Repairing Radial Deformation in Multi-Strand Wire Using Segmented Rollers
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Solution Overview
Problem
Multi-strand wires, such as high-voltage transmission wires, often suffer from 'bird cage' defects due to buckling of tensile armor wire strands, leading to radial deformation, which causes issues like voltage loss, power wastage, and potential arc or flash-over, necessitating costly replacement of entire transmission lines.
Innovation Solution
An apparatus comprising an electrically non-conductive base with rollers having annular grooves is used to re-form radially deformed multi-strand wires by rolling them over the wire, allowing for in-situ correction of bird cage defects without disconnection from support towers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If operators hammer or press the strands back into shape while the wire is suspended, then the deformation may be corrected, but the wire must be disconnected from support towers and replaced if correction fails, resulting in great expense of materials and labor
Solution Approach 1:
The repair apparatus segments the repair function into multiple rollers (first roller, second roller, third roller, fourth roller, fifth roller) that can independently apply corrective force to different portions of the deformed wire, enabling precise localized repair without affecting the entire transmission line
Solution Approach 2:
The repair apparatus introduces rollers as intermediary elements between the operator and the deformed wire. These rollers mechanically transmit and distribute the corrective force evenly across the wire strands, enabling effective deformation correction while the wire remains suspended and connected
2Reliability
If entire stretches of transmission line are replaced and re-strung, then the deformation defect is eliminated, but the expense of materials and labor increases greatly
Solution Approach 1:
The repair apparatus performs preliminary correction of the bird cage deformation before the wire is disconnected or replaced. By restoring the wire's proper shape while it remains in service, the apparatus prevents the need for complete replacement and maintains transmission line integrity
Solution Approach 2:
Instead of discarding the entire transmission line section with the defect, the apparatus recovers the functional integrity of the deformed portion through mechanical reformation, allowing the wire to continue serving its purpose without replacement
3Ease of repair
If the wire is disconnected from support towers for repair, then deformation can be corrected, but productivity decreases and time is lost
Solution Approach 1:
The repair apparatus is designed to be dynamically applied to and removed from the suspended wire. The apparatus can be positioned, adjusted, and removed without disconnecting the wire from support towers, maintaining continuous operation and high productivity
Solution Approach 2:
The wire maintains its own suspended state and connection to support towers throughout the repair process. The repair apparatus serves the wire in its existing configuration rather than requiring the wire to be disconnected or repositioned
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
Enables effective on-site correction of bird cage defects in multi-strand wires, reducing material and labor costs by allowing for the repair of transmission lines without the need for complete re-stringing.
Implementation Method 1
A radially deformed multi-strand wire may be re-formed when the first roller is rolled over a first side of the radially deformed multi-strand wire and the second is rolled over a second side of the radially deformed multi-strand wire
Data Source
AI summary
Apparatuses and methods for correcting radial deformation in multi-strand wire, including a method comprising obtaining an apparatus comprising a base and a first and second roller rotatably attached to the base and laterally aligned with and laterally offset from one another, wherein each of the first and second rollers has an annular groove with a concave configuration; positioning the apparatus on a radially deformed multi-strand wire suspended between two support members such that the multi-strand wire is positioned substantially linearly in the lateral offset between the first and second rollers; and moving the apparatus over the radially deformed multi-strand wire such that a first side of the multi-strand wire is received in the groove of the first roller and a second side of the multi-strand wire is received in the groove of the second roller whereby the length of radially deformed multi-strand wire is reformed.