Power Driven Circuit Wire Box Spool Management

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Solution Overview

Problem

Existing methods for dispensing and retracting electrical wire and cable from wooden reels or plastic/metal spools are inefficient, leading to tangles, snags, and manual handling difficulties, requiring additional equipment and significant preparation time, especially when dealing with multiple spools.

Innovation Solution

A power-driven circuit wire box that uses a power tool to rotate a spool gear attached to each spool, allowing for efficient dispensing and retraction of wire or cable, with transparent design for visibility and independent spool management, reducing manual labor and equipment needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual wire retraction is used, then the operator can control the wire placement, but the process is time-consuming and physically demanding

Engineering Contradiction:

Improvemanual wire retractionVSAvoidretraction time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical retraction system with a power-driven motor system. The motor automatically winds the wire back onto the spool, eliminating the need for the operator to manually rotate the spool and handle the wire, thus reducing both time and physical effort while maintaining control through automated mechanical action.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The power-driven system enables the wire retraction process to be performed autonomously without continuous manual intervention. The motor self-regulates the winding process, and the system automatically manages the wire placement and spool rotation, freeing the operator from the repetitive manual task of retraction.

Inventive Principle:

Principle #25Self-service

2Area of stationary object

If multiple spools are placed on the same shaft, then space is optimized, but removing a single spool requires removing all spools on that shaft

Engineering Contradiction:

Improvestorage spaceVSAvoidspool removal

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The patent divides the storage system into multiple independent shafts, each capable of holding a single spool. This segmentation allows each spool to be accessed and removed independently from the others, eliminating the need to remove entire groups of spools together while maintaining compact vertical stacking for space efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from horizontal arrangement of spools on shared shafts to vertical stacking of individual shafts. This dimensional change allows multiple spools to be stored in a compact vertical space while maintaining independent access to each spool through its dedicated shaft, solving both space optimization and operational ease.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Area of stationary object

If wire is pushed back into an opaque box, then storage is compact, but the operator cannot monitor retraction progress and wire may become tangled

Engineering Contradiction:

Improvestorage volumeVSAvoidretraction monitoring

Core Design Contradiction:

Area of stationary objectVSDifficulty of detecting and measuring

Solution Approach 1:

The patent applies transparency or translucency to the wire box material, allowing the operator to visually monitor the wire retraction process, detect tangles, and observe wire placement without opening the box. This optical property change maintains the compact storage volume while enabling continuous visual inspection of the wire condition and retraction progress.

Inventive Principle:

Principle #32Color changes

4Productivity

If traditional racks with multiple spools per shaft are used, then transport efficiency is improved, but the rack becomes heavy and difficult to transport

Engineering Contradiction:

Improvetransport efficiencyVSAvoidrack weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The patent segments the traditional heavy rack into multiple lightweight individual shafts that can be independently handled. Each shaft is designed to hold a single spool, allowing operators to transport only the needed shafts rather than moving entire heavy rack assemblies, thus reducing transport weight while maintaining efficient spool organization and access.

Inventive Principle:

Principle #1Segmentation

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 power-driven system enhances efficiency by minimizing tangles and manual effort, enabling easy management of multiple spools and reducing preparation time, while allowing for independent spool operation and improved visibility during the process.

Implementation Method 1

The power tool connects to a power gear which is in mesh with a spool gear attached to the wire or cable spool. As the power tool rotates the power gear, the power gear rotates the spool gear and the spool.

Methodology Applied

Scientific EffectGear meshing: Gear

Data Source

PatentUS11745976B1Power driven circuit wire box

Publication Date: 2023.09.05 ENCORE WIRE CORP

AI summary

An apparatus for the dispensing and retraction of wire or cable. The apparatus including a first and second plate, at least one shaft attached to the first plate and the second plate, a spool gear attached to the shaft, a power gear shaft attached to the first or second plate, and a power gear attached to the power gear shaft and in mesh with the spool gear, wherein when the power gear is rotated, the spool gear is rotated.