Flattenable Cable Reel Winding for Minimum Bend Radius Transport
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Solution Overview
Problem
Existing cable reels for transporting large high voltage cables are too large due to the requirement of maintaining a minimum bending radius, making them unsuitable for railroad transport and viaduct lorry crossings.
Innovation Solution
A method and system for winding a cable onto a cable reel with a drum that forms continuous helical windings at an offset angle, allowing the reel to be flattened while maintaining the minimum bending radius, using elongated support elements and hinges to switch between winding and transportation states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cable reel with a circular cross-section is used to maintain the minimum bending radius, then the cable is protected from damage, but the reel becomes too large for railroad transport and viaduct lorry crossings
Solution Approach 1:
The cable reel is designed with a transformable structure that can change its cross-sectional shape from circular to flattened. The drum and end flanges are connected via hinges, allowing the reel to dynamically adjust its geometry between a circular configuration during cable winding/unwinding operations and a flattened configuration for transportation through constrained spaces such as railroad cars and viaducts.
Solution Approach 2:
The invention transforms the cable reel from a two-dimensional circular cross-section to a three-dimensional flattened configuration by introducing an offset angle between the main bending axes of the cable windings and the longitudinal axis of the drum. This dimensional transformation reduces the reel's width and height while maintaining the cable's minimum bending radius, enabling transport through previously inaccessible routes.
2Device complexity
If the cable is wound with main bending axes parallel to the drum's longitudinal axis, then the winding structure is simple, but the reel cannot be flattened for transport
Solution Approach 1:
The cable windings are arranged asymmetrically on the drum, with the main bending axes of the cable forming an offset angle with respect to the longitudinal axis of the drum. This asymmetric winding pattern enables the reel to be flattened for transport while maintaining proper cable geometry and protecting the cable from damage during both winding and transportation phases.
Data Source
AI summary
A method for winding a cable (12) onto a cable reel (22) includes providing a cable reel (22) having a drum (24) arranged between two end flanges (28, 30). The drum (24) has a longitudinal axis (26), and the cable is placed (12) on the drum (24) to form a plurality of continuous helical windings (32) on the drum (24). Consecutive windings (32) are directly adjacent to each other, where main bending axes (34) of the continuous helical windings (32) and the longitudinal axis (26) of the drum (24) enclose an offset angle (α) greater than zero.