Cable Reel Stand Coupling for Safer Hoist Rope Replacement
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Solution Overview
Problem
The installation process of cable reels on reel stands for electric rope shovels is complex and poses safety risks due to the need for precise alignment of coupling jaws and flanged collars in tight spaces, which can lead to worker injuries.
Innovation Solution
A cable reel stand design featuring spaced stanchions with rotatable cradles and a brake rotor, utilizing a non-circular coupling pin to secure the axle to the brake rotor, eliminating the need for manual alignment and reducing worker interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment of coupling jaws and flanged collars is performed in tight spaces, then precise alignment can be achieved, but worker safety is compromised due to injury risks
Solution Approach 1:
The coupling pin with non-circular cross-section performs self-alignment during insertion. The asymmetric geometry of the coupling pin automatically orients itself relative to the brake rotor and axle, eliminating the need for manual alignment operations by workers in tight spaces.
Solution Approach 2:
The coupling pin features a non-circular cross-section that creates an asymmetric mechanical interface. This asymmetry ensures that the coupling pin can only be inserted in the correct orientation, providing automatic alignment guidance and eliminating the need for manual positioning of coupling jaws and flanged collars.
2Reliability
If complex alignment procedures are performed, then secure connection is achieved, but installation time increases
Solution Approach 1:
The connection system is divided into separate functional elements: the axle with flanged collar, the brake rotor with coupling jaw, and the coupling pin. This segmentation allows each component to be independently manufactured and assembled, with the coupling pin serving as a simple connector that requires no complex alignment procedures.
Solution Approach 2:
The coupling pin automatically performs the alignment function during its insertion process. The non-circular cross-section of the coupling pin creates a self-aligning mechanism that guides the assembly together without requiring manual adjustment or complex procedures, thereby reducing installation time while maintaining secure connection.
3Measurement precision
If multiple manual adjustments are required, then precise positioning is achieved, but device complexity increases
Solution Approach 1:
The coupling pin employs a non-circular cross-section that creates an asymmetric mechanical interface between the axle and brake rotor. This asymmetry provides inherent positioning guidance, eliminating the need for multiple manual adjustments to achieve precise positioning, thereby reducing device complexity.
Solution Approach 2:
Instead of requiring the operator to manually adjust and align multiple components to achieve precise positioning, the design inverts the approach by having the coupling pin itself carry the alignment information through its non-circular geometry. The coupling pin's shape dictates the correct relative positioning of all components during insertion.
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
Simplifies the installation process, enhances safety by minimizing manual adjustments, and ensures secure rotational support of the cable reel during unspooling.
Implementation Method 1
a brake caliper cooperatively associated therewith, of which said brake rotor is selectively couplable to the axle... operable, under action of the brake caliper on said brake rotor, to impart a braking effect on rotation of the axle
Data Source
AI summary
An improved cable reel stand for rotational support of a cable reel comprising a spool and a length of cable wound thereon, which spool is carriable by an axle spanning axially through said spool. Two stanchions of the stands carry two respective axle cradles, of which on is neighboured by a brake selectively couplable to the axle by a coupling of non-circular profile that cooperates with non-circular internal profiles of the brake and the axle to provide rotational interlocking thereof. The axle cradles are roller cradles serving to self-align the axle into a properly seated position atop two adjacent cradle rollers, and are equipped with hold-downs for positive capture of the seated axle. The axle features a circumferential V-groove for mating with tapered cradle rollers at one of the axle cradles.