Bulk Wire Distribution Cart with Interlocking Spools
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Solution Overview
Problem
Current methods for transporting and managing heavy electrical wires on job sites are inefficient, as they often result in damage to wooden spools and uneven uncoiling rates between conductor and ground wires, requiring multiple handling and re-spooling, and are difficult to maneuver in confined spaces.
Innovation Solution
A bulk wire distribution cart with inter-locking spools and a releasable ground conductor spool, featuring a rectangular frame with roller bearings, high-pressure wheels, a locking mechanism, and independent rotation of the ground spool, allowing secure locking and easy movement, and equipped with a handle and drive motor for efficient wire management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire spools are transported individually on wooden spools using forklift, then the wire can be delivered to the job site, but the spools are prone to damage and require multiple handling operations
Solution Approach 1:
The patent combines multiple wire spools onto a single distribution cart with a central spool shaft, eliminating the need for separate forklift handling of each spool. The cart integrates conductor spools and ground wire spool into one unified transport unit that can be moved as a single entity, reducing handling operations and preventing spool damage.
Solution Approach 2:
The distribution cart is designed with modular components including removable spools, interchangeable wheels, and separable frame sections. This segmentation allows easy maintenance and replacement of individual components without affecting the entire system, thereby maintaining spool integrity while simplifying operations.
2Productivity
If gang spools are used to transport bulk wire, then transportation efficiency is improved, but the ground conductor wire piles up on the ground due to uneven uncoiling rates
Solution Approach 1:
The ground wire spool is designed with independent rotation capability relative to the conductor spools. This dynamic feature allows the ground wire spool to rotate at a different speed than the conductor spools, preventing wire pile-up. The independent rotation mechanism adjusts automatically to maintain proper wire feed rates during uncoiling operations.
Solution Approach 2:
The spool system is segmented into independently rotating conductor spools and ground wire spool, each capable of rotating at different rates. This segmentation allows the ground wire spool to operate independently from the conductor spools, solving the uneven uncoiling problem while maintaining transportation efficiency.
3Quantity of substance
If a large trailer is used to transport bulk wire, then the wire can be delivered to the job site, but the trailer is difficult to maneuver in confined spaces
Solution Approach 1:
The patent divides the wire transport system into a compact distribution cart that can be easily maneuvered in confined spaces. The cart is designed to hold multiple spools in a space-efficient configuration, segmenting the transport function from the bulky trailer while maintaining adequate wire capacity through optimized spool arrangement and frame design.
Solution Approach 2:
The distribution cart utilizes vertical space efficiently with spools arranged in a multi-level configuration on the central shaft. This dimensional optimization allows the cart to accommodate substantial wire quantities in a compact footprint, enabling easy maneuverability in confined job site spaces while maintaining adequate wire capacity.
4Ease of operation
If the cart is designed to be easily moved by hand, then maneuverability is improved, but the locking mechanism may not securely hold the cart in place
Solution Approach 1:
The cart features a dynamic locking system with cam-actuated locking skids that can be quickly deployed or retracted. The locking mechanism transitions from a movable state during transport to a securely locked state during wire distribution operations. The cam-over mechanism provides rapid, reliable locking that maintains cart stability while preserving ease of mobility when unlocked.
Solution Approach 2:
The locking skids act as an intermediary between the cart frame and the ground surface. When deployed, these skids provide secure anchoring points that prevent cart movement during wire distribution. The skids can be quickly raised or lowered to transition between mobile and stationary states, maintaining both ease of operation and locking stability.
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
Enables efficient transportation and secure locking of wire spools, preventing damage and ensuring equal uncoiling rates of conductor and ground wires, facilitating easy handling and installation by a single user, even in tight spaces.
Implementation Method 1
supports a central spool shaft or axle on a plurality of roller bearings
Implementation Method 2
a pair of high ground pressure wheels aligned parallel with the long side rails of the frame
Implementation Method 3
A single front caster wheel is attached to the front portion of the frame
Data Source
AI summary
The present invention is a bulk wire distribution cart configured to dispense bulk conductor wires and a single ground wire efficiently, safely and without slack or wire damage, directly from the cart to the electrical conduit.