Cable Reel Compensation Loop Structure to Prevent Fixed-End Twisting
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Solution Overview
Problem
Devices for winding and unwinding elongated flexible elements, such as electrical cables and hoses, face issues with twisting at the spatially fixed end, leading to potential damage and leakage, especially in large diameter cables used for electric vehicle charging, where existing coupling systems are elaborate and prone to failure.
Innovation Solution
A device that divides the elongated flexible element into a use portion and a compensation portion, with the compensation portion being fixed to a rotatable drum, allowing the use portion to be wound and unwound in a first plane while the compensation portion is coiled and uncoiled in a parallel second plane, effectively converting twisting into looped portions to minimize torque on the fixed end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connection coupling that permits twisting is used to prevent twisting damage, then the connection reliability is improved, but the device complexity increases and the coupling becomes susceptible to damage
Solution Approach 1:
The elongated flexible element is segmented into two functional portions: a use portion that is wound on the drum and a compensation portion that remains coiled. This segmentation allows each portion to serve its specific function - the use portion for active winding/unwinding operations and the compensation portion for absorbing twisting forces, thereby eliminating the need for complex coupling systems while maintaining connection reliability.
Solution Approach 2:
The compensation portion acts as an intermediary element between the fixed end and the use portion. It absorbs and compensates for twisting forces generated during drum rotation, preventing these forces from being transmitted to the fixed end connection. This intermediary approach protects the connection without requiring elaborate coupling mechanisms.
2Volume of moving object
If the elongated flexible element is wound on a rotatable drum, then the space-saving winding function is achieved, but twisting occurs at the fixed end leading to potential damage
Solution Approach 1:
By dividing the flexible element into use portion and compensation portion, the patent enables the use portion to be efficiently wound on the drum for space-saving storage while the compensation portion remains coiled to absorb twisting stresses, thus achieving both compact winding and protection against twisting damage.
Solution Approach 2:
The patent converts the potentially harmful twisting forces generated during drum rotation into a beneficial function. The compensation portion is deliberately designed to coil and uncoil in response to drum rotation, transforming the harmful twisting effect into a useful mechanism for absorbing stress and protecting the fixed end connection.
3Power
If large diameter cables are used for rapid charging, then the charging power is improved, but the stiffness increases and twisting generates high torque on the connection
Solution Approach 1:
The patent segments the large diameter cable into use portion and compensation portion, allowing the use portion to deliver high power for rapid charging while the compensation portion absorbs the high twisting torques generated by the stiff cable during drum rotation, protecting the connection from damage.
Solution Approach 2:
The compensation portion serves as an intermediary that absorbs and dissipates the high twisting forces generated by stiff, large-diameter cables. This protects the fixed end connection from the full impact of these forces while allowing the use portion to maintain its high power transmission capability for rapid charging applications.
Data Source
AI summary
A device for winding up and unwinding an elongated flexible element having a free end and a spatially fixed end. The elongated flexible element is divided over its length at least into a use portion and a compensation portion, wherein the use portion has the free end and the compensation portion has the spatially fixed end. The device includes a rotatable drum configured on its circumference to wind up and unwind at least the use portion in a first winding plane, wherein the end of the compensation portion is spatially fixed relative to the drum. The elongated flexible element in the transition from the use portion to the compensation portion is fixed at a fastening point to the drum, and when the drum is rotated the compensation portion is coiled up and uncoiled in the form of at least one looped portion in a second winding plane.