Rotatable Reel Cable Storage for Wire Saw Tension
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Solution Overview
Problem
Conventional cable storage devices for wire saws face challenges in maintaining tension and storage capacity, particularly in spatially constrained environments, due to the need for significant force to keep rollers separate and the transmission of vibrations during cutting operations, which impairs cable circulation and requires complex mechanisms and excessive rope length, leading to inefficiencies and increased costs.
Innovation Solution
A cable store design featuring a rotatable reel with a cable guide assembly and interlocking rollers that allow for stepless adjustment of cable tension and storage capacity, enabling flexible cable management and efficient use of rope length, even in tight spaces, by defining the cable path and allowing continuous winding and unwinding without slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the number of rollers in the cable store is increased to maintain cable tension, then the cable tension is maintained, but the device complexity and force requirements increase significantly
Solution Approach 1:
The patent replaces the conventional mechanical block-and-tackle system with a reel-based winding mechanism. Instead of using multiple rollers and rope sections to maintain tension through mechanical advantage, the system uses a reel to wind and store the cable, maintaining tension through the winding action rather than through multiple rope sections running between roller sets. This substitution eliminates the need for complex mechanisms while maintaining the required cable tension.
2Quantity of substance
If the distance between roller sets is increased to increase storage capacity, then the storage capacity increases, but vibrations and impacts are transmitted causing cable sections to vibrate and impair circulation
Solution Approach 1:
The patent transitions from a linear arrangement of rollers to a rotational reel-based system. Instead of increasing the linear distance between roller sets to gain storage capacity, the system uses the rotational dimension of the reel to store cable. The cable is wound around the reel in concentric layers, utilizing the radial and angular dimensions rather than just the linear distance between rollers. This dimensional change allows for increased storage capacity while keeping the cable path compact and stable, minimizing vibration transmission.
3Productivity
If a longer cable is used to ensure complete cut without interruption, then the cutting operation can be completed, but the storage requirements and costs increase
Solution Approach 1:
The patent implements a cable recovery system where the used cable is wound back onto the reel during and after the cutting operation. Instead of discarding the entire cable after use, the system recovers and stores the cable on the reel. This allows the same cable to be reused for multiple cutting operations, reducing the total amount of cable needed while maintaining continuous productivity. The reel serves as both a tensioning device and a storage mechanism for recovered cable.
4Force
If the drive unit is moved continuously to maintain cable tension during cutting, then the cable tension is maintained, but the operational complexity and time requirements increase
Solution Approach 1:
The patent implements a self-tensioning system where the reel automatically winds the cable during the cutting operation, maintaining tension without requiring external intervention or movement of the drive unit. The rotational movement of the reel during cable payout and retrieval automatically maintains the required tension through the winding action. This self-service mechanism eliminates the need for continuous resetting or adjustment of the drive unit position, saving time and operational complexity.
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 solution enhances cable tension management and storage capacity, reducing operational complexity and costs by allowing flexible rope usage and minimizing interruptions during cutting operations, while maintaining efficient cable circulation and preventing premature rope wear.
Implementation Method 1
a reel (34) onto which the cable (31) can be wound
Implementation Method 2
at least one further roller (50, 51), arranged in such a way that the cable (31) can run through the cable store (30) at any time and independently of the winding state
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The storage (30) has a rotatable spool (34) for winding a closed loop rope (31), and a cable guide mechanism (37) for determining a path of the rope such that the rope is wound up by the rotatable spool. A drive unit rotates the rope during cutting operation of a rope saw. The spool comprises two winding arms (46, 47) that are arranged at same distance from a rotation axis (40), where the arms and the rotation axis are aligned in a same direction. The winding arms are arranged parallel to each other. Rollers (50, 51) are rotatably arranged in the rotatable spool.