Systems and Methods for Layering Multiple Conduit Runs Onto a Reel

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/640,434, entitled “Systems and Methods for Layering Multiple Conduit Runs Onto a Reel” filed Apr. 30, 2024, which is incorporated herein by reference in its entirety.

BACKGROUND

Conduit plays a crucial role in the installation of cable by providing a protective and organized pathway for cable systems. Conventionally, conduit is installed at a jobsite before cables are then fed through the installed conduit using appropriate techniques and tools. Alternatively, to simplify the installation process in certain situations, conduit, such as high density polyethylene (“HDPE”) conduit, can be extruded loosely around one or more cables prior to shipping the conduit to a jobsite for installation, or one or more cables can be installed within conduit prior to the conduit being shipped to a jobsite for installation. However manufactured, the resulting cable and conduit assembly is known as cable in conduit (“CIC”). CIC can be manufactured in many configurations. For instance, conduit size, color, and material as well as the number and type of cables and/or innerducts preinstalled in the conduit of CIC can be customized. Currently, if multiple runs of one or more conduits or CIC need to be installed at a jobsite, cither multiple reels or segmented reels are needed to hold and transport the multiple runs. However, loading multiple reels and segmented reels can be time consuming and expensive. In addition, segmented reels typically have drums with diameters that cause distortion to conduit loaded on the reels.

SUMMARY

The present disclosure is directed to systems and methods for layering multiple runs of conduit on a single reel. According to various embodiments of the concepts and technologies described herein, the reel includes a first conduit run comprising at least one conduit. The first conduit run can be wound onto the reel in a first layer. A first protective layer can be wound over at least a portion of the first conduit run. The reel can also include a second conduit run comprising at least one conduit. The second conduit run can be wound onto the reel in a second layer over the first conduit run and the first protective layer.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating a reel loaded with a conduit run, according to an illustrative embodiment.

FIG. 2 is a cross-section of a reel loaded with multiple conduit runs, according to an illustrative embodiment.

FIG. 3 is a diagram illustrating a cutaway view of a reel loaded with multiple conduit runs, according to an illustrative embodiment.

FIG. 4 is a flow diagram illustrating a method for layering multiple conduit runs onto a reel, according to an illustrative embodiment.

FIG. 5 is a diagram illustrating a terminating end of a conduit of a conduit run, according to an illustrative embodiment.

FIG. 6 is a diagram illustrating preparation of a terminating end of a conduit of a conduit run, according to an illustrative embodiment.

DETAILED DESCRIPTION

The following detailed description is directed to systems and methods for layering multiple runs of conduit on a single reel. Utilizing embodiments provided herein, more than one run consisting of one or more conduits may be wound onto a single reel in layers, stacked one on top of the other, for delivery to a jobsite. Each run on the reel may then be payed-out separately for multiple, independent conduit installations. The conduits making up the conduit runs may be empty or may have one or more cables and/or innerducts installed therein prior to shipment to a jobsite. This description provides various components, one or more of which may be included in particular implementations of the systems and methods disclosed herein. In illustrating and describing these various components, however, it is noted that implementations of the embodiments disclosed herein may include any combination of these components, including combinations other than those shown in this description.

FIG. 1 illustrates a reel 100 in accordance with an illustrative embodiment. The reel 100 includes a first conduit run 102 made up of a continuous length of a first conduit 104a and a continuous length of a second conduit 104b wound side-by-side, also referred to herein as “in parallel,” around a drum 106, shown in FIG. 2, of the reel 100. Although FIG. 1 illustrates two conduits, denoted as 104a and 104b, loaded in parallel making up the first conduit run 102, implementation of this description encompasses conduit runs made up of any number of conduits loaded in parallel on a single reel. In a further embodiment, multiple conduit runs, each comprising one or more conduits, may be wound onto the reel 100 in layers, stacked one on top of the other, as will be described further below.

According to embodiments, the first conduit 104a and/or the second conduit 104b of the first conduit run 102 may be CIC in which one or more cables, such as cables 502 and/or 504 illustrated in FIG. 5, and/or innerducts are installed within the first and/or second conduits 104a, 104b prior to being loaded on the reel 100 and shipped to a jobsite for installation. The conduit of a CIC can be any type of conduit including, but not limited to, HDPE conduit, electrical polyethylene conduit (“EPEC”), plastic pipe, polyethylene (“PE”) conduit, thermoplastic pipe, or the like. The conduits of the first and second conduits 104a, 104b may have the same or different diameters, as illustrated in FIG. 1, have the same or different wall thicknesses, be made from the same or different materials, be the same or different colors, and/or have the same or different striping or other markings. When the first and/or second conduits 104a, 104b are CIC, the one or more cables within the first conduit 104a may be any type or size and may be the same as or different from the one or more cables within the second conduit 104b. For example, the one or more cables may be copper and aluminum THHN, XHHW, and/or USE, medium voltage cable, copper and/or aluminum photovoltaic wire, airport lighting cable, communications cable, category cables, fiber-in-conduit, and/or the like that can be preinstalled in a conduit. Alternatively, the first conduit 104a and/or the second conduit 104b may be empty or contain preinstalled pull tape when loaded on the reel 100. In such embodiments, one or more cables and/or innerducts are pulled into the first conduit 104a and/or the second conduit 104b after installation at the jobsite. In this case, the first and second conduits 104a, 104b may have the same or different diameters, as illustrated in FIG. 1, have the same or different wall thicknesses, be made from the same or different materials, be the same or different colors, and/or have the same or different striping or other markings.

As described above with regard to FIG. 1, multiple conduit runs, each consisting of one or more conduits, may be wound onto a reel, such as the reel 100, in layers, stacked one on top of the other, for delivery to a jobsite. Each conduit run on the reel 100 may then be payed-off separately for multiple, independent conduit installations. FIG. 2 illustrates a cross-section of the reel 100 containing the first conduit run 102 introduced in FIG. 1 wound onto the drum 106 of the reel 100, a second conduit run 202 wound on top of the first conduit run 102, and a third conduit run 204 wound on top of the second conduit run 202. According to embodiments, the drum 106 of the reel 100 is at least 24 inches in diameter to prevent conduits of a conduit run from deforming when wrapped around the drum 106. As will be understood by one skilled in the art, a drum with a larger diameter may be needed based on the bend radius of the one or more conduits of a particular conduit run.

As discussed above, each of the conduit runs 102, 202-204 loaded onto the reel 100 can include one or more conduits with or without cable and/or innerducts preinstalled therein. For example, the first conduit run 102 can include the first conduit 104a having a diameter of 2 inches and the second conduit 104b having a diameter of 1 inch loaded in parallel, each approximately 150 feet in length; the second conduit run 202 can include a third conduit having a diameter of 1¼ inches and a fourth conduit having a diameter of ¾ inch loaded in parallel, each approximately 100 feet in length; and the third conduit run 204 can include a fifth conduit having a diameter of 3 inches and a length of approximately 100 feet. Upon delivery of the reel 100 to the jobsite, installers may pull the third conduit run 204 from the reel 100, then the second conduit run 202 from the reel 100, and finally the first conduit run 102 from the reel 100. Although only one jobsite is discussed, it should be understood by one skilled in the art that the reel 100 may be loaded with conduit runs for multiple jobsites.

According to embodiments, one or more conduit runs, such as the conduit runs 102, 202, and 204, loaded on the reel 100 can be covered by a protective layer, such as one of protective layers 206a-206c illustrated in FIGS. 2 and 3. For instance, one of the protective layers, such as the protective layer 206a, can cover the last conduit run loaded on the reel 100, such as the conduit run 204, to protect the conduit run 204 from the environment as well as help hold in place all of the conduit runs 102, 202, and 204 wound on the reel 100. The remaining protective layers, such as the protective layers 206b-206c, can help separate a conduit run from an adjacent conduit run and allow the conduit runs 202 and 204 to be paid off without interference from the conduit run below. The protective layers 206a-206c can include one or more sheets of material such as, for example, a shrink-wrap material, a plastic film, paper, fabric, and/or any other kind of flexible, thin material, that can serve as a barrier between adjacent conduit runs. One or more of the protective layers 206a-206c can be labeled with descriptive information associated with one or more of the conduit runs 102, 202, and 204 wound on the reel 100. For example, the protective layer 206a can include a label describing the first and second conduits 104a, 104b of the first conduit run 102, the payoff direction of the first conduit run 102, measurements associated with the reel 100 as loaded, the jobsite where the reel 100 is to be transported, and/or any other information related to the conduit runs 102, 202, and 204 loaded on the reel 100. A protective layer, such as any of the protective layers 206a-206c, can be wrapped around a conduit run such that the protective layer covers at least a portion of the conduit run. A protective layer, such as any of the protective layers 206a-206c, can be overlapped on itself while being wrapped around a corresponding conduit run such that the protective layer covers approximately all of the corresponding conduit run.

FIG. 4 illustrates a method 400 for layering multiple conduit runs onto a single reel, such as the reel 100. The method 400 will be described with reference to FIG. 4 and additional reference to FIGS. 1-3. It should be understood that the operations of the methods disclosed herein are not necessarily presented in any particular order and that performance of some or all of the operations in an alternative order(s) is possible and is contemplated. The operations have been presented in the demonstrated order for ease of description and illustration. Operations may be added, omitted, and/or performed simultaneously, without departing from the scope of the concepts and technologies disclosed herein.

The method 400 begins at operation 402, where a leading end of a first conduit of a conduit run, such as the first conduit 104a of the first conduit run 102, is fed through a counter 108 and a leading end of a second conduit of the conduit run, such as the second conduit 104b of the first conduit run 102, is fed through a roller 110, as illustrated in FIG. 1. The first and second conduits 104a, 104b may be stored on master reels 116a, 116b, respectively, loaded on one or more payoff systems positioned near a take-up system 112 on which the reel 100 is mounted for receiving one or more conduit runs. The payoff systems work in conjunction with the take-up system 112 to unspool the first and second conduits 104a, 104b from the master reels 116a, 116b loaded on the payoff systems and to spool the first and second conduits 104a, 104b onto the reel 100 loaded on the take-up system 112. The counter 108 and the roller 110 may be attached to the take-up system 112 on which the reel 100 is mounted for receiving one or more conduit runs. The counter 108 determines a length of the first conduit 104a being wound onto the reel 100. According to embodiments, the length of the first conduit 104a is used to determine when a requested length of the first conduit run 102 including the first conduit 104a and the second conduit 104b has been reached. Although the method 400 describes using the counter 108 to determine the length of a conduit run, such as the first conduit run 102, loaded onto the reel 100, the leading ends of the first and second conduits 104a, 104b may instead both be fed through one or more rollers, such as the roller 110, and another measuring technique, such as using a measuring tape, can be used to measure the length of the conduit run. Moreover, although the first conduit run 102 described with regards to the method 400 includes only two conduits, this is merely illustrative and not intended to be limiting in any way. The method 400 can be applied to conduit runs loaded on a reel, such as the reel 100, that have fewer or greater than two conduits.

From operation 402, the method 400 proceeds to operation 404, where the leading end of the first conduit 104a and the leading end of the second conduit 104b emerging from the counter 108 and the roller 110, respectively, are fed through a coupling device 114 and then attached to the reel 100 to begin winding the first conduit run 102 onto the reel 100. As illustrated in FIG. 1, the coupling device 114 may be a length of rope tied with a loop at one end through which the leading ends of the first and second conduits 104a, 104b are fed. The other end of the rope of the coupling device 114 may be attached to the take-up system 112. According to embodiments, the coupling device 114 urges the first conduit 104a and the second conduit 104b together so that the first and second conduits 104a, 104b are wound side-by-side, or in parallel, onto the reel 100. Although a coupling device 114 constructed of rope is illustrated, it should be understood by one skilled in the art that the coupling device 114 can be constructed of any material that causes two or more conduits to be held together such that the conduits are loaded in parallel onto the reel 100. According to embodiments, a rope can be attached to the leading ends of the first and second conduits 104a, 104b and tied off via a hole drilled through a flange of the reel 100 to attach the leading ends to the reel 100 to start the wind.

From operation 404, the method 400 proceeds to operation 406, where the first and second conduits 104a, 104b continue to be wound in parallel onto the reel 100 until a requested length of the first conduit run 102 is achieved. As the first and second conduits 104a, 104b are unwound from the master reels 116a, 116b on the payoff systems and wound onto the reel 100, the payoff systems can apply tension to the first and second conduits 104a, 104b to ensure that the first and second conduits 104a, 104b are unwound smoothly from the master reels 116a, 116b without tangling or snapping and are wound uniformly onto the reel 100. Since the first conduit 104a can have a different diameter than the second conduit 104b, the tension applied to the first conduit 104a by the payoff system holding the master reel 116a of the first conduit 104a may need to be different than the tension applied to the second conduit 104b by the payoff system holding the master reel 116b of the second conduit 104b in order to uniformly wind the first and second conduits 104a, 104b in parallel onto the reel 100. According to embodiments, the tensions asserted on the first and second conduits 104a, 104b by the payoff systems can be adjusted at the payoff systems according to the diameter of each of the first and second conduits 104a, 104b.

Once the requested length of the first conduit run 102 is reached, the method 400 proceeds from operation 406 to operation 408, where one or more of the first and second conduits 104a, 104b are cut in order to terminate the installation of the first conduit run 102 onto the reel 100. In preparation for cutting, the first and second conduits 104a, 104b can be secured together using, for example, one or more pieces of tape 300, such as duct or friction tape, wrapped around the first and second conduits 104a, 104b proximate to where the first and second conduits 104a, 104b are to be cut, as illustrated in FIG. 3. When the first and second conduits 104a, 104b are empty (i.e., do not have cable and/or innerducts preinstalled), a length of rope, pull tape, or similar 302 may be tied around the first and second conduits 104a, 104b proximate to the tape 300 and stapled to a flange of the reel 100 and/or tied off through a hole, such as the hole 304, in a flange of the reel 100 in order to secure the first conduit run 102 on the reel 100 at a first location. The first and second conduits 104a, 104b can then be cut to create terminating ends. The terminating ends of the first and second conduits 104a, 104b can be covered by a cap, duct or friction tape, or other covering in order to keep debris and moisture from entering the first and second conduits 104a, 104b.

If, on the other hand, at least one of the first or second conduits 104a, 104b is CIC (i.e., includes preinstalled cable(s), such as one or more of the cables 502, 504 illustrated in FIG. 5, and/or innerduct(s)), the first and second conduits 104a, 104b can be secured to the reel 100 twice in preparation for being cut after being wound onto the reel 100. For example, in addition to the rope 302 discussed above, a length of rope, pull tape, or similar may be tied around the first and second conduits 104a, 104b at least 5 feet from where the first and second conduits 104a, 104b are to be cut. This rope, pull tape, or similar can then be attached to a flange of the reel 100 by staples or by being tied off through a hole in the flange at a second location to keep the first and second conduits 104a, 104b from unwinding after the rope 302 is cut and while, for example, pulling heads are installed on one or more cables, such as the cables 502 and/or 504, of the first and/or second conduits 104a, 104b at the jobsite. Conduit(s) of the first and/or second conduits 104a, 104b can then be cut to create terminating ends and to expose the one or more cables 502, 504 and/or innerducts within the first and/or second conduits 104a, 104b. The one or more cables 502, 504 and/or innerducts can then be cut to create terminating ends, which are folded over the terminating ends of the conduit(s) of the first and/or second conduits 104a, 104b, as illustrated in FIG. 5. The terminating ends of the conduit(s) of the first and/or second conduits 104a, 104b with the one or more cables 502, 504 and/or innerducts folded over can then be wrapped with tape, such as duct or friction tape, and covered by a cap 600 or other covering in order to keep debris and moisture from entering the first and/or second conduits 104a, 104b, as illustrated in FIG. 6.

From operation 408, the method 400 proceeds to operation 410, where the first conduit run 102 is wrapped with a protective layer, such as the protective layer 206c. This may be accomplished by winding one or more sheets of material onto the reel 100 to form the protective layer 206c around the first conduit run 102 loaded on the reel 100, as shown in FIGS. 2 and 3. The protective layer 206c may serve to separate the first conduit run 102 from a conduit run, such as the second conduit run 202, wound on top of the first conduit run 102, allowing the second conduit run 202 to be paid out without interference from the first conduit run 102. A protective layer, such as any of the protective layer 206a-206c, can be wrapped around a conduit run such that the protective layer covers at least a portion of the conduit run. The one or more sheets of material of any of the protective layers 206a-206c can be overlapped on itself while being wrapped around a corresponding conduit run such that the protective layer covers at least a portion of the corresponding conduit run.

From operation 410, the method 400 proceeds to operation 412, where a determination is made whether more conduit runs are to be loaded onto the reel 100. If at least one more conduit run is to be loaded onto the reel 100, the method 400 proceeds from operation 412 back to operation 402, where the leading ends of conduits of another conduit run, such as the second conduit run 202, can be fed through the counter 108 and the roller 110, respectively, to begin loading the second conduit run 202 onto the reel 100 on top of the first conduit run 102 covered with the protective layer 206c. It will be appreciated that any number of conduit runs may be wound onto the reel 100 in the manner set forth by the method 400, provided that the entire quantity and weight of the combined conduit runs do not exceed the relevant capacity of the reel 100. Returning to operation 412, if no further conduit runs are to be loaded on the reel 100, the method 400 proceeds to operation 414, where the method 400 ends.

The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the present invention, which is encompassed in the following claims.