling wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional reel-based wire installation is used, then wire can be stored and managed in traditional manner, but the process becomes labor-intensive requiring at least three electricians to overcome the inertia of multiple reels weighing 50 pounds each
Solution Approach 1:
The wire storage system is segmented into multiple individual containers (first container, second container, third container) rather than using traditional reels. Each container holds a separate length of conductor, allowing independent handling and payoff without the inertia problems of large reels. This segmentation enables a single electrician to manage multiple conductors simultaneously.
Solution Approach 2:
A wire guide is introduced as an intermediary component between the container and the conduit. The wire guide facilitates smooth wire extraction and routing, reducing friction and making it easier to pull wires through conduits. This intermediary device eliminates the need for multiple electricians to manually manage wire tension and routing.
2Length of moving object
If multiple reels holding 50 pounds of wire each are used, then sufficient wire length can be provided, but the force required to pull wire exceeds 3,500 pounds for seven reels due to stationary inertia
Solution Approach 1:
Instead of using one or two large reels containing thousands of pounds of wire, the system segments the wire supply into multiple smaller containers, each holding a manageable length. This segmentation reduces the stationary inertia that must be overcome during wire payoff, allowing a single electrician to handle each container individually with minimal force.
Solution Approach 2:
The wire containers are positioned at convenient locations (e.g., on the ground or on easily movable stands) rather than requiring elevation or complex support structures. This equipotential positioning eliminates the need to lift heavy reels and ensures that wire extraction occurs at a consistent, manageable height, reducing the force required during installation.
3Productivity
If traditional wire feeding methods are used, then wire can be installed through conduits, but the process becomes strenuous and time-consuming requiring multiple workers
Solution Approach 1:
The wire guide is designed to automatically guide the wire from the container through the conduit without requiring manual intervention to manage tension or routing. The system serves itself by using the wire's own tension and the guide's geometry to facilitate smooth extraction and installation, eliminating the need for multiple workers to coordinate their efforts.
Solution Approach 2:
The system changes the physical parameters of wire storage from traditional reels to rectangular containers with optimized dimensions. This parameter change allows for easier stacking, handling, and positioning of wire supplies. The containers can be arranged in configurations that optimize access and minimize the force required for wire extraction, directly improving installation speed while reducing physical strain.
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.