Spray-On Wire Lubrication With Enclosure and Drying Chamber
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation of wires and cables is hindered by high friction, requiring excessive pulling force, and existing methods for reducing friction are inefficient, messy, and affect the aesthetic quality of the final product.
Innovation Solution
A system and method for spraying a pulling lubricant onto wires or cables during manufacturing, using an enclosure with adjustable nozzles to apply a fine mist and a drying chamber to prevent excess lubricant dispersal, reducing friction and pulling force during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If manual lubricating techniques are used at the job site, then the coefficient of friction is reduced, but the process becomes time consuming and messy
Solution Approach 1:
The lubricant is applied to the wire or cable during the manufacturing process, before the wire leaves the manufacturing site. This preliminary application eliminates the need for manual lubricating at the job site, reducing both application time and mess while ensuring consistent lubricant coverage on the wire surface.
2Force
If lubricant is incorporated into the outer jacket material, then the coefficient of friction is reduced, but the process becomes complicated and expensive
Solution Approach 1:
Instead of incorporating lubricant into the outer jacket material during the complex extrusion process, the lubricant application is extracted as a separate, simpler step. The wire receives lubricant application after extrusion but before leaving the manufacturing site, decoupling the lubricant application from the jacket formation process and simplifying overall manufacturing.
3Force
If spray-on lubricant application is used without enclosure, then the coefficient of friction is reduced, but excess lubricant disperses and creates safety and efficiency issues
Solution Approach 1:
An enclosure system with walls and a collectable floor forms a contained space around the wire during lubricant application. This enclosure prevents excess lubricant mist and spray from dispersing into the manufacturing environment, containing it within the enclosure where it can be collected and reused, thereby eliminating safety and efficiency issues while maintaining effective lubricant application.
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 method effectively reduces the coefficient of friction and pulling force required for wire and cable installation, maintaining a clean and efficient manufacturing environment while allowing for lubricant reuse.
Implementation Method 1
The air system provides air to aerosolize the lubricant into a mist and to power the lubricant pump system
Implementation Method 2
The wire then enters the drying chamber where air dries the excess moisture from the spray-on lubricant dispersed upon the wire or cable
Implementation Method 3
spray-on application of a pulling lubricant to a wire or cable, causing a reduced coefficient of friction and reduced pulling force
Data Source
AI summary
A system, method, and apparatus lubricating a wire or cable during manufacturing, wherein the wire is aligned with an entry to a spraying enclosure and passes through a first seal of the spraying enclosure. Lubricant is sprayed onto the wire inside of the spraying enclosure while the unapplied, but sprayed, lubricant is collected at the bottom of the spraying enclosure. The wire passes through a second seal of the spraying enclosure, is aligned, and exits from the spraying enclosure.