Cable Reel Spacer for Stable Forklift Stacking
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Solution Overview
Problem
Existing cable reels face challenges in being properly supported during storage and transportation, particularly when stacked, as the forks of a fork lift struggle to position correctly under the flanges, leading to potential tipping and falling due to lateral loadings and uneven weight distribution.
Innovation Solution
The introduction of a spacer that extends axially from one flange to support the cable reel when upright or stacked, allowing the forks to be positioned correctly and providing stability against tipping, with alignment features on the flanges to facilitate secure stacking and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cable reel is stacked upright on top of another cable reel, then storage space is optimized, but the reel becomes unstable and may tip or fall due to lateral loadings
Solution Approach 1:
The spacer is integrated into the flange structure, with the alignment feature formed as part of the spacer assembly. This nested configuration allows the alignment mechanism to be contained within the existing flange geometry, providing stabilization functionality without adding external protruding elements that would increase the reel's external dimensions or interfere with stacking arrangements.
Solution Approach 2:
The spacer acts as an intermediary element between the flange and the support surface (or lower reel). It provides a stable contact point that distributes lateral loads and prevents the reel from tipping, while the alignment feature on the spacer mediates the positioning between stacked reels to ensure proper alignment and stability.
2Stability of the object's composition
If the forks are positioned under the lower flange towards the outer portion, then the reel has a wide base to protect against tipping, but the flange may bow or sag under the weight and eventually crack
Solution Approach 1:
The alignment feature is positioned at a specific location on the spacer that is optimized for both alignment and load distribution. This localized feature concentrates the interaction between stacked reels at a point that does not compromise the overall flange structure, allowing fork placement for stability while preventing excessive bending moments that would cause bowing or cracking.
3Area of stationary object
If the bottom face of the lower flange is contacting and flush with the ground surface or stacked flush on top of another reel, then maximum contact area is achieved, but the forks cannot be properly positioned for lifting
Solution Approach 1:
The spacer is pre-positioned on the flange at a height that automatically provides the necessary gap for fork insertion. This preliminary positioning ensures that when the reel is placed on the ground or stacked, the forks can be easily inserted between the spacer and the support surface without requiring additional manual adjustment or forcing, while still maintaining adequate contact area through the spacer's base.
Data Source
AI summary
A cable reel for holding a cable wound thereon that includes a cylindrical drum having a longitudinal axis, a first end, and a second end spaced from the first end. The cable reel also includes a first flange that is coupled to the first end of the cylindrical drum and a second flange that is coupled to the second end of the cylindrical drum. The cable reel further includes a spacer that extends axially outward from the first flange. The spacer is configured to support the reel with the first flange spaced above a support surface when the longitudinal axis of the reel is in a substantially vertical orientation and with the reel being supported on the support surface by the spacer.