Cable Drum Assembly Without Arc Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable drum designs fail to facilitate simple assembly and fixation of components made from various materials without the need for arc welding, which can damage the external plastic sheath of cables and result in short operating life and environmental concerns due to frequent production of wooden drums.
Innovation Solution
A cable drum design featuring side walls with radial grooves and bushings, where connecting lugs on a cylindrical core element are fixed into the grooves, and a spacer tube is secured within the bushings, allowing for shape-locking assembly without arc welding, using materials like metal, plastic, or paper, and enabling easy assembly and fixation of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If arc welding is used to fix metal components of the cable drum, then the structural strength is improved, but the external plastic sheath of cables can be damaged by welds on the surface
Solution Approach 1:
The cable drum is divided into separate components (side walls, core element, connecting rings, connecting lugs) that can be assembled without welding. The segmentation allows each component to be manufactured separately and joined through mechanical interlocking, eliminating the need for arc welding that would damage the plastic sheath.
Solution Approach 2:
Connecting lugs serve as intermediary elements between the core element and side walls. These lugs are fixed into grooves of the side walls, providing a welding-free mechanical connection that maintains structural integrity while protecting the plastic sheath from welding damage.
2Object-affected harmful factors
If wooden cable drums are used to avoid weld damage, then the external plastic sheath is protected, but the operating life is short and environmental impact increases
Solution Approach 1:
The cable drum combines metal components (side walls, core element, connecting rings) with plastic/bushings to create a composite structure. This allows the use of durable metal materials while avoiding welding through mechanical assembly, thereby extending operating life and reducing environmental impact compared to wooden drums.
3Strength
If traditional cable drum designs are used, then structural integrity is maintained, but assembly and fixation of components from various materials is complex
Solution Approach 1:
The cable drum is segmented into standardized components (side walls with grooves, core element with connecting lugs, connecting rings, bushings) that can be easily assembled. The grooves and lugs are designed to fit together in a simple snap-fit manner, greatly simplifying assembly while maintaining structural integrity.
Solution Approach 2:
The connecting lugs are designed to be self-fixing into the grooves of the side walls through a snap-fit mechanism. The bushings in the grooves guide and secure the lugs during assembly, enabling workers to assemble the cable drum without specialized welding equipment or complex fixation procedures.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The subject of the invention is a cable drum established from one or more materials without arc welding, which solution allows the simple and easy assembling and fixing of components of the cable drum made from various materials, and it is possible to omit the use of seams of arc welding at the connections of the metal parts of the cable drum. Cable drum created from one or more materials without arc welding, which consists of side walls that contain bushings, winding space bordered by core element, and a spacer tube located within the core element. It is characterised by that, the cable drum (1) has two rims (8) having diameter "d" with radially aligned grooves (7) having width V, which are formed in a torus shape or out of a torus shape along its external perimeter, and it has a bushing (4) containing the grooves (7) in a shape locking manner having height H along the perimeter with diameter Dl, where the connecting lugs (10) of the radially aligned connecting rings (9) that are attached to the internal surface of both ends of the cylindrical core element (3) in the side walls (2) having ring shape with diameter D, are fixed with their upper parts having height "m" into the nests (24) having height H2 at this point of the grooves (7), where H2 > m, and in this way the side walls (2) and the core element (3) create the winding space (6), while the cylindrical spacer tube is fixed in a shape locking manner to the internal surfaces of bushings (4) of the side walls (2).