Removable Ramp for Cable Reels
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Solution Overview
Problem
Reels with built-in ramps are difficult and costly to manufacture, and customers must purchase new reels when changing cable diameters, as built-in ramps are permanent and cannot be switched out.
Innovation Solution
A reel system with a removable ramp made of lightweight materials like plastic or dense foam, comprising multiple sections that can be easily affixed and detached from the reel, allowing for interchangeable ramps of varying widths to accommodate different cable diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If built-in ramps are used on reels, then cable access is enabled, but manufacturing becomes difficult and labor intensive
Solution Approach 1:
The ramp is divided into multiple separate sections that can be individually manufactured and then assembled together to form the complete ramp structure. This segmentation allows each section to be produced using simpler, less labor-intensive processes while maintaining the functional capability of providing cable access when assembled.
Solution Approach 2:
The ramp is extracted from being an integral, built-in component and transformed into a removable, separate accessory that attaches to the reel. This extraction eliminates the need for complex integrated manufacturing while preserving the cable access function through a simpler attachment mechanism.
2Ease of operation
If built-in ramps are permanently fixed on reels, then cable access is provided, but customers must buy new reels when changing cable diameters
Solution Approach 1:
The ramp system transitions from a static, permanent fixture to a dynamic, interchangeable component. Multiple ramp sections with different widths can be attached and detached as needed, allowing the reel to adapt to different cable diameters without requiring replacement of the entire reel assembly.
Solution Approach 2:
The reel is designed with universal compatibility for multiple ramp widths, allowing a single reel base to serve multiple functions with different cable diameters. The interchangeable ramp sections enable the same reel to accommodate various cable sizes, increasing versatility and reducing the need for multiple specialized reels.
3Adaptability or versatility
If complete new reels are purchased for different cable diameters, then proper ramp width is obtained, but cost increases
Solution Approach 1:
The ramp is segmented into interchangeable sections that can be configured in different combinations to match various cable diameters. This allows customers to use a single reel base with multiple ramp configurations rather than purchasing multiple complete reels, reducing the total quantity of reel assemblies needed.
Solution Approach 2:
Instead of discarding the reel base when changing cable diameters, customers can discard only the incompatible ramp sections and retain the reusable reel base. The old ramp sections are discarded while the valuable reel component is recovered and reused with new ramp sections matched to the new cable diameter.
Data Source
AI summary
A reel for winding cable comprising a drum, a first flange, a second flange and a ramp removably affixed to a flange. The ramp extends around part of the drum adjacent the inner side of the first flange. The ramp has a cylindrical drum facing surface which mates with the cylindrical surface of the drum, and a smooth continuous cable supporting surface. The ramp may comprise at least two sections. Preferably the ramp is made of a lightweight material such as plastic or dense foam.