Reel Take-Up Apparatus for Heavy Cable Handling
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Solution Overview
Problem
Existing cable handling equipment is inadequate for transferring large, bulky cables from large manufacturer reels to smaller reels that can be easily transported and handled by end users, particularly in field applications where cables are very large and cumbersome.
Innovation Solution
A reel take-up apparatus comprising a frame, drive mechanism, support rollers, and positioning actuators that allow for the lifting, rotation, and repositioning of reels, enabling a single operator to load and unload reels, support them using flanges instead of an axle, and facilitate easy attachment of cables for winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cable is purchased on large reels weighing up to 20,000 pounds, then cable supply capacity is sufficient for bulk operations, but the reels become too heavy and bulky for easy transportation and field handling
Solution Approach 1:
The system segments the cable supply into two stages: first, cable is stored on large master reels (up to 20,000 pounds) for bulk storage; second, the take-up reel transfers cable to smaller distribution reels (e.g., 2,000-pound capacity) that can be easily transported and handled in the field. This segmentation allows the heavy master reel to remain stationary while lighter distribution reels are moved to job sites.
Solution Approach 2:
The take-up reel acts as an intermediary device between the large master reel and the smaller distribution reels. It receives cable from the master reel and winds it onto distribution reels, enabling transfer of cable without requiring direct handling of the heavy master reel at the job site.
2Ease of manufacture
If traditional cable handling equipment is used, then cable transfer can be performed, but multiple operators are required to load and unload reels, increasing operational complexity and time
Solution Approach 1:
The take-up reel is designed with self-aligning features including alignment guides that automatically position the reel on the axle, and flange-supported loading where the reel flanges rest on support surfaces during loading. These features enable a single operator to load and unload reels without requiring multiple personnel to manually position and secure the heavy reels.
3Stability of the object's composition
If reels are supported on axles during rotation, then rotational stability is maintained, but the loading and unloading process becomes more complex and time-consuming
Solution Approach 1:
Instead of supporting the reel during rotation with an axle (traditional method), the system inverts the support approach: the reel is supported on its flanges by support rollers during both loading/unloading and rotation. The flanges rest on support surfaces, eliminating the need for axle insertion and removal operations.
4Quantity of substance
If large reels are handled directly in field applications, then cable supply is充足, but the bulky size makes transportation and on-site manipulation difficult
Solution Approach 1:
The cable supply system is segmented into a stationary master reel (large capacity) and mobile distribution reels (smaller size). The take-up reel enables transfer from master reel to distribution reels, allowing cable supply from large reels while the actual field handling is performed with smaller, more manageable distribution reels.
Solution Approach 2:
The take-up reel serves as an intermediary that enables field operations with smaller reels while maintaining connection to the large master reel supply. It transfers cable from the master reel to distribution reels that can be easily transported to and manipulated at job sites.
Data Source
AI summary
A reel take-up apparatus includes a frame, a drive mechanism, a pair of support rollers, and a pair of positioning actuators. The frame may be configured to receive a reel from one end. The drive mechanism is generally slidably mounted to the frame and configured to rotate the reel. The pair of support rollers generally extend from the frame and may be configured to provide support to the reel while allowing the reel to rotate. The pair of positioning actuators may be configured to move the pair of support rollers toward and away from each other so as to (i) lift the reel from a support surface, (ii) support the reel during rotation by the drive mechanism, and (iii) lower the reel to the support surface for removal from the frame.