Wire Pulling Connector With Spring-Biased Cams
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Solution Overview
Problem
Existing methods for installing wires through conduits often result in a loss of connection between the pulling line and the wire, leading to significant time and monetary losses due to the high forces required and the damage caused by attaching the pulling line, especially in municipal applications where large wires are used.
Innovation Solution
A connector with a body and cams that grip the wire, biased by an elastic ring to maintain contact regardless of tension or orientation, combined with a Kellum grip to apply high pulling forces securely and easily, allowing for reliable transmission of thousands of pounds of force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pulling line is attached to the wire to pull it through the conduit, then the wire can be installed through the conduit, but the connection between the pulling line and wire may be lost during the pull
Solution Approach 1:
The connector uses dynamic cams that can rotate between open and closed positions. The cams are biased by springs to automatically grip the wire during pulling while allowing easy insertion. This dynamic mechanism ensures reliable connection without requiring complex static structures.
Solution Approach 2:
The connector design allows the wire to automatically trigger the cam closure mechanism during insertion. The wire itself serves to activate the gripping action, eliminating the need for separate actuation mechanisms and reducing overall system complexity while maintaining reliability.
2Force
If high pulling force is applied to install the wire through the conduit, then the wire can be pulled through lengthy conduits with bends, but the connection between the pulling line and wire may be lost
Solution Approach 1:
The cam mechanism is designed to engage and lock under load. As pulling force is applied, the cams naturally rotate into their closed gripping position, with spring bias ensuring continuous contact. This dynamic engagement ensures the connection remains secure even under high pulling forces of a thousand pounds or more.
Solution Approach 2:
The spring-biased cam mechanism provides built-in compliance and stress distribution. The springs absorb shock and maintain constant contact pressure, preventing connection failure under sudden or varying loads during the pulling operation.
3Productivity
If the pulling line is attached to the wire every few yards during the pull, then the wire can be installed through long conduits, but the wire is damaged and rendered unusable
Solution Approach 1:
The connector is designed as a disposable component that remains attached to the wire after installation. Instead of repeatedly attaching and detaching the pulling line (which damages the wire), a single-use connector is left on the wire, eliminating the need for reattachment and preventing damage from multiple attachment cycles.
Solution Approach 2:
The connector design allows the pulling line to be nested within or integrated with the connector body. This nested configuration enables the pulling line to be easily removed after installation while leaving the connector securely attached to the wire, avoiding damage to the wire from repeated manipulations.
4Reliability
If a secure connection is provided between the pulling line and wire, then the wire can be pulled through the conduit without losing connection, but the connector becomes more complex
Solution Approach 1:
The cam mechanism provides automatic gripping action that secures the wire reliably once inserted. The dynamic cam rotation ensures firm engagement without requiring complex adjustment mechanisms, maintaining ease of operation while achieving high connection reliability.
Solution Approach 2:
The connector automatically grips the wire through spring-biased cams that engage during the natural insertion process. This self-gripping mechanism eliminates the need for separate locking actions or complex fastening procedures, maintaining simplicity and ease of use while ensuring secure connection.
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 connector provides a secure and reliable connection that remains intact even if tension is lost or the orientation changes, enabling efficient and high-force pulling of wires through conduits without damaging them, significantly reducing the risk of connection loss and increasing productivity.
Implementation Method 1
an elastic ring to maintain contact regardless of tension or orientation
Implementation Method 2
a Kellum grip to apply high pulling forces securely and easily, allowing for reliable transmission of thousands of pounds of force
Data Source
AI summary
A wire pulling grip easy and reliably grips wire for pulling the same through a conduit or the like. The grip has cams which maintain contact with the wire even when tension is not applied and regardless of the orientation of the grip, significantly reducing the likelihood that the connection with the wire is lost. The cams are selectively releasable to allow the wire to be easily removed from the grip.