Modular Wire Roller Assembly for Precise Tie Wire Coiling
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Solution Overview
Problem
Existing methods for securing electrical distribution lines to insulators using tie wire are inefficient and lack a dedicated tool for effectively rolling and shaping wire segments.
Innovation Solution
A wire roller assembly with a rotatable roller shaft, removable plates, and a roller disk that can retain and roll wire segments, facilitated by an actuator mechanism, allowing for the formation of coiled wire segments for secure attachment to electrical insulators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dedicated wire rolling tool is implemented, then the efficiency and reliability of tie wire attachment is improved, but the device complexity increases
Solution Approach 1:
The rolling assembly is divided into modular components including a rolling drum, support plates, and an actuator mechanism. Each component performs a specific function and can be independently manufactured and assembled, reducing overall system complexity while maintaining rolling efficiency.
Solution Approach 2:
The rolling assembly is designed to perform multiple functions: the rolling drum both rotates to form wire coils and provides structural support, while the support plates serve both as mounting surfaces and as guides for wire positioning. This multi-functionality reduces the number of separate components needed.
2Ease of operation
If the roller assembly is designed with removable plates for wire segment removal, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The support plates are designed to be selectively removable from the rolling drum, transforming the assembly from a static structure to a dynamic one that can adapt its configuration. This allows operators to easily access and remove wire segments by removing plates, while the plates can be reattached to restore the complete rolling function.
3Manufacturing precision
If the wire roller disk is configured to releasably retain wire segment ends, then the manufacturing precision of wire coiling is improved, but the device complexity increases
Solution Approach 1:
The rolling drum surface features localized coiling surfaces with specific geometric profiles designed to guide and shape the wire into precise coils. These localized features provide the necessary precision for wire formation without requiring the entire drum structure to be complex, as only specific areas of the drum surface need precise geometry.
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 wire roller assembly efficiently forms coiled wire segments, enhancing the securement of electrical distribution lines to insulators, improving the efficiency and reliability of the attachment process.
Implementation Method 1
a roller assembly bearing supported by the roller mount assembly
Data Source
AI summary
Wire rollers may include a wire roller assembly including a rotatable roller assembly shaft. A first roller assembly plate may be on the roller assembly shaft and a second roller assembly plate may be on the roller assembly shaft. At least one of the first roller assembly plate and the second roller assembly plate may be selectively removable with respect to the roller assembly shaft. A roller space may be between the first roller assembly plate and the second roller assembly plate. A wire roller disk may be in the roller space and engaged for rotation by the roller assembly shaft. The wire roller disk may be configured to releasably retain at least one end of a wire segment. A roller assembly actuator may operably engage the roller assembly shaft of the wire roller assembly for rotation of the roller assembly shaft and the wire roller disk.