Wire Joint Insulation Coating with Air-Bag Compaction
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Solution Overview
Problem
Existing electric wire insulating coating methods have low winding efficiency, uncontrollable construction quality, and rely heavily on worker experience, leading to inconsistent results and potential operational risks due to the use of insulated rubber tape.
Innovation Solution
An insulating coating device featuring a pressing pipe with an air bag and filling pipe, which uses a self-curing insulating material and a motor-driven system to uniformly coat and compact the material on electric wire joints, reducing cavities and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If insulated rubber tape is used for winding insulation restoration, then the insulation can be restored, but the winding efficiency is low and construction quality is uncontrollable
Solution Approach 1:
The patent replaces the manual mechanical winding process with an automated coating system that uses a coating head to apply insulating material directly onto the wire surface, eliminating the need for manual tape winding and significantly improving both efficiency and quality consistency
Solution Approach 2:
The coating system automatically controls the application of insulating material through the coating head, with the material being applied uniformly without requiring manual intervention for each winding operation, enabling the system to perform the insulation restoration task autonomously
2Reliability
If thick insulating gloves are worn for safety, then protection is provided, but operation becomes difficult and construction effect cannot be guaranteed
Solution Approach 1:
The patent introduces an automated coating head as an intermediary tool that performs the insulation application task, allowing operators to work from a distance without needing to wear thick insulating gloves directly on their hands, thus maintaining safety while improving operational ease
3Ease of manufacture
If manual winding with insulated rubber tape is used, then insulation restoration is achieved, but construction quality depends excessively on worker experience
Solution Approach 1:
The patent replaces the manual winding process with an automated coating system that uses a coating head to apply insulating material uniformly, eliminating the variability introduced by different workers' experiences and skills
Solution Approach 2:
The coating system controls the application parameters such as material flow rate, coating head movement speed, and layer thickness to ensure consistent quality output regardless of operator experience, standardizing the construction quality through controlled parameters
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
The device simplifies and enhances the insulating coating process, reducing reliance on worker experience and ensuring consistent, high-quality insulation with improved durability and reduced operational risks.
Implementation Method 1
an air pump, a material storage box and a delivery pump are fixed to a bottom surface of the pressing pipe... an output end of the air pump is detachably connected to the air pipe joint through a hose
Data Source
AI summary
Provided is an insulating coating device for an electric wire, including a pressing pipe. The pressing pipe includes two first pressing parts which are configured to divide the pressing pipe into two parts along a longitudinal cross section of the pressing pipe, an inner wall of the pressing pipe is provided with an air bag, and the air bag is provided with an air pipe joint which penetrates to an outside of the pressing pipe. In the insulating coating device for the electric wire, a self-curing insulating material is coated on joints of the electric wires, the air bag is used to squeeze the self-curing insulating material such that the self-curing insulating material is shaped and compacted, so that cavities generated in a coating process is reduced, and the self-curing insulating material is uniformly attached to the joints of the electric wires.