Systems and Methods for Layering Multiple Conduit Runs Onto a Reel

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.

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.

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.

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.

illustrates a reelin accordance with an illustrative embodiment. The reelincludes a first conduit runmade up of a continuous length of a first conduitand a continuous length of a second conduitwound side-by-side, also referred to herein as “in parallel,” around a drum, shown in, of the reel. Althoughillustrates two conduits, denoted asandloaded in parallel making up the first conduit run, 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 reelin layers, stacked one on top of the other, as will be described further below.

According to embodiments, the first conduitand/or the second conduitof the first conduit runmay be CIC in which one or more cables, such as cablesand/orillustrated in, and/or innerducts are installed within the first and/or second conduitsprior to being loaded on the reeland 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 conduitsmay have the same or different diameters, as illustrated in, 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 conduitsare CIC, the one or more cables within the first conduitmay be any type or size and may be the same as or different from the one or more cables within the second conduitFor 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 conduitand/or the second conduitmay be empty or contain preinstalled pull tape when loaded on the reel. In such embodiments, one or more cables and/or innerducts are pulled into the first conduitand/or the second conduitafter installation at the jobsite. In this case, the first and second conduitsmay have the same or different diameters, as illustrated in, 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, multiple conduit runs, each consisting of one or more conduits, may be wound onto a reel, such as the reel, in layers, stacked one on top of the other, for delivery to a jobsite. Each conduit run on the reelmay then be payed-off separately for multiple, independent conduit installations.illustrates a cross-section of the reelcontaining the first conduit runintroduced inwound onto the drumof the reel, a second conduit runwound on top of the first conduit run, and a third conduit runwound on top of the second conduit run. According to embodiments, the drumof the reelis at least 24 inches in diameter to prevent conduits of a conduit run from deforming when wrapped around the drum. 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,-loaded onto the reelcan include one or more conduits with or without cable and/or innerducts preinstalled therein. For example, the first conduit runcan include the first conduithaving a diameter of 2 inches and the second conduithaving a diameter of 1 inch loaded in parallel, each approximately 150 feet in length; the second conduit runcan 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 runcan include a fifth conduit having a diameter of 3 inches and a length of approximately 100 feet. Upon delivery of the reelto the jobsite, installers may pull the third conduit runfrom the reel, then the second conduit runfrom the reel, and finally the first conduit runfrom the reel. Although only one jobsite is discussed, it should be understood by one skilled in the art that the reelmay be loaded with conduit runs for multiple jobsites.

According to embodiments, one or more conduit runs, such as the conduit runs,, and, loaded on the reelcan be covered by a protective layer, such as one of protective layers-illustrated in. For instance, one of the protective layers, such as the protective layercan cover the last conduit run loaded on the reel, such as the conduit run, to protect the conduit runfrom the environment as well as help hold in place all of the conduit runs,, andwound on the reel. The remaining protective layers, such as the protective layers-can help separate a conduit run from an adjacent conduit run and allow the conduit runsandto be paid off without interference from the conduit run below. The protective layers-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-can be labeled with descriptive information associated with one or more of the conduit runs,, andwound on the reel. For example, the protective layercan include a label describing the first and second conduitsof the first conduit run, the payoff direction of the first conduit run, measurements associated with the reelas loaded, the jobsite where the reelis to be transported, and/or any other information related to the conduit runs,, andloaded on the reel. A protective layer, such as any of the protective layers-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-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.

illustrates a methodfor layering multiple conduit runs onto a single reel, such as the reel. The methodwill be described with reference toand additional reference to. 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 methodbegins at operation, where a leading end of a first conduit of a conduit run, such as the first conduitof the first conduit run, is fed through a counterand a leading end of a second conduit of the conduit run, such as the second conduitof the first conduit run, is fed through a roller, as illustrated in. The first and second conduitsmay be stored on master reelsrespectively, loaded on one or more payoff systems positioned near a take-up systemon which the reelis mounted for receiving one or more conduit runs. The payoff systems work in conjunction with the take-up systemto unspool the first and second conduitsfrom the master reelsloaded on the payoff systems and to spool the first and second conduitsonto the reelloaded on the take-up system. The counterand the rollermay be attached to the take-up systemon which the reelis mounted for receiving one or more conduit runs. The counterdetermines a length of the first conduitbeing wound onto the reel. According to embodiments, the length of the first conduitis used to determine when a requested length of the first conduit runincluding the first conduitand the second conduithas been reached. Although the methoddescribes using the counterto determine the length of a conduit run, such as the first conduit run, loaded onto the reel, the leading ends of the first and second conduitsmay instead both be fed through one or more rollers, such as the roller, 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 rundescribed with regards to the methodincludes only two conduits, this is merely illustrative and not intended to be limiting in any way. The methodcan be applied to conduit runs loaded on a reel, such as the reel, that have fewer or greater than two conduits.

From operation, the methodproceeds to operation, where the leading end of the first conduitand the leading end of the second conduitemerging from the counterand the roller, respectively, are fed through a coupling deviceand then attached to the reelto begin winding the first conduit runonto the reel. As illustrated in, the coupling devicemay be a length of rope tied with a loop at one end through which the leading ends of the first and second conduitsare fed. The other end of the rope of the coupling devicemay be attached to the take-up system. According to embodiments, the coupling deviceurges the first conduitand the second conduittogether so that the first and second conduitsare wound side-by-side, or in parallel, onto the reel. Although a coupling deviceconstructed of rope is illustrated, it should be understood by one skilled in the art that the coupling devicecan 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. According to embodiments, a rope can be attached to the leading ends of the first and second conduitsand tied off via a hole drilled through a flange of the reelto attach the leading ends to the reelto start the wind.

From operation, the methodproceeds to operation, where the first and second conduitscontinue to be wound in parallel onto the reeluntil a requested length of the first conduit runis achieved. As the first and second conduitsare unwound from the master reelson the payoff systems and wound onto the reel, the payoff systems can apply tension to the first and second conduitsto ensure that the first and second conduitsare unwound smoothly from the master reels,without tangling or snapping and are wound uniformly onto the reel. Since the first conduitcan have a different diameter than the second conduitthe tension applied to the first conduitby the payoff system holding the master reelof the first conduitmay need to be different than the tension applied to the second conduitby the payoff system holding the master reelof the second conduitin order to uniformly wind the first and second conduitsin parallel onto the reel. According to embodiments, the tensions asserted on the first and second conduitsby the payoff systems can be adjusted at the payoff systems according to the diameter of each of the first and second conduits

Once the requested length of the first conduit runis reached, the methodproceeds from operationto operation, where one or more of the first and second conduitsare cut in order to terminate the installation of the first conduit runonto the reel. In preparation for cutting, the first and second conduitscan be secured together using, for example, one or more pieces of tape, such as duct or friction tape, wrapped around the first and second conduitsproximate to where the first and second conduitsare to be cut, as illustrated in. When the first and second conduitsare empty (i.e., do not have cable and/or innerducts preinstalled), a length of rope, pull tape, or similarmay be tied around the first and second conduitsproximate to the tapeand stapled to a flange of the reeland/or tied off through a hole, such as the hole, in a flange of the reelin order to secure the first conduit runon the reelat a first location. The first and second conduitscan then be cut to create terminating ends. The terminating ends of the first and second conduitscan 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

If, on the other hand, at least one of the first or second conduitsis CIC (i.e., includes preinstalled cable(s), such as one or more of the cables,illustrated in, and/or innerduct(s)), the first and second conduitscan be secured to the reeltwice in preparation for being cut after being wound onto the reel. For example, in addition to the ropediscussed above, a length of rope, pull tape, or similar may be tied around the first and second conduitsat least 5 feet from where the first and second conduitsare to be cut. This rope, pull tape, or similar can then be attached to a flange of the reelby staples or by being tied off through a hole in the flange at a second location to keep the first and second conduitsfrom unwinding after the ropeis cut and while, for example, pulling heads are installed on one or more cables, such as the cablesand/or, of the first and/or second conduitsat the jobsite. Conduit(s) of the first and/or second conduitscan then be cut to create terminating ends and to expose the one or more cables,and/or innerducts within the first and/or second conduitsThe one or more cables,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 conduitsas illustrated in. The terminating ends of the conduit(s) of the first and/or second conduitswith the one or more cables,and/or innerducts folded over can then be wrapped with tape, such as duct or friction tape, and covered by a capor other covering in order to keep debris and moisture from entering the first and/or second conduitsas illustrated in.

From operation, the methodproceeds to operation, where the first conduit runis wrapped with a protective layer, such as the protective layerThis may be accomplished by winding one or more sheets of material onto the reelto form the protective layeraround the first conduit runloaded on the reel, as shown in. The protective layermay serve to separate the first conduit runfrom a conduit run, such as the second conduit run, wound on top of the first conduit run, allowing the second conduit runto be paid out without interference from the first conduit run. A protective layer, such as any of the protective layer-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-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, the methodproceeds to operation, where a determination is made whether more conduit runs are to be loaded onto the reel. If at least one more conduit run is to be loaded onto the reel, the methodproceeds from operationback to operation, where the leading ends of conduits of another conduit run, such as the second conduit run, can be fed through the counterand the roller, respectively, to begin loading the second conduit runonto the reelon top of the first conduit runcovered with the protective layerIt will be appreciated that any number of conduit runs may be wound onto the reelin the manner set forth by the method, provided that the entire quantity and weight of the combined conduit runs do not exceed the relevant capacity of the reel. Returning to operation, if no further conduit runs are to be loaded on the reel, the methodproceeds to operation, where the methodends.

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.