Cable Pay-off Assembly with A-Frame Bracing and Reel Locking
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Solution Overview
Problem
The handling and installation of large cable reels with heavy gauge conductors are challenging due to their size and weight, leading to potential damage and safety issues during transportation and cable pull operations.
Innovation Solution
An improved pay-off assembly that includes lateral support braces to prevent the A-frame structure from collapsing, a reel lock assembly for secure transport and pay-off, an end cap assembly with a hand-wheel for secure attachment, a dog hole arm to prevent cable reel rotation, and a braking system to maintain cable tension during pay-off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional reel stand is used to support large cable reels, then the cable reel can be rotated for conductor payment, but the reel stand may become disengaged due to high pulling forces, causing damage or injury
Solution Approach 1:
The reel stand is divided into separate functional components: an A-frame support structure, a base with forklift pockets, and a reel locking mechanism. This segmentation allows each component to be optimized independently - the A-frame provides structural support, the base enables transport, and the locking mechanism ensures reel security during high-force operations.
Solution Approach 2:
The reel is secured to the A-frame using a locking mechanism that engages before cable payment begins. The forklift pockets are pre-positioned on the base to receive forklift tines, ensuring the reel is properly secured and positioned before any high-force cable pulling occurs, preventing disengagement during operation.
2Length of moving object
If cable reels are made large to accommodate long conductors, then the conductors can be pulled over long distances, but the reels become very heavy and difficult to handle and transport
Solution Approach 1:
The base acts as an intermediary between the heavy cable reel and the forklift truck. The forklift pockets on the base provide a standardized interface that allows forklifts to easily lift and transport the reel, distributing the weight handling task to the forklift's lifting mechanism rather than requiring manual handling or custom lifting solutions.
Solution Approach 2:
The base with forklift pockets serves multiple functions: it provides a stable foundation for the A-frame structure, enables easy transport by forklift, and offers a platform for the reel locking mechanism. This multi-functionality reduces the need for separate handling equipment despite the reel's large size and weight.
3Weight of moving object
If the A-frame structure is made lightweight for easy transport, then the reel can be moved more easily, but the frame may collapse under the weight of the cable reel and cable
Solution Approach 1:
The A-frame is constructed from high-strength steel materials that provide the necessary structural strength to support heavy cable reels and cables while maintaining a relatively compact and manageable size. The material selection optimizes the strength-to-weight ratio, ensuring the frame can handle full load capacities without excessive weight.
Solution Approach 2:
The reel locking mechanism engages the reel to the A-frame before cable payment begins, distributing the load through proper contact points. This preliminary securing ensures the A-frame structure experiences balanced, predictable forces during operation, preventing structural failure even with lightweight construction.
4Ease of operation
If the reel lock assembly is made simple for easy operation, then it can be opened and closed quickly, but it may not securely hold the arbor assembly under load
Solution Approach 1:
The reel locking system is segmented into multiple independent locking points that engage with the arbor assembly at different locations. This segmentation allows each locking point to be simple in design while collectively providing secure retention of the arbor assembly under high cable pulling forces.
Data Source
AI summary
An improved pay-off assembly allowing cable loaded on a cable reel to be transported to an installation site and/or paid-off during a cable pull is described. The pay-off assembly may include one or more of lateral support braces that provide stability and strength to an A-frame structure supporting the cable reel; a reel lock assembly for securely holding the cable reel in place during transport and/or pay-off of the cable; an end cap assembly that prevents detachment from an arbor as the arbor and cable reel rotate during pay-off; a dog hole stop assembly that engages a “dog hole” in the cable reel to prevent the cable reel from rotating during transport; a braking system for controlling the rotational speed of the cable reel during pay-off; and a ground attachment assembly that allows an additional cable reel to be loaded for transport and/or pay-off of the cable.