Cable Coiling Machine Using Offset Rollers to Prevent Tangling
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Solution Overview
Problem
Existing coiling methods for heavy-duty electrical cables, such as reel-to-reel spooling, lead to tangling and damage due to opposing the natural twist of the cables, making them labor-intensive and time-consuming to unwind and store.
Innovation Solution
A cable coiling device using offset rollers with a controlled angular offset and pressure system to mimic the over-under coiling method, allowing the cable to twist according to its natural state, eliminating tangling and facilitating easy unwinding and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reel-to-reel spooling is used to coil heavy-duty cables, then the coiling process is simple and straightforward, but the cable becomes tangled and twisted when unwound, requiring time-consuming and labor-intensive uncoiling
Solution Approach 1:
The patent applies the inversion principle by reversing the traditional coiling direction. Instead of always coiling in the same direction (straight coiling), the system alternates between coiling and uncoiling directions. The cable is coiled in one direction for the first loop, then uncoiled for the second loop, creating an over-under pattern that prevents cumulative twisting and enables easy uncoiling without tangles.
2Productivity
If straight coiling is used to coil cables, then the coiling process is efficient and quick, but the cable is twisted and damaged due to opposing the natural twist
Solution Approach 1:
The system reverses the coiling direction alternately to match the cable's natural twist characteristics. By switching between coiling and uncoiling directions, the cable experiences alternating torsional stresses that prevent cumulative twisting damage, maintaining cable integrity while preserving coiling efficiency.
Solution Approach 2:
The patent implements periodic action by alternating the coiling direction in regular intervals. The cable is coiled in one direction, then uncoiled in the opposite direction, creating a periodic pattern of over-and-under loops. This periodic reversal prevents continuous twisting in one direction, eliminating stress accumulation and preserving cable reliability.
3Ease of operation
If over-under coiling is performed by hand, then the cable is coiled correctly without tangles, but the process is very time consuming and labor intensive for heavy-duty cables
Solution Approach 1:
The system applies self-service by using the cable's own weight and tension to assist in the coiling process. As the cable is fed through the alternating coiling/uncoiling mechanism, its natural tension and flexibility work with the system to create neat loops without requiring manual manipulation, thereby maintaining high coiling quality while improving efficiency for heavy-duty cables.
Solution Approach 2:
The patent replaces manual mechanical manipulation with an automated mechanical system. Instead of hand-coiling heavy-duty cables, an automated device with rollers, guides, and tension control mechanisms performs the alternating coiling/uncoiling action, eliminating labor intensity while preserving the quality benefits of over-under coiling.
4Ease of manufacture
If cable is coiled in the same direction repeatedly, then the coiling process is consistent and simple, but the cable does not lie flat and cannot be stored compactly
Solution Approach 1:
The system reverses the coiling direction alternately, creating over-under loops that allow the cable to lie flat. This directional inversion causes successive loops to nest within each other rather than stacking in parallel, dramatically reducing the volume required for storage and enabling compact bundling while maintaining consistent coiling quality.
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 device significantly reduces coiling time, minimizes cable damage, and enables efficient storage by creating knot-free, loop-free bundles that can be easily unwound, saving time and human effort in handling heavy-duty cables.
Implementation Method 1
The first roller and the second roller are spaced from each other, forming an opening. This opening permits a cable to pass between the first and second roller. As the cable passes through the opening, an angular offset between the rollers causes the cable between the rollers to twist as the cable passes between the two rollers against the circumferential surfaces of the rollers.
Data Source
AI summary
The cable coiling device automatically coils heavy-duty electrical cable into a coiled bundle having a predetermined coil diameter. This device matches the over/under coiling method used to manually coil cables that eliminate unnecessary twists and knots in cables. The cable coiling device has a first roller and a second roller that is angularly offset from the first roller. The angular offset adds a twist to the cable as it passes between the rollers. The device maintains the first and second rollers at a predetermined distance away from each other so that the cable does not slip out of the opening between the rollers. When the coil exits the rollers, the resulting cable is coil bundled and has a specific predetermined coil bundle diameter. Guide wheels positioned at specific locations guide the cable through the device, which prevents cable looping before and after the cable passes through the rollers.