Rotating Inner Flange Reel for Twist-Free Wire Spooling
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Solution Overview
Problem
The existing methods for spooling electrical wires during installation are cumbersome, requiring large and heavy reel assemblies supported by jack stands, which are costly, space-consuming, and pose safety risks, especially in smaller construction sites, and often lead to issues with wire twisting or kinking when multiple wires of different diameters are installed simultaneously.
Innovation Solution
A compact reel assembly comprising an inner flange assembly that can freely rotate relative to an outer flange assembly, allowing wire spooling directly on the ground or any surface, eliminating the need for jack stands and enabling efficient handling of multiple wires without twisting or kinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional large reel assemblies supported by jack stands are used, then wire spooling capacity is sufficient for large-scale installations, but the equipment becomes heavy, space-consuming, and costly
Solution Approach 1:
The reel assembly is divided into two functional parts: a stationary outer flange assembly that remains on the ground, and a rotating inner flange assembly that holds the wire. This segmentation allows the wire-spooling function to be separated from the support structure, enabling the reel to operate without heavy jack stands while maintaining adequate wire capacity on the inner flange.
2Ease of operation
If jack stands are used to support the reel assembly, then wire spooling is enabled, but floor space consumption increases and equipment complexity increases
Solution Approach 1:
The outer flange assembly serves as both the support structure and the operational base, eliminating the need for separate jack stands. By making the outer flange itself the support element that contacts the ground, the system achieves wire spooling capability directly from the reel assembly without requiring additional space-consuming equipment.
3Adaptability or versatility
If multiple wires of different diameters are spooled on a traditional reel, then multi-wire installation is enabled, but wire twisting and kinking occur
Solution Approach 1:
The inner flange assembly is designed with localized features including grooves, channels, or raised sections that create distinct spooling zones for different wire diameters. This local differentiation in the flange structure allows each wire type to be spooled in its optimal zone, preventing cross-interference, twisting, and kinking while enabling simultaneous installation of multiple wires with different specifications.
Data Source
AI summary
A reel apparatus and method comprising an inner flange assembly, an outer flange assembly, and a bearing assembly coupled to the inner flange assemblies. The inner flange assembly is capable of freely rotating relative to the outer flange assembly. In another embodiment, wire is spooled from a reel assembly comprising an inner flange assembly and an outer flange assembly.