Optical Fiber Tail Spool Winding Mechanism
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Solution Overview
Problem
Conventional winding processes for long products like optical fiber cables require multiple operators to manage and secure the tail section, leading to excess loose fiber and inefficient winding, especially during the ramp-up phase.
Innovation Solution
A tail spool apparatus that maintains tautness of the optical fiber cable during winding, using a reusable lead wire to feed the cable onto both the tail spool and main spool, allowing for independent rotation and automatic winding of the tail section, reducing operator interactions and excess fiber accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple operators manually manage and secure the tail section during conventional winding, then the tail section can be handled, but excess loose fiber accumulates and operator requirements increase
Solution Approach 1:
The tail spool automatically winds the tail section of optical fiber cable without requiring manual intervention from operators. The spool self-regulates the winding process, maintaining tension and securing the tail section through automatic rotation and friction engagement, eliminating the need for operators to manually handle and secure the tail section.
Solution Approach 2:
The tail spool acts as an intermediary device between the main winding system and the tail section of the cable. It receives the tail section from the main spool and independently winds it onto its own drum, serving as a mediator that prevents excess loose fiber accumulation while reducing operator involvement.
2Reliability
If multiple operators are used to manage the tail section, then the cable can be secured, but operator requirements and complexity increase
Solution Approach 1:
The tail spool system performs the cable securing function automatically through its own rotation and friction-based engagement mechanism. The spool self-regulates tension and secures the tail section without requiring multiple operators to coordinate their actions, thereby reducing operational complexity while maintaining reliability.
Solution Approach 2:
The tail spool extracts the tail section handling function from the main winding system and operators. By separating this specific function into an independent device, the system eliminates the need for multiple operators to manage the tail section while maintaining secure cable handling.
3Ease of operation
If manual winding of tail section is used, then operators can control the process, but start-up time and efficiency are reduced
Solution Approach 1:
The tail spool automatically initiates and controls the winding of the tail section without requiring operators to manually guide or secure the cable during start-up. The spool self-regulates the winding process from the beginning, eliminating delays associated with manual intervention and significantly reducing start-up time.
Solution Approach 2:
The tail spool is pre-configured with the necessary components (drum, flanges, friction surfaces) to immediately begin winding the tail section as soon as the cable is fed onto it. This preliminary preparation eliminates the need for operators to perform preliminary securing actions, enabling faster start-up.
Data Source
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AI summary
Embodiments of a method of collecting a tail section of a long product, such as an optical fiber cable (20), are provided. In the method, a lead wire (52) from a tail spool (40) is unwound, and the lead wire (52) is fed through a flange (44) of a main spool (38). The tail spool (40) and the main spool (38) have a common rotation axis. The lead wire (52) is attached to the long product (20). The tail spool (40) is rotated while holding the main spool (38) stationary so as to wind the lead wire (52) and the tail section onto the tail spool (40). The rotation of the tail spool (40) is stopped, and the main spool (38) and the tail spool (40) are rotated together so as to wind the long product (20) onto the main spool (38). Also provided are embodiments of a winding apparatus (26) using the tail spool (40) and a tail reel (37) that includes the tail spool (40) and a drive mechanism (56).