Expandable Reel Flange Adapter for Axle-Free Cable Handling
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Solution Overview
Problem
Existing solutions for managing and installing reels, such as cable reels, lack maneuverability and flexibility, requiring axles of fixed widths and necessitating additional material handling, which complicates the process of positioning and unspooling cables.
Innovation Solution
The development of independently rotating flanges with arbor hole adapters that can be removably attached to reels, allowing for flexible attachment to any width material-carrying apparatus, eliminating the need for axles and enabling independent rotation of the flanges relative to the reel, facilitating easier loading, lifting, and maneuvering of reels to installation locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If axles of fixed widths are used to attach flanges to reels, then the attachment structure is simple, but the adaptability to different reel widths is poor
Solution Approach 1:
The flange attachment system transitions from fixed-width axles to dynamically adjustable arbor hole adapters that can be configured for different reel widths. The adapters include adjustable arms or spreaders that can be extended or retracted to match various reel diameters, allowing the same flange assembly to adapt to different reel sizes without requiring multiple fixed-width components.
Solution Approach 2:
The attachment mechanism incorporates adjustable parameters such as the distance between attachment points or the width of the adapter structure. By allowing these parameters to be changed based on the reel width, the system achieves versatility across different reel sizes while maintaining a relatively simple base structure that can be adjusted rather than completely redesigned for each application.
2Ease of operation
If axles are used to attach flanges to reels, then the attachment is secure, but additional material handling is required
Solution Approach 1:
The flange assembly and attachment mechanism are merged into a single integrated unit. The arbor hole adapters are permanently mounted to the flanges, eliminating the need for separate axle components that would require additional handling, alignment, and installation steps. This integration reduces the number of discrete parts that need to be managed during loading and installation operations.
Solution Approach 2:
The traditional axle component is extracted and replaced with arbor hole adapters that attach directly to the flange structure. This extraction eliminates the intermediate axle element that would otherwise require separate handling and installation, streamlining the material handling process while maintaining secure attachment functionality.
3Ease of operation
If flanges are fixed to the reel, then the structure is stable, but independent rotation of flanges is prevented
Solution Approach 1:
The attachment system is segmented into distinct functional components: the flange body, the arbor hole adapter, and the connection interface. This segmentation allows the flange to remain structurally stable while the adapter provides the rotational degree of freedom. The flange maintains its structural integrity through rigid construction, while the adapter mechanism enables independent rotation without compromising the overall stability of the assembly.
4Adaptability or versatility
If reels of varying sizes are accommodated, then the versatility increases, but the device complexity increases
Solution Approach 1:
The arbor hole adapter is designed as a universal component that can accommodate multiple reel sizes through adjustment mechanisms rather than requiring different adapter models for each reel size. The same basic adapter structure can be configured for various widths by adjusting arm positions, spreader extensions, or mounting hole selections, providing multi-functionality that reduces overall system complexity despite the need to handle varying reel sizes.
Data Source
AI summary
A flange for use on a reel, a flange adapter, and a flange stand are provided. The flange may include an outer circumference, a hub assembly, and an arbor hole adapter that is adapted to engage an arbor hole to secure the flange to the reel. The arbor hole adapter may include an expandable portion that is movable between an extended position and a retracted position. First and second expansion plates may be coupled to the arbor hole adapter and connected by shoulder bolts that guide movement of the plates between an abutting configuration and a spaced-apart configuration, allowing movement of the expandable portion relative to the reel for modified engagement. The flange stand may include a base, a support portion, and a coupler for engaging a central extension of the flange to allow the flange to be supported in an upright position.