Cable Reel Hub With Flexible Segments and Braking Mechanism
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Solution Overview
Problem
Cable installers face challenges with existing solutions as they often payout too much cable when carrying it to installation locations, leading to a need for a more efficient and controlled method to manage and install cable coils.
Innovation Solution
A cable reel design featuring first and second opposing flanges with hub portions, where the first hub portion has an elongated wall with flexible segments and the second hub portion has a truncated wall for engagement, along with a braking mechanism to prevent overpayout, allowing for secure and controlled cable payoff.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cable is wound on a reel and packaged in a box or bag for payout during installations, then cable can be transported and paid out during installation, but the installer may payout too much cable if the installer pulls too hard on the cable
Solution Approach 1:
The braking mechanism is pre-configured on the reel to automatically apply resistance when cable payout force exceeds a predetermined threshold. This preliminary anti-action prevents overpayout before it occurs by counteracting excessive pull forces during cable deployment
Solution Approach 2:
The braking mechanism provides real-time feedback control during cable payout by sensing the force applied to the cable and automatically adjusting the brake engagement to maintain controlled payout. This feedback system prevents overpayout by continuously monitoring and regulating cable tension
2Ease of manufacture
If the first hub portion includes an elongated wall with flexible segments and the second hub portion includes a truncated wall for engagement, then the cable reel allows for easy installation of cable, but the structure becomes more complex
Solution Approach 1:
The hub portion is segmented into multiple flexible segments within the elongated wall structure. These segments can independently deflect and engage with the cable, allowing easy cable installation while distributing the structural complexity across multiple simple, identical elements rather than a single complex component
Solution Approach 2:
The elongated wall incorporates flexible segments that act as thin, deflectable structures. These flexible elements provide the necessary compliance for easy cable installation while maintaining structural integrity, replacing what would otherwise require complex rigid mechanisms
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 design enables easy installation and controlled payout of cable coils, preventing overpayout and ensuring efficient cable management during installations by using flexible segments and a braking mechanism to manage cable tension.
Implementation Method 1
The truncated wall includes a tapered outer surface for engaging and expanding the plurality of flexible segments
Implementation Method 2
The engagement of the gear members provides a friction for cable payoff
Data Source
AI summary
A cable reel apparatus that has a cable reel for holding a coil of cable and includes a central longitudinal axis. A first flange is configured to be rotatably coupled to a first frame and has opposite inner and outer sides. A second flange that is separate from the first flange is configured to be rotatably coupled to a second frame and has opposite inner and outer sides. One of the first and second flanges includes a hub portion that extends transversely from the inner side thereof. The first and second flanges are configured to be releasably coupled to one another for supporting a coil of cable on the hub portion between the first and second flanges along the central longitudinal axis of the cable reel and are configured to be decoupled from one another when replacing the coil of cable once dispensed from the cable reel apparatus.