Helical Binding Element Cable Assembly for Conduit Installation
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Solution Overview
Problem
Conventional methods for pulling 600V underground electrical cables through conduits are time-consuming due to the need for compressed air to 'blow' a line through and then pull a rope to guide the cable, often resulting in cable buckling or deformation, known as 'bird caging', which increases the pushing force required.
Innovation Solution
A cable assembly with a helically configured binding element, such as a skid wire, is applied to the conductor core to minimize buckling and reduce the pushing force needed to push the cable through a conduit, eliminating 'bird caging' and deformation by providing a lower friction interface and maintaining conductor alignment through bends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional UD electrical cables are pulled through a conduit using compressed air and pull rope, then the cable can be installed, but the process is time-consuming and causes cable buckling or deformation
Solution Approach 1:
The cable is pre-configured with a helical binding element structure before installation. This preliminary structural preparation allows the cable to resist buckling during the pushing installation process, eliminating the need for complex pull-rope mechanisms and compressed air blowing, thereby speeding up installation while preventing deformation
Solution Approach 2:
The cable structure is modified by adding a helical binding element that changes the mechanical parameters of the cable. This helical configuration provides structural support and rigidity to prevent buckling during installation, allowing the cable to be pushed through conduits without deformation while maintaining installation efficiency
2Ease of operation
If conventional UD electrical cables are pulled through a conduit, then the cable can be installed, but the process requires multiple steps including blowing line and attaching Kellum Grip
Solution Approach 1:
Instead of pulling the cable through the conduit using external forces (compressed air and pull rope), the invention inverts the approach by pushing the cable directly through the conduit using its own structural integrity provided by the helical binding element. This eliminates the need for intermediate tools like Kellum Grip attachments and line blowing procedures
Solution Approach 2:
The invention extracts and eliminates the unnecessary intermediate steps from the installation process. By designing the cable with an inherent helical binding structure that provides self-support during installation, the complex multi-step process of blowing line, attaching pull ropes, and using gripping devices is removed, leaving only a simple push-through installation method
Data Source
AI summary
A cable assembly may have a conductor core and a binding element. The binding element may be configured helically around the conductor core. In addition, the binding element may be configured to, when the cable assembly is pushed through a conduit having at least one sweep, eliminate buckling of the cable assembly. The binding element may be made of a material configured to be stretched to a predetermined percentage of a length of the material without breaking.