Note: Descriptions are shown in the official language in which they were submitted.
CA 02911286 2015-11-03
ROTATABLE CABLE REEL
BACKGROUND
The present disclosure is directed to cable reels. More particularly, the
present
disclosure is directed to a cable reel having components with independent
rotation about an
axis.
Electrical needs of modern facilities such as houses, apartment buildings,
warehouses,
manufacturing facilities, office buildings, and the like, have increased as
the use of electrical
devices has increased. During the construction of buildings or the upgrade
of
electrical/communication systems, cables are typically pulled through a
conduit from a source
to a destination. For example, a building may be upgraded from copper wires
for
communication to fiber optic cables. To upgrade, the currently installed
cables are typically
removed by pulling the cables through a conduit or off of support structures
such as cable
trays or overhead power lines. Fiber optic cables can be run from a source,
such as a cable
box outside the building, providing the link to the communication network,
such as the
Internet, to the building or a structure configured to receive the fiber optic
cable.
Because of the length of cable needed in certain installations, the cable is
typically
wound around a cable reel at an installation facility. The technicians
transport the cable reel,
which may weigh several tons, from the installation facility in which the
cable was wound to
the site in which the cable is to be installed. The cable reel is typically
lifted from a truck
carrying the cable reel to the location in which the cable is to be installed
by transport
machinery, such as a forklift. In some systems in use today, the cable reel
remains loaded on
the truck and the cable is pulled from the reel while the reel is on the
truck. In other cable
installations, because of geographical limitations, the cable reel may need to
be moved from
the truck to the installation location because the truck cannot be physically
located at the
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installation location. The geographical limitations may also prevent the use
of transport
machinery, such as a forklift, to transport the cable reel to the installation
location. This
would require the technicians to manually rotate the cable reel to move it
from the truck to
the installation location.
Conventional systems may also require the use of labor intensive procedures at
the
cable winding facility. In the facility, an empty cable reel may need to be
moved manually
from a storage location to the winding machine. Once wound, the cable reel may
need to be
manually moved from the winding location to the truck. As mentioned briefly
above, a fully
wound cable reel can weigh several tons. Even when no cable is wound on a
cable reel, if
constructed from a material like metal, the cable reel itself can weigh almost
a ton. The
movement of a cable reel from location to location, whether with cable or
empty, can be a
labor intensive operation having significant safety concerns. In addition,
conventional reels
require systems, such as capstans to rotate the conventional reel or otherwise
assist in rotating
the conventional reel.
It is with respect to these and other considerations that the disclosure made
herein is
presented.
SUMMARY
The present disclosure is directed to concepts and technologies for a cable
reel having
components with independent rotation about an axis. A cable reel of the
present disclosure
can include two flanges and a drum. The drum, which can be configured to
receive a length
of cable, can be rotatably mounted on an axle. The two flanges can be
rotationally mounted
on the axle at opposing, distal ends of the axle. The two flanges are
rotatably mounted on the
axle independent of the drum. In some configurations, this provides for the
ability of the
drum to rotate about the axle independent of both flanges. In further
configurations, the
flanges can rotate independently of the drum and of each other.
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The cable reel may also be configured with additional features. In one
implementation, the width of the cable reel may be adjustable. The flanges may
be
repositioned along various positions on the axle. The placement of the flanges
can increase
or decrease the width between the flanges, thus increasing or decreasing the
width between
the flanges. Although not limited to any particular advantage or feature,
providing a cable
reel having an adjustable width between the flanges can provide some benefits.
For example,
it may be beneficial to have a relatively smaller width between the flanges
when transporting
a cable reel having cable loaded onto it. The relatively smaller width can
compress the
flanges against the cable, thus reducing the likelihood that the drum will
rotate unnecessarily.
In a similar manner, during a payoff of the cable, the width between the
flanges can be
increased to relieve the pressure applied to the cable to reduce the amount of
pulling force
necessary to pay off the cable. A resistance braking device to control payoff
speed may be
added. The resistance braking device can act as a drum speed control by
providing an
opposing force to the rotational force generated by the drum during payoff.
The opposing
force can help slow down the drum when it is desired to reduce the rate of the
payoff of the
cable.
In another configuration, adjusting the width between the flanges can be used
to
accommodate drums of various sizes or to change the number of drums installed
on the axle.
The drum configuration can be adjusted depending on the particular
implementation of the
cable reel. For example, the cable reel may be used to install a single cable
in one instance,
and then, may need to be used to install multiple types of the cables in
another instance. In
one implementation, the single drum configuration can be modified by removing
the single
drum, installing the multiple drums to accommodate the multiple types of
cables, and
adjusting the width between the flanges to complete the reconfiguration.
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In another configuration, the drum of the cable reel may be fixable to either
flange, or
both. In a still further configuration, the cable reel may have one or more
shields to protect
the cable during the loading or payoff stage. The shielding can act as a
barrier between the
rotating drum and the fixed flanges during the two stages, reducing wear and
tear on the
cables. In another implementation, the shield may also reduce the friction
between the cable
and the flanges. This shield may include a lubricant incorporated in the
shield material to
reduce the force required to pull the cable against the flanges. The lubricant
can be a fluidic
or solid lubricant suitable for use in a cable reel. For example, and not by
way of limitation,
the lubricant can be graphite, oil, or grease. The shield may also include
bearings, wheels or
other rotatable components that reduce the force necessary to pull the cable
against the
flanges.
This Summary is provided to introduce a selection of concepts in a simplified
form
that are further described below in the Detailed Description. This Summary is
not intended to
be used to limit the scope of the claimed subject matter. Furthermore, the
claimed subject
matter is not limited to implementations that solve any or all disadvantages
noted in any part
of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of
this
disclosure, illustrate various embodiments of the present disclosure. In the
drawings:
FIGURE 1 is an exploded, perspective view of a cable reel, according to
exemplary
embodiments;
FIGURE 2A is a side view of a cable reel, according to exemplary embodiments;
FIGURE 2B is a side view of an alternate cable reel without an axle, according
to
exemplary embodiments;
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FIGURES 3A-3C are side views showing the adjustment of the width of a cable
reel,
according to exemplary embodiments;
FIGURE 4A is a side view of a cable reel in which a shield is used to reduce
the
coefficient of friction between the cables and the cable reel, according to
exemplary
embodiments;
FIGURE 4B is a side view of a cable reel showing an alternate shield
configuration,
according to exemplary embodiments;
FIGURE 5 is perspective view of an exemplary bearing structure, according to
exemplary embodiments;
FIGURE 6 is a side view of an alternate bearing structure used in a cable
reel,
according to exemplary embodiments;
FIGURE 7 is an illustration showing the securement of a cable reel onto a
truck,
according to exemplary embodiments;
FIGURE 8A is a side view of a cable reel, according to exemplary embodiments;
FIGURES 8B and 8C are a detail portions of the cable reel illustrated in
FIGURE 8A,
according to exemplary embodiments;
FIGURE 9 shows a side view of a cable reel comprising an over-spin control,
according to exemplary embodiments;
FIGURE 10 shows an over-spin control, according to exemplary embodiments;
FIGURES 11A and 11B shows a scotch, according to exemplary embodiments;
FIGURE 12 shows a bearing assembly, according to exemplary embodiments;
FIGURE 13 shows a wire guide assembly, according to exemplary embodiments;
FIGURE 14 shows a wire guide assembly support, according to exemplary
embodiments;
FIGURE 15 shows a connector assembly, according to exemplary embodiments;
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FIGURE 16 shows a graph showing average forces needed to cause unassisted
cable
reel rotation, according to exemplary embodiments;
FIGURE 17 shows a graph showing average maximum forces needed to cause
unassisted cable reel rotation, according to exemplary embodiments;
FIGURE 18 shows a graph showing a maximum point force needed to cause
unassisted cable reel rotation, according to exemplary embodiments;
FIGURE 19 shows a graph showing standard deviations for forces needed to cause
unassisted cable reel rotation, according to exemplary embodiments;
FIGURE 20 shows a diagram for a data collection procedure, according to
exemplary
embodiments;
FIGURE 21 shows a graph showing average forces needed to pull cable from a
cable
reel, according to exemplary embodiments;
FIGURE 22 shows the standard deviation for average forces needed to pull cable
from a cable reel, according to exemplary embodiments; and
FIGURE 23 shows a graph showing maximum forces needed to pull cable from a
cable reel, according to exemplary embodiments.
DESCRIPTION
The following detailed description is directed to concepts and technologies
relating to
a cable reel having components with independent rotation about an axis. This
description
provides various components, one or more of which may be included in
particular
implementations of the systems and apparatuses disclosed herein. In
illustrating and
describing these various components, however, it is noted that implementations
of the
embodiments disclosed herein may include any combination of these components,
including
combinations other than those shown in this description.
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FIGURE 1 is an exploded, perspective view of a cable reel 100, according to an
exemplary embodiment. In the illustrated embodiment, the cable reel includes a
drum 102
that is to be rotationally mounted on an axle 104, described in more detail in
FIGURE 2
below. In some embodiments, the drum 102 includes a central volume 106 running
the
length of the drum 102 to receive the axle 104. Although not limited to any
particular
configuration, the axle 104 may also include an inner void having an inner
diameter sufficient
to receive a securement mechanism, described in further detail by way of
example in
FIGURE 2. For example, when transporting the cable reel 100, the cable reel
100 may need
to be securely affixed to the bed of a truck upon which the cable reel 100 is
mounted. In
some configurations, a chain or other securement mechanism (not shown) may be
inserted
through the inner void of the axle 104. The chain may be of sufficient length
so that when
inserted through the inner void, the ends of the chain can be secured to a
securement point on
the truck, shown in more detail in FIGURE 7, below.
The radius "R" of the drum 102 may vary depending on the particular
implementation
of the cable reel 100. For example, some installation operations may require a
significant
amount of cable 105. In order to accommodate the amount of the cable 105
required, or
based on the bend radius of the cable 105, the radius R of the drum 102 may be
small to
allow a large amount of cable 105 to be wound onto the drum 102. In another
installation
example, the amount of cable 105 may be small when compared to the previous
example or,
the bend radius of the cable 105 requires the radius of the drum 102 to be
larger. However,
the concepts and technologies described herein are not limited to any
particular radius
configuration.
The cable reel 100 also includes flanges 108A and 108B (collectively referred
to
herein as "the flanges 108"). The flanges 108A and 108B are rotationally
mounted onto the
axle 104 proximate to the opposing ends of the drum 102. The flanges 108A and
108B
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include bearings 110A and 110B that are installed at the center of the flanges
108A and
108B, respectively (collectively referred to herein as "the bearings 110").
The bearings 110A
and 110B provide for rotational freedom of the flanges 108A and 108B about the
axle 104,
allowing the flanges 108 to rotate freely with respect to each other, the axle
104 and the drum
102, as described in more detail in FIGURE 2 below. In some configurations,
the bearings
110 can allow for a full rotation of the flanges 108 about the axle 104. As
used herein, "full
rotation" means a 360 degree rotation.
A limiting apparatus can be used to limit the movement of the flanges 108A and
108B
outwards from the center point of the axle 104. Shown in FIGURE I are end
collars 112A
and 112B, mounted onto the axle 104 proximate to the flanges 108A and 108B,
respectively
(collectively referred to herein as "the end collars 112"). The end collars
112 can be affixed
to their respective ends of the axle 104 using various techniques. For
example, the end
collars 112 can be welded onto their respective ends of the axle 104. In
another example, the
end collars 112 can be affixed to the end of the axle 104 by screwing the end
collars 112 onto
a thread of the axle 104.
In some configurations, it may be desirable to limit the physical interaction
of the
flanges 108 with the end collars 112. In this configuration, the cable reel
100 also includes
shaft collars 114A and 114B (collectively referred to herein as "the shaft
collars 114"). The
shaft collars 11=4A and 114B can be mounted onto the axle 104 proximate to the
flanges 108A
and 108B, respectively in such a way that the shaft collars 114 can be
adjusted from a first
position to a second position along the axle 104. The shaft collars 114 can be
mounted to the
axle 104 using various techniques, of which the concepts and technologies
described herein
are not limited to any particular one.
The cable reel 100 can also include a locking pin 116. The locking pin 116 is
a pin
that is inserted into one of the flanges 108 to lock the rotation of the
particular flange with the
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rotation of the drum, described in more detail in FIGURE 2 below. In some
implementations,
the locking pin 116 can be a rod or other object inserted through an aperture
118 of the flange
108A into an aperture 120 of the drum 102. In this configuration, the
independent rotation of
the drum 102 is impeded by the pin 116.
The cable reel 100 can further include a chock 122 to limit the rotation of
the flange
108A. The chock 122 can be removably affixed to various components of the
cable reel 100.
In FIGURE 1, the chock 122 is shown as being affixed to the flange 108A. If it
is desirable
or needed to limit the movement of the cable reel 100 along the ground, the
chock 122 can be
removed from the flange 108A and placed in a suitable location, typically at
or near a
location of the flange 108A in contact with the ground. Once suitably located,
the chock 122
can provide a physical impediment to the rotation of the flange 108A, thus
preventing or
reducing the amount of movement of the cable reel 100 along the ground. It
should be
understood that the present disclosure is not limited to the use of the chock
122 as a way to
reduce or abate movement of the cable reel 100 along the ground. Other
technologies may be
used and are considered to be within the scope of the presently disclosed
subject matter.
Further, it should be appreciated that the movement of the flange 108B may be
limited in a
similar manner.
FIGURE 2A is a side view of the cable reel 100 in one configuration. As
illustrated,
the axle 104 is inserted through the central volume 106 of the drum 102. In
some
conventional cable reels, the drum and the flanges are one integral unit,
typically made of
wood. The force of pulling the cable from the conventional cable reel imparts
a rotational
force on the drum, which because of the integral construction, imparts a
rotation force on the
flanges. In that example, in order to pay off the conventional cable reel, the
cable reel would
need to be mounted onto an apparatus in such a way as to allow the rotation of
the flanges.
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FIGURE 2A illustrates a way in which a rotational force applied to the drum
102 may
not be transferred to the flanges 108. In one configuration, the outer surface
of the axle 104
and the inner surface of the central volume 106 are cylindrical in nature,
allowing the drum
102 to rotate about the axle 104. In addition, as discussed further below, the
flanges 108 are
rotatably mounted to the axle 104 by bearings 110 and are not attached or
physically
connected to the drum 102 when the locking pin 116 is removed from the
apertures 118 and
120. This can provide a first degree of rotational freedom for the cable reel
100. In some
configurations, this can allow the drum 102 of the cable reel 100 to allow
cable to be wound
onto or wound off of the drum 102 (paid off) without requiring the rotation of
any other
portions of the cable reel 100. When installing or removing cable from the
cable reel 100, the
movement of the cable will cause the drum 102 to rotate about the axle 104
without also
rotating the flanges 108. In doing so, in some configurations, there may not
be a need for
special mounting equipment for the cable reel 100 that helps to facilitate the
rotation of the
drum 102, since the drum 102 can rotate independently, while allowing the
flanges 108 to be
rotationally stationary.
Although the axle 104 and the drum 102 are illustrated as separate components,
the
axle 104 and the drum 102 may be combined into an integrated apparatus. For
example, as
illustrated in FIGURE 2B, the drum 102 includes a first end 101. The first end
101 receives
the bearing 110A to rotatably mount the drum 102 onto the flange 108A. As
illustrated, the
drum 102 remains independently rotatable with respect to the flanges 108. In
some
configurations, the first end 101 of the drum 102 and the flange 108A can be
further secured
using the end collar 112A and the shaft collar 114A.
Returning to FIGURE 2A, as mentioned briefly above, the flanges 108 are
mounted
onto the axle 104 by bearings 110. The bearing 110A provides for a second
degree of
rotational freedom for flange 108A and the bearing 110B provides for a third
degree of
CA 02911286 2015-11-03
rotational freedom for flange 108B about the axle 104. In particular, the
bearings 110A and
110B allow the flanges 108A and 108B to rotate independently of one another as
well as the
drum 102.
The bearings 110 can be of various types of construction. For example, the
bearings
110 can be thrust bearings using ball bearings to facilitate the rotation of
the flanges 108
about the axle 104. The bearings 110 can also be, but are not limited to,
roller bearings or
ball bearings. It should be appreciated that the flanges 108 may be
rotationally mounted to
the axle 104 without the use of the bearings 110 so as to allow the flanges
108 to rotate about
the axle 104. Various embodiments of the present disclosure use bearings to
reduce wear and
tear on the various parts of the cable reel 100, while also reducing the
amount of torque that
may be needed to rotate the flanges 108.
As mentioned briefly above, the required width between the flanges 108 may
vary
depending on the particular installation or on the particular operation being
performed. For
example, the cable reel 100 may need to be used with multiple drums, or one
drum of one
length may need to be switched out to one or more drums of different lengths.
In those cases,
it may be desired to adjust the width between the flanges 108. In other
embodiments, the
width between the flanges 108 may need to be increased or decreased to change
the pressure
and friction between the inner walls of the flanges 108 and a cable wound on
the drum 102.
In one configuration, the location of the shaft collars 114A and 114B on the
axle 104 can be
changed to adjust the width between the flanges 108. FIGURES 3A-3C illustrate
a way in
which the width between the flanges 108 may be adjusted.
FIGURE 3A illustrates the shaft collars 114A and 114B at locations "S" and "W"
along axle 104 to provide for a width between the flanges 108 of "Z". To
facilitate the
movement of the shaft collars 114A and 114B from locations "S" and "W", the
shaft collars
114A and 114B can be relocated to another position. The concepts and
technologies
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described herein may use various securement technologies to secure the shaft
collars 114A
and 114B onto the axle 104. For example, the shaft collars 114A and 114B may
be bolted
onto the axle 104. In another example, the shaft collars 114A and 114B may be
pipe clamps
that are secured using screws. These and other securement technologies are
considered to be
within the scope of the presently disclosed subject matter.
Further illustrated is cable 105 wound around the drum 102. When in the
configuration of FIGURE 3A, the width "Z" causes the cable 105 to be
compressed against
the inner walls of the flanges 108. As discussed above, while in transport or
other similar
operation, placing the cable reel 100 in the configuration illustrated in
FIGURE 3A can help
secure the drum 102 by reducing the ability of the drum 102 to rotate due to
the pressure
imparted onto the cable 105 by the inner walls of the flanges 108. Although
this may provide
certain benefits in operations in which it is desirable or necessary to
compress the cable 105
against the flanges 108, it may be beneficial to reduce the compressive forces
by moving the
flanges 108 to another position along the axle 104 to provide a relatively
larger width
between the flanges 108. FIGURE 3B illustrates one implementation in which the
width
between the flanges 108 may be increased.
In FIGURE 3B, the shaft collars 114A and 114B have been moved from locations
"S"
and "W" to locations "M" and B" along with axle 104 to provide for a width of
"Y," which is
greater than the width "Z" illustrated in FIGURE 3A. The larger width of "Y"
can increase
the space in which the cable 105 can be located. The cable 105 is shown in
FIGURE 3B as
being decompressed when compared to the cable 105 when in the configuration
illustrated in
FIGURE 3A. The decompression of the cable 105 can reduce the amount of contact
and the
amount of pressure between the cable 105 and the flanges 108. This can reduce
the amount
of pulling force necessary to pay off the cable 105.
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As mentioned above, moving the shaft collars 114A and 114B from the width "Z"
between the flanges 108, as illustrated in FIGURE 3A, to a larger width, such
as the width
"Y" illustrated in FIGURE 3B, can also allow for a change from one drum of one
length to a
drum of another length or from one drum to several drums. FIGURE 3C
illustrates a cable
reel 100 configured to handle several drums. In FIGURE 3C, the flanges 108A
and 108B at
placed at locations "G" and "T," respectively, along the axle 104 to provide
for the width of
"Y" between the flanges 108. The second width of "Y" can allow the drum 102 of
FIGURE
2 to be replaced with drums 302A and 302B.
As illustrated in FIGURE 3C, the end collar 112A and the shaft collar 114A
have
been removed from the axle 104. The removal of the end collar 112A and the
shaft collar
114A from the axle 104 can allow the drum 102 to be removed from the cable
reel 100 along
the length of the axle 104. Subsequently, another drum, such as the drums 302A
and 302B,
may then be installed on the axle 104. To secure the drums 302A and 302B onto
the cable
reel 100, the end collar 112A and the shaft collar 114A can be reinstalled in
the configuration
illustrated by way of example in FIGURE 3B.
The ability to modify the configuration of the cable reel 100 from one drum to
multiple drums may provide benefits in various situations. For example, the
cable reel 100
may be used to install a single type of cable in one installation and, in a
subsequent
installation, be used to install multiple types of cables. Instead of using
multiple cable reels,
the cable reel 100 can be reconfigured from handling a single type of cable,
using the drum
102, to handling multiple types of cable on multiple drums, using the drums
302A and 302B.
When winding the cable 105 onto or paying off the cable 105 from the cable
reel 100,
the cable 105 may come in contact with the flanges 108. While the cable 105 is
stationary on
the drum 102, the cable 105 may be in a state in which damage may not be
imparted onto the
cable 105. But, if the drum 102 is being rotated, either during a windup or
payoff operation,
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the portion of the cable 105 closest to the flanges 108 may rub against or
otherwise come in
frictional contact with the flanges 108. If the cable 105 is a sturdy cable
that can handle the
frictional contact, any frictional effects on the cable 105 may be minimal.
But, in some
implementations, the frictional contact may damage or deform the cable 105,
reducing the
integrity of the cable 105. This can be especially troublesome for cable
installed below
ground, where access to the cable 105 is likely impeded by either the ground
or a structure
such as a building.
FIGURE 4A is an illustration showing the cable reel 100 in a configuration
that can
reduce the frictional impact on the cable 105. Shown installed on the cable
reel 100 are the
drum 102 and the flanges 108. As mentioned above, if the drum 102 is rotated
relative to the
flanges 108, the cable 105 proximate to the flanges may rub against or
otherwise come in
moving contact with the surface of the flanges 108. The pressure, heat and
abrasion that can
occur may cause the cable 105 to be damaged or deformed. This can be
especially true if the
coefficient of friction between the cable 105 and the flanges 108 is
relatively high.
To reduce the coefficient of friction, a material having a lower coefficient
of friction
may be installed as a barrier between the cable 105 and the flanges 108.
Illustrated in
FIGURE 4A is a shield 400A and 400B (collectively referred to herein as "the
shields 400")
installed proximate to the flanges 108A and 108B, respectively, between the
cable 105 and
the flanges 108A and 108B. The shields can be a material that reduces the
coefficient of
friction applied to the cables. In some implementations, the material can be
constructed of a
polymeric material such as polyvinyl chloride (PVC) or polytetrafluoroethylene
(TEFLON).
In some implementations, the PVC or TEFLON can act as a barrier to reduce the
frictional
impact on the cable, while the flanges 108 are used to support the weight of
the cable reel.
As it should be appreciated, other materials, including non-polymers or
plastic, may be used
and are considered to be within the scope of the present disclosure.
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FIGURE 4B is an alternate shield configuration for the cable reel 100.
Illustrated in
FIGURE 4B are flanges 108 rotatably mounted onto the axle 104. Rotatably
mounted onto
the axle 104 is the drum 402. As discussed above in regard to FIGURE 4A, when
a drum,
such as the drum 402, is rotated about the axle 104 while the flanges 108
remain stationary,
cable on the drum 402 can come in contact with the flanges 108. To reduce or
eliminate the
impact caused by the rotation of the drum 402, the drum 402 has drum flanges
408A and
408B. In one implementation, the drum flanges 408A and 408B are fixedly
mounted onto the
drum 402. In this implementation, when the drum 402 is rotated about the axle
104, the drum
flanges 408A and 408B also rotate at the same speed and in the same direction
as the drum
402. Thus, during installation or during payoff, damage or deformation that
may be caused
by frictional forces may be reduced. It should be appreciated that the drum
flanges 408A and
408B and the drum 402 may be one unit or may be an integrated apparatus.
FIGURE 5 is an illustrative bearing 500 that may be used for the bearings 110A
and
110B, illustrated by way of example in FIGURE 1. The bearing 500 may include a
flange
bearing 502 with an inner surface disposed proximate to and in contact with
the outer surface
of an axle, such as the axle 104 of FIGURE 1. In some implementations, the
contact may be
secured based on the physical dimensions of the flange bearing 502 and the
axle 104. For
example, the inner diameter of the flange bearing 502 may be just large enough
to allow
placement of the bearing 500 over the surface of the axle 104.
In some configurations, the inner diameter of the flange bearing 502 may be so
close
to the outer diameter of the axle 104 that special means may be used to
install the flange
bearing 502 on the axle 104. For example, the flange bearing 502 may be heated
to cause the
flange bearing to expand, thus allowing the flange bearing 502 to be placed
onto the axle 104.
In the alternative, the axle 104 may be cooled to cause the axle 104 to
contract. In some
implementations, the flange bearing 502 may be forced onto the axle by means
of a striking
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motion, such as from a hammer or other tool. In other configurations, the
flange bearing 502
may be fixedly installed onto the axle 104 using adhesives or welding. The
concepts and
technologies described herein are not limited to any particular manner in
which the flange
bearings 502 are installed onto the axle.
In a similar manner, a flange bearing spacer 504 may be installed on the
flange
bearing 502. In some configurations, the flanges, such as the flanges 108, may
not have an
inner diameter close to the outer diameter of the flange bearings 502. In this
configuration,
the flange bearing spacer 504 may be installed between the inner surface of
the flanges 108 to
which the flange bearings 502 are to be installed and the flange bearings 502
themselves. It
should be appreciated that the disclosure provided herein is not limited to
the type of bearing
described as the flange bearings 502 or the need to include the flange bearing
spacer 504.
FIGURE 6 is a side view of a cable reel 600 using an alternative bearing
arrangement.
Illustrated in FIGURE 6 are flanges 608A and 608B installed on an axle 604.
The cable reel
600 also includes a drum 602 rotatably mounted onto the axle 604. The
rotational motion of
the drum 602 about the axle 604 is provided by bearings 610A and 610B
(collectively
referred to herein as "the bearings 610"). The bearings 610 are disposed in
the drum 602
rather than in the flanges 608A and 608B, illustrated by way of example in
FIGURE 1,
above. Specifically, in FIGURE 1, the bearings 110 are vertically supported by
the flanges
108, whereas in FIGURE 2, the bearings 610 are vertically supported by the
drum 602. This
configuration may provide for various benefits. For example, the bearings 610
of FIGURE 6
are disposed within the cable reel 600, whereas the bearings 110 of FIGURE 1
are disposed
in the flanges 108. This may help to protect the bearings 610 from damage
caused by outside
forces.
FIGURE 7 is an illustration showing the transportation of a cable reel 700 on
a flatbed
742 of a truck (not illustrated). As illustrated, a cable reel 700 includes
flanges 708A and
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708B rotatably mounted onto an axle 704 having an inner void 730. During
transport, it may
be desirable or required to secure the cable reel 700 to the flatbed 742. In
one configuration,
the cable reel 700 axle 704 has an inner aperture 730 running the length of
the axle 704. The
inner aperture 730 may be large enough to allow a chain 744 to be installed
through the inner
aperture 730. In some implementations, the chain 744 has a length to allow for
the chain 744
to be installed through the axle 704 and have its ends 746A and 746B secured
to securement
points 748A and 748B of the flatbed 742. In this implementation, by securing
the cable reel
700 to the flatbed 742 using the chain 744, the cable reel 700 may be
transported from one
location to the next in a safe and legal manner.
FIGURES 8A-8C show further configurations for the cable reel 100, according to
an
exemplary embodiment. Illustrated in FIGURE 8A are the flanges 108 rotatably
mounted
onto opposing, distal ends of the axle 104. As discussed above, a drum, such
as the drum
402, may be rotatably mounted onto the axle 104 such that the drum rotates
independent of
the axle as illustrated in FIG. 2A, or the drum may be fixedly mounted to the
axle such that
the drum rotates along with the axle as the axle rotates as illustrated in
FIG. 2B. As discussed
above in regard to FIGURE 4A, when a drum, such as the drum 402, is rotated,
whether that
rotation is independent of the axle 104 or along with the axle, while the
flanges 108 remain
stationary, cable on the drum 402 can come in contact with the flanges 108. To
reduce or
eliminate the impact caused by the rotation of the drum 402, the drum 402 has
drum flanges
408A and 408B. Consistent with embodiments, the drum flanges 408A and 408B are
fixedly
mounted onto the drum 402. In this embodiment, when the drum 402 is rotated,
according to
some embodiments independently of the axle 104 or according to other
embodiments along
with the axle 104, the drum flanges 408A and 408B also rotate at the same
speed and in the
same direction as the drum 402. Thus, during installation or during payoff,
damage or
deformation that may be caused by frictional forces may be reduced. In
addition, when the
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flanges 108 are rotated (e.g., during transport of the cable reel 100), the
drum 402 may not
rotate or rotate very little since the flanges 108 and the drum rotate
independently of one
another. The lack of rotation the drum 402 exhibits when the flanges 108 are
rotated may
ease transportation due to a lack of rotational inertia exhibited by the drum
402. In other
words, moving the cable reel 100 may be easier because when a user tries to
stop the cable
reel 100, rotational inertia of the drum 402 will not be as great, and the
user will only need to
break the linear inertia exhibited by the drum as opposed to both the linear
inertia and the
rotational inertia. It should be appreciated that the drum flanges 408A and
408B and the
drum 402 may be one unit or may be an integrated apparatus.
In addition, to reduce friction and possible binding between the flanges 108
and the
flanges 408A and 408B, a first space 802 (shown in FIGURE 8B) may be created
between
the flange 108A and the flange 408A as well as between the flange 108B and the
flange
408B. Although only the configuration of the flange 108A, the flange 408A, and
the first
space 802 is illustrated in FIGS. 8B and 8C and discussed below, it should be
understood that
the configuration of the flange 108B, the flange 408B, and the first space 802
of the cable
reel 100 is the same, according to an exemplary embodiment. The first space
802 may be
sized to reduce the need for grease or other lubricants between the flanges
108 and the
flanges 408A and 408B. In addition, the first space 802 may be sized to
prohibit insertion of
a thumb, finger, or other limb of a user between the flange 108A and the
flange 408A.
However, the first space 802 may collect dirt and other debris during use. To
help minimize
dirt and debris accumulation within the first space 802, the flanges 108 may
include a lip 804
as shown in FIGURE 8B. The lip 804 may be a separate piece of material that is
attached to
the flanges 108 and can be removed. Having the lip 804 be removable may assist
in
replacing the lip 804 due to excessive wear. In addition, removing the lip 804
may assist in
regular maintenance by allowing service personal to access the first space 802
for cleaning
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and lubricating without having to disassemble the cable reel 100 or completely
remove the
flanges 108. Accordingly to further embodiments, the flanges 108 and the lip
may be one
unit.
As shown in FIGURE 8B, the lip 804 may extend from the flange 108A and be
flush
with a side 806 of the flange 408A. Consistent with embodiments, the lip 804
may extend
past an edge 808 of the flange 108A and thus past the side 806 of the flange
408A, or the lip
may extend only partially across the edge 808 of the flange 408A. The
extension of the lip
804 may create a second space 810 between the lip 804 and the edge 808 of the
flange 408A.
The second space 810 may be sized to be large enough to reduce the need for
grease or other
lubricants between the flanges 108 and 408. However, the second space 810 may
also be
small enough such that debris and other materials that may increase friction
between the
flanges 408 and the flanges 108 cannot easily enter and collect within the
second space 810.
In addition, the second space 810 may be sized to prohibit insertion of a
thumb, finger, or
other limb of a user between the flange 108A and the edge 808 of the flange
408A. For
example, the second space 810 may be large enough not to cause binding, yet
small enough
to prevent small rocks, wood chips, other construction type debris, or limbs
of users from
entering or getting stuck. For example, in various embodiments, the second
space may
provide for 1/4 of an inch clearance between the flange 108A and the flange
408A.
Furthermore, as shown in FIGURE 8C, the lip 804 may include an angled surface
812 to help
minimize debris collecting within the second space 810.
As shown in FIGURE 8C, a protective cover 812 may be attached to either the
flange
108A or the flange 408A to provide a physical barrier to hinder debris from
entering the
second space 810. The protective cover 812 may be a plastic, metallic, or
ceramic material.
If the protective cover 812 is attached to the flange 108A (e.g., at a side
814 of the lip 804), a
portion of the protective cover 812 overlapping the flange 408A may rest
against a portion of
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the side 806 of the flange 408A or may overlap the portion of the side 806 of
the flange 408A
and be positioned proximate the portion of the side 806 of the flange 408A
without resting
against the portion of the side 806 of the flange 408A. If the protective
cover 812 is attached
to the flange 408A (e.g., at the side 806 of the flange 408A), a portion of
the protective cover
812 overlapping the lip 804 may rest against a portion of the side 814 of the
lip 804 or may
overlap the portion of the side 814 of the lip 804 and be positioned proximate
the portion of
the side 814 of the lip 804 without resting against the portion of the side
814 of the lip 804.
The first space 802 and the second space 810 may create equal spacing between
the
flange 408A and the flange 108A, or the spacings created by the first space
802 and the
second space 810 may be different. According to exemplary embodiments, for
instance, the
first space 802 may provide for a distance of 1/4 of an inch between the
flange 408A and the
flange 108A, and the second space 810 may provide for a distance of 1/4 of an
inch between
the flange 408A and the flange 108A.
FIGURE 9 shows a further configuration of the cable reel 100, according to an
exemplary embodiment. As shown in FIGURE 9, the cable reel 100 includes an
over-spin
control 902 and a brake disc 904. As illustrated in FIGURE 9, the flanges 108
are rotatably
mounted onto the axle 104. As discussed above, a drum, such as the drum 402,
may be
rotatably mounted onto the axle 104 such that the drum rotates independent of
the axle as
illustrated in FIG. 2A, or the drum may be fixedly mounted to the axle such
that the drum
rotates along with the axle as the axle rotates, as illustrated in FIG. 2B. As
discussed above
in regard to FIGURE 4A, the flanges 108 of the cable reel 100 remain
stationary while the
drum 402 rotates, whether the rotation of the drum is independent of the axle
104 or along
with the axle. However, at times, such as when cable, like the cable 105, is
loaded on the
drum 402, it may be desirable to have the drum 402 locked to at least one of
the flanges 108
(e.g., the flange 108A as shown in FIGURE 9). The over-spin control 902 in
conjunction
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with the brake disc 904 may be used to lock the flange 108A and the drum 402
together to
hinder separate rotation of the flanges 108 and the drum 402. In addition, the
over-spin
control 902 may provide resistance such that the flanges 108 rotate
independent of the drum
402, but with a back tension to prevent excess slack from developing within a
cable, such as
the cable 105, when the cable is being paid off the cable reel 100.
FIGURE 10 illustrates further details of the over-spin control 902 of FIGURE
9,
according to an exemplary embodiment. The over-spin control 902 includes a
brake pad
1002, a threaded shaft 1004, a locking nut 1006, a fixed nut 1008, an over-
spin control body
1010, a spring 1012, and a piston 1014. The piston 1014 may be connected to
the brake pad
1002 via a bolt 1016. As shown in FIGURE 9, the over-spin control 902 is
located, at least
partially, within the drum 402. The over-spin control 902 may be connected to
the flange
108A. For example, the threaded shaft 1004 may protrude through the flange
108A, and a
portion of the flange 108A may be sandwiched between the over-spin control
body 1010 and
the fixed nut 1008. To secure the over-spin control 902 in a desired position,
the user may
cinch the locking nut 1006 to the fixed nut 1008 to prevent rotation of the
threaded shaft
1004. Still consistent with embodiments, the portion of the flange 108A may be
sandwiched
between the fixed nut 1008 and the locking nut 1006. In this instance,
friction between the
threaded shaft 1004 and the fixed nut 1008 and the locking nut 1006 may be
sufficient to
secure the over-spin control 902.
During use of the cable reel 100, the flanges 108 may rotate freely of the
drum 402.
To engage the over-spin control 902 and sync rotation of the flanges 108 and
the drum 402,
or increase the back tension and allow the flanges 108 to continue to rotate
independently of
the drum 402, a user may rotate the threaded shaft 1004 in a first direction.
Rotation of the
threaded shaft 1004 in the first direction causes the threaded shaft 1004 to
apply a force to the
spring 1012, which in turn applies a force to the piston 1014, which in turn
presses the brake
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pad 1002 against the brake disc 904 resulting in an increased coefficient of
static friction. To
rotate the threaded shaft 1004, the user may use a wrench or a knob (not
shown) attached to
the end of the threaded shaft 1004.
To release the pressure exerted by the brake pad 1002 on the brake disc 904,
and thus
decrease the back tension, the threaded shaft 1004 may be rotated in a second
direction.
Rotation of the threaded shaft 1004 in the second direction causes the force
applied to the
spring 1012 by the threaded shaft 1004 to decrease, which in turn causes the
force applied to
the piston 1014 by the spring 1012 to decrease, which in turn causes the force
applied by the
piston 1014 to the brake pad 1002 to decrease resulting in a decreased
coefficient of static
friction. Consistent with the embodiments, the threaded shaft 1004 may be
connected
directly to the piston 1014 or the brake pad 1002. Still consistent with
embodiments, the
spring 1012 may be connected directly to the brake pad 1002.
FIGURES 11A and 11B show a scotch 1100, according to an exemplary embodiment.
The scotch 1100 may be used to hinder rotation of the flanges 108. For clarity
purposes only,
the flange 108B is shown, but the scotch 1100 may be located on the flange
108A, the flange
108B, or both of the flanges 108.
The scotch 1100 may be connected to the axle 104. The scotch 1100 may include
an
opening 1102 that allows the scotch 1100 to traverse the axle 1004 in a first
direction,
indicated by an arrow 1110, perpendicular to an axis of the axle 104 and in a
second
direction, indicated by an arrow 1114, perpendicular to the axis of the axle
and opposite the
first direction. In addition, the scotch 1100 may include stoppers 1104 and a
handle 1106.
The stoppers 1104 may protrude into pockets 1108 as shown in FIGURE 11A or
other
recesses (not shown) in the flange 108B
While the cable reel 100 is being rotated, the stoppers 1104 may rest in the
pockets
1108 attached to the flange 108B, as shown in FIGURE 11A. Once the cable reel
100 is in a
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desired location, a user may pull the handle 1106, which may cause the scotch
1100 to flex.
The flexing motion allows the stoppers 1104 to clear the pockets 1108. Once
the stoppers
1104 have cleared the pockets 1108, the scotch may traverse in the first
direction (as
indicated by the arrow 1110) until the stoppers 1104 clear the edge of the
flange 108B. As
shown in FIGURE 11B, after the stoppers 1104 have cleared the edge of the
flange 108B, the
scotch 1100 may return to an unflexed state and the stoppers 1104 may rest
between the edge
of the flanges 108B and a surface (not shown) supporting the cable reel 100
and provide an
obstacle to prevent the flange 108B from rotating. The stoppers 1104 may be
returned to the
pockets 1108 by moving the scotch 1100 in the second direction (as indicated
by the arrow
1114) when the cable reel 100 needs to be rotated to be transported to a new
location or
otherwise repositioned.
The scotch 1100 may be constructed of a metal, polymer, or other material that
may
allow the scotch 1100 to flex such that the stoppers 1104 can be deployed. As
shown in
FIGURE 11A, the scotch 1100 may include curved portions 1112 that may
facilitate flexing
the scotch 1100 during use. In addition, a hinge 1116 (shown in FIGURE 11B) or
other
mechanisms may be used to allow the scotch 1100 to bend and not cause binding
between the
axle 104 and the opening 1102. For example, the hinge 1116 may be placed
proximate the
curved portions 1112. The scotch 1100 may be made up of an upper half 1120 and
a lower
half 1122. The hinge 1116 may allow the lower half 1122 to be pulled away from
the flange
108B so that the upper half 1120 of the scotch 1100 may traverse the axle 104
without
binding.
While FIGURES 11A and 11B show the scotch 1100 mechanically fastened to the
axle 104, still consistent with embodiments, the scotch 1100 may comprise
magnetic
fasteners that may facilitate securing the scotch 1100 to the cable reel 100,
while still
allowing the scotch 1100 to be repositioned. For example, magnets (not shown)
may be
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=
attached or embedded within stoppers 1104. The magnets may allow the stoppers
1104 to
adhere to a side of the flange 108B for storage. During deployment of the
scotch 1100, the
stoppers 1104 may be removed from the pockets 1108 and placed in a desired
position.
FIGURE 12 shows a bearing assembly 1200, according to an exemplary embodiment.
The bearing assembly 1200 includes a first bearing 1202 and a second bearing
1204. The
first bearing 1202 and the second bearing 1204 each includes a plurality of
rollers 1206 and
1208, respectively.
The first bearing 1202 and the second bearing 1204 may be press fitted into a
flange,
such as the flange 108B. Although FIG. 12 illustrates a bearing assembly 1200
in association
with the flange 108B, it should be understood that a second bearing assembly
comprising the
same configuration may be used in association with the flange 108A. The axle
104 passes
through the first bearing 1202 and the second bearing 1204. A collar 1210 is
used to secure
the flange 108B to the axle 104. The collar 1210 may screw onto a treaded
portion of the
axle 104, be press fitted onto the axle 104, or may be bolted to the axle 104.
During
construction of the cable reel 100, the first bearing 1202 and the second
bearing 1204 may
slide over the axle 104. Due to possible imperfections within the first
bearing 1202 and the
second bearing 1204, the flange 108B may not have a tight fit with regards to
the axle 104.
In other words, the flange 108B may wobble on the axle 104 due to slack in the
first bearing
1202 and the second bearing 1204. To remove the slack, the collar 1210 may
press against
the first bearing 1202, which may in turn press against the second bearing
1204. The
increased pressure may cause the slack in the first and second bearings 1202,
1204 to
diminish. In addition, when use of the first bearing 1202 and the second
bearing 1204 causes
wear, the collar 1210 may be readjusted to remove any slack that develops.
As illustrated by FIGURE 12, the plurality of rollers 1206 and 1208 may be at
an
angle that is not parallel or perpendicular to the axle 104. For example, the
first bearing 1202
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and the second bearing 1204 may be tapered bearings. Having the plurality of
rollers 1206
and 1208 at angles allows the first bearing 1202 and the second bearing 1204
to
accommodate both radial and axial loads. As a result, use of tapered bearings,
such as the
first and second bearings 1202 and 1204, may allow the cable reel 100 to be
constructed
without having to have separate bearings to accommodate both radial and axial
loads. Grease
or other lubricants may be packed into the first bearing 1202 and the second
bearing 1204 to
decrease wear and reduce rolling resistance.
FIGURE 13 shows a wire guide assembly 1300 attached to the cable reel 100,
according to an exemplary embodiment. The wire guide assembly 1300 includes a
first
support 1302, a second support 1304, a cross-bar 1306, and a wire guide 1308.
The first
support 1302 and the second support 1304 are attached to the flanges 108A and
108B,
respectively, as shown in greater detail with regards to the first support and
the flange 108B
in FIGURE 14. During use, the drum 402 may rotate while the flanges 108A and
108B
remain stationary. As the drum 402 rotates, cable, such as the cable 105 (not
shown in
FIGURE 13), may pass through the wire guide 1308. In addition, during
operation, the wire
guide 1308 may oscillate as shown by arrow 1310 to help accommodate placement
of the
cable 105. The oscillation of the wire guide 1308 may be caused by a force
acting on the
wire guide 1308 by the cable. For example, as the cable passes through the
wire guide 1308,
the cable may strike a portion of the wire guide 1308 and cause the wire guide
to move as
indicated by arrow 1310. The movement of the wire guide 1308 by forces
impacted from the
cable may allow the wire guide 1308 to self-center around the wire guide 1308.
Still
consistent with various embodiments, the wire guide 1308 may have a fixed
position on the
cross-bar 1306. For instance, the wire guide 1308 may be fixed in the center
of the cross-bar
1306.
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FIGURE 14 shows the first support 1302 attached to the flange 108A, according
to an
exemplary embodiment. The first support 1302 includes a plate 1402, a clamp
1404, and a
cross-bar support 1406. During installation, the plate 1402 rests against a
portion of the
flange 108A, and a crank 1408 is used to tighten the clamp 1404 thereby
securing the first
support 1302 to the flange 108A. The cross-bar support 1406 extends from the
plate 1402
and connects the cross-bar 1306 to the first support 1302. For example, the
cross-bar 1306
may be bolted to the cross-bar support 1406 or may fit through an orifice (not
shown) in the
cross-bar support 1406.
FIGURE 15 shows a connector assembly 1500, according to an exemplary
embodiment. The connector assembly 1500 includes a body 1502, a panel
connection 1504,
and a wire guide assembly connector 1506. During use, the wire guide assembly
connector
1506 may pass through a bracket 1508 located on the wire guide assembly 1300.
The wire
guide assembly connector 1506 may be secured to the bracket 1508 using a pin
(not shown)
and a plurality of holes 1510 located in the wire guide assembly connector
1506. The panel
connection 1504 connects to an electrical panel 1512. During use, the
connector assembly
1500 helps to secure the cable reel 100 into position and keep the cable reel
100 from moving
when the cable 105 is paid off the cable reel 100. The cable 105 may pass
through the wire
guide 1308 and over a roller 1514 before passing through the panel connector
1506. Once
the cable 105 passes through the panel connector 1506, the cable 105 goes to
the panel 1512.
Exemplary embodiments of the cable reels, such as the cable reel 100,
disclosed
herein exhibit various characteristics that are an improvement over existing
cable reels.
FIGURE 16 shows a graph illustrating an average force needed to cause a cable
reel, such as
the cable reel 100, to rotate from a stationary position through an angle of
90 for various
configurations in comparison to an average force needed to cause an existing
cable reel to
rotate from a stationary position through an angle of 90 . One configuration
includes an
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empty cable reel. An empty cable reel, as used herein, is a cable reel, such
as the cable reel
100, with no wire or cable loaded onto the cable reel. A second configuration
is a full cable
reel. Examples of a full cable reel include, but are not limited to, a cable
reel, such as the
cable reel 100, having as much wire or cable as will fit on the cable reel, or
a cable reel
including an amount of wire or cable sold for a particular size reel. For
example, a 48 inch
cable reel may be sold with 2,500 feet of wire or cable installed. The 48 inch
cable reel with
2,500 feet of wire or cable as sold would be considered a full cable reel.
The data in FIGURE 16 is for cable reels, such as the cable reel 100, having a
drum,
such as the drum 402, of approximately 24 inches in diameter, flanges (e.g.,
flanges 108) of
approximately 48 inches in diameter, and a traverse dimension of approximately
26 inches.
The speed at which a cable reel is moved as well as the weight of the cable
reel can impact
the force required to move the cable reel. The weight of an empty cable reel,
according to
exemplary embodiments, for the data shown in FIGURE 16 is approximately 573
pounds.
The weight of a full cable reel, according to exemplary embodiments, for the
data shown in
FIGRURE 16 is approximately 2,339 pounds. The weight of an empty existing
cable reel for
the data shown in FIGURE 16 is approximately 282 pounds and the weight of a
full existing
cable reel for the data shown in FIGURE 16 is approximately 2081 pounds.
Table 1 shows a normalized average force needed to cause cable reels, such as
the
cable reel 100, to rotate from a stationary position through an angle of 90 .
The normalized
force is the force needed to cause motion of the cable reel divided by the
weight of the cable
reel. For example, for an empty cable reel according to exemplary embodiments,
the average
forced needed to cause an unassisted rotation of the flanges (e.g. flanges
108) from a
stationary position through 90 for a 573 pound cable reel is about 4.34
pounds. Thus, the
normalized average force needed to cause the unassisted rotation is 4.34 lbs
divided by 573
lbs, which equals 0.0075. An unassisted rotation is a rotation where no
machines or other
27
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equipment are used to rotate the drum or flanges of the cable reel. For
unassisted rotation, a
machine may be used to pull the wire or cable off the cable reel, but a
machine or cable reel
support may not be used to rotate the cable reel, the drum, or lift the cable
reel into the air.
FIGURE 16 and Table 1 show two full cable reel linear speeds, one being 10.5
feet
per minute (LS) and the second being 55 feet per minute (MS). The linear speed
is the speed
along the ground an axle, such as the axle 104, traverses as flanges, such as
the flanges 108,
rotate. The procedure for collecting data used to form FIGURE 16 and Table 1
is listed
below. As shown in Table 1, the normalized forces for cable reels, such as the
cable reel 100,
according to exemplary embodiments are reduced as compared to the normalized
forces for
existing cable reels.
Average Force
Empty Full (LS) Full (MS)
Cable
0.00757 0.00183 0.00333
Reel 100
Existing 0.01085 0.00458 0.00370
Table 1: Normalized Average Force
FIGURE 17 shows a graph showing an average maximum force needed to cause cable
reels, such as the cable reel 100, to rotate from a stationary position
through an angle of 90
for various configurations. One configuration includes an empty cable reel, or
a cable reel
with no wire or cable loaded onto the cable reel. A second configuration is a
full cable reel.
The data in FIGURE 17 is for cable reels, such as the cable reel 100, having a
drum
402 of approximately 24 inches in diameter, flanges (e.g., flanges 108) of
approximately 48
inches in diameter, and a traverse dimension of approximately 26 inches. Just
as with the
average force, the speed at which a cable reel is moved as well as the weight
of the cable reel
can impact the maximum force required to move the cable reel. The weight of an
empty
cable reel, according to exemplary embodiments, for the data shown in FIGURE
17 is
approximately 573 pounds. The weight of a full cable reel, according to
exemplary
embodiments, for the data shown in FIGRURE 17 is approximately 2,339 pounds.
The
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weight of an empty existing cable reel for the data shown in FIGURE 17 is
approximately
282 pounds and the weight of a full existing cable reel for the data shown in
FIGURE 17 is
approximately 2081 pounds.
Just as in Table 1, Table 2 shows normalized forces, (i.e., average maximum
forces
for multiple tests) needed to cause cable reels to rotate from a stationary
position through an
angle of 900. The normalized maximum force is the force needed to cause motion
of the
cable reel divided by the weight of the cable reel. For example, for an empty
cable reel
according to exemplary embodiments, the maximum average force needed to cause
an
unassisted rotation of the flanges (e.g. flanges 108) from a stationary
position through an
angle of 90 for a 573 pound cable reel is about 10.92 pounds. Thus, the
normalized
maximum average force needed to cause the unassisted rotation is 10.92 lbs
divided by 573
lbs, which equals 0.019.
FIGURE 17 and Table 2 also show two full cable reel linear speeds, one being
10.5
feet per minute (LS) and the second being 55 feet per minute (MS). The linear
speed is the
speed along the ground an axle, such as the axle 104, traverses as flanges,
such as the flanges
108, rotate. The procedure for collecting data used to form FIGURE 17 and
Table 2 is listed
below.
Max Force - Average
Empty Full (LS) Full (MS)
Cable
0.01906 0.00845 0.02121
Reel 100
Existing 0.02752 0.01643 0.01228
Table 2: Normalized Average Maximum Force
FIGURE 18 shows a graph showing a maximum point force needed to cause cable
reels, such as the cable reel 100, to rotate from a stationary position
through 90 for various
configurations. The maximum point force is the maximum force experienced
during a test.
One configuration includes an empty cable reel, or a cable reel with no wire
or cable loaded
onto the cable reel. A second configuration is a full cable reel.
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CA 02911286 2015-11-03
The data in FIGURE 18 is for cable reels having a drum, such as the drum 402,
of
approximately 24 inches in diameter, flanges (e.g., flanges 108) of
approximately 48 inches
in diameter, and a traverse dimension of approximately 26 inches. Just as with
the average
force, the speed at which a cable reel is moved as well as the weight of the
cable reel can
impact the maximum force required to move the cable reel. The weight of an
empty cable
reel according to exemplary embodiments for the data shown in FIGURE 18 is
approximately
573 pounds. The weight of a full cable reel according to exemplary embodiments
for the data
shown in FIGURE 18 is approximately 2,339 pounds. The weight of an empty
existing cable
reel for the data shown in FIGURE 18 is approximately 282 pounds and the
weight of a full
existing cable reel for the data shown in FIGURE 18 is approximately 2081
pounds.
Just as in Tables 1 and 2, Table 3 shows normalized forces (i.e., maximum
forces
exhibited for multiple tests) needed to cause cable reels to rotate from a
stationary position
through an angle of 90 . The normalized maximum point force is the force
needed to cause
motion of the cable reel divided by the weight of the cable reel. For example,
for an empty
cable reel according to exemplary embodiments, the maximum point force needed
to cause an
unassisted rotation of the flanges (e.g. flanges 108) from a stationary
position through 90 for
a 573 pound cable reel is about 13.00 pounds. Thus, the normalized maximum
point force
needed to cause the unassisted rotation is 13.00 lbs divided by 573 lbs, which
equals 0.022.
FIGURE 18 and Table 3 also show two full cable reel linear speeds, one being
10.5
feet per minute (LS) and the second being 55 feet per minute (MS). The linear
speed is the
speed along the ground the axle, such as the axle 104, traverses as the
flanges, such as the
flanges 108, rotate. The procedure for collecting data used to form FIGURE 18
and Table 3
is listed below.
CA 02911286 2015-11-03
Max Force - Point
Empty Full (LS) Full (MS)
Cable
0.02269 0.01167 0.02334
Reel 100
Existing 0.03404 0.01812 0.01720
Table 3: Normalized Maximum Force
FIGURE 19 shows a graph showing a standard deviation for a force needed to
cause
cable reels, such as the cable reel 100, to rotate from a stationary position
through an angle of
90 for various configurations. One configuration includes an empty cable
reel, or a cable
reel with no wire or cable loaded onto the cable reel. A second configuration
is a full cable
reel.
The data in FIGURE 19 is for cable reels having a drum, such as the drum 402,
of
approximately 24 inches in diameter, flanges (e.g., flanges 108) of
approximately 48 inches
in diameter, and a traverse dimension of approximately 26 inches. Just as with
the average
force, the speed at which a cable reel is moved as well as the weight of the
cable reel can
impact the standard deviations. The weight of an empty cable reel according to
exemplary
embodiments for the data shown in FIGURE 19 is approximately 573 pounds. The
weight of
a full cable reel according to exemplary embodiments for the data shown in
FIGRURE 19 is
approximately 2,339 pounds. The weight of an empty existing cable reel for the
data shown
in FIGURE 19 is approximately 282 pounds and the weight of a full existing
cable reel for
the data shown in FIGURE 19 is approximately 2081 pounds.
Table 4 shows a normalized data during unassisted rotations from a stationary
position through an angle of 90 . The normalized data is the standard
deviation divided by
the weight of the cable reel. For example, for an empty cable reel according
to exemplary
embodiments, the standard deviation during rotation of the flanges (e.g.
flanges 108) from a
stationary position through 90 for a 573 pound cable reel is about 2.58
pounds. Thus, the
normalized standard deviation during rotation is 2.58 lbs divided by 573 lbs,
which equals
0.0045.
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FIGURE 19 and Table 4 also show two full cable reel linear speeds, one being
10.5
feet per minute (LS) and the second being 55 feet per minute (MS). The linear
speed is the
speed along the ground the axle traverses as the flanges rotate. The procedure
for collecting
data used to form FIGURE 19 and Table 4 is listed below.
Standard Deviation
Empty Full (LS) Full (MS)
Cable
0.00450 0.00170 0.00548
Reel 100
Existing 0.00638 0.00370 0.00344
Table 4: Normalized Standard Deviation
FIGURE 20 shows a diagram for the procedure for acquiring the data shown in
FIGURES 16-19. The procedure includes acquiring a cable reel, such as the
cable reel 100,
with a desired amount of wire or cable to be tested. For example, an empty
cable reel might
be selected or a full cable reel might be selected. A force gauge 2002 is
connected to a puller
2004 and aligned with the center of the cable reel 100. The force gauge 2002
can be
connected to a rope or other cable 2006 that is connected to the cable reel
100. For example,
a block (e.g., a 2X4 piece of lumber) may be attached to the cable reel 100
via the flanges
108, and the rope or other cable 2006 may be connected to the block.
The rope or other cable 2006 is connected at a 0 angle as shown in FIGURE 20.
After
everything is connected, the puller 2004 pulls the rope or other cable 2006 at
a constant speed
(e.g., 10.5 feet per minute or 55 feet per minute), and the force is recorded
via the force gauge
2002. Data is recorded as the cable reel 100 rotates until the end of the rope
or cable 2006
attached to the cable reel 100 has traveled 90 as shown by arrow 2008. During
the testing, the
axle 402 of the cable reel 100 may travel in a linear direction at a linear
speed as shown by
arrow 2012. During testing, a surface 2010 on which the cable reel 100 rolls
should be smooth
and approximately level.
FIGURE 21 shows a graph showing an average force needed to pay off 241 inches
of
cable (e.g., SOUTHWIRE 550-37 compressed cable) from a full cable reel. A
forklift
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CA 02911286 2015-11-03
connected to a free end of the cable is used to pull 241 inches of cable from
the full cable
reel. The forklift is set at the minimum speed for the forklift (10.5 feet per
minute). The data
in FIGURE 21 is for cable reels having a drum of approximately 24 inches in
diameter,
flanges (e.g., flanges 108) of approximately 48 inches in diameter, and a
traverse dimension
of approximately 26 inches. The weight of an empty cable reel according to
exemplary
embodiments for the data shown in FIGURE 21 is approximately 573 pounds. The
weight of
a full cable reel according to exemplary embodiments for the data shown in
FIGRURE 21 is
approximately 2,339 pounds. The weight of an empty existing cable reel for the
data shown
in FIGURE 21 is approximately 282 pounds and the weight of a full existing
cable reel for
the data shown in FIGURE 21 is approximately 2081 pounds.
As shown in FIGURE 21, cable reels, such as the cable reel 100, according to
exemplary embodiments experience a dramatic decrease in overall force required
to pull wire
or cable from the drum. Existing cable reels required on average of 88.28
pounds of force to
pull 241 inches of cable, whereas cable reels, such as the cable reel 100,
required on average
of only 13.85 pounds of force to pull 241 inches of cable. In other words,
existing cable reels
require about 630 percent more force to pull the same length of cable. Figure
22 shows the
standard deviation for overall forces needed to pull cable from a cable reel.
As shown in
FIGURE 22, the standard deviation for cable reels according to exemplary
embodiments is
substantially less than the standard deviation for existing cable reels. This
difference, in
conjunction with the data shown in at least FIGURES 21 and 23 (described
below), provides
confidence that cable reels, such as the cable reel 100, according to
exemplary embodiments
are far easier to use than existing cable reels.
FIGURE 23 shows a graph showing maximum forces needed to pay off 241 inches of
cable (e.g., SOUTHWIRE 550-37 compressed cable) from a full cable reel. A
forklift
connected to a free end of the cable is used to pull 241 inches of cable from
the full cable
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CA 02911286 2015-11-03
reel. The forklift is set at the minimum speed for the forklift (10.5 feet per
minute). The data
in FIGURE 23 is for cable reels having a drum of approximately 24 inches in
diameter,
flanges (e.g., flanges 108) of approximately 48 inches in diameter, and a
traverse dimension
of approximately 26 inches. The weight of an empty cable reel according to
exemplary
embodiments for the data shown in FIGURE 23 is approximately 573 pounds. The
weight of
a full cable reel according to exemplary embodiments for the data shown in
F1GRURE 23 is
approximately 2,339 pounds. The weight of an empty existing cable reel for the
data shown
in FIGURE 23 is approximately 282 pounds and the weight of a full existing
cable reel for
the data shown in FIGURE 23 is approximately 2081 pounds.
As shown in FIGURE 23, cable reels according to exemplary embodiments
experiences a dramatic decrease in overall force required to pull wire or
cable from the drum.
For example, existing cable reels required on average a maximum point force
(i.e., a highest
force during testing) of 123.1 pounds of force to pull 241 inches of cable,
whereas cable
reels, such as the cable reel 100, showed on average a maximum point force of
25.00 pounds
of force to pull 241 inches of cable. In other words, existing cable reels
require about 492
percent more force pull the same length of cable. Existing drums required an
average
maximum force (i.e., average maximum forces exhibited during testing) of
120.68 pounds of
force to pull 241 inches of cable whereas cable reels according to exemplary
embodiments
required an average maximum force of 23.68 pounds of force to pull 241 inches
of cable. In
other words, existing cable reels require about 509 percent more force pull
the same length of
cable.
Table 5 shows normalized data for the data shown in FIGURES 21-23. The
normalized data is various forces or the standard deviation divided by the
weight of the cable
reel. For example, for a full cable reel according to exemplary embodiments,
the average
forced needed to cause rotation of the drum to pay off 241 feet of cable for a
2339 pound
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CA 02911286 2015-11-03
cable reel is about 13.85 pounds. Thus, the normalized average force needed to
cause the
unassisted rotation is 13.85 lbs divided by 2339 lbs, which equals 0.0059. As
shown in Table
5, existing cable reels, as compared to cable reels according to exemplary
embodiments,
require increases in normalized pulling forces ranging from about 550 percent
to over 700
percent. The increase in normalized standard deviation is about 325 percent.
Max Max
Average STD
(Average) (Point)
Cable
0.00592 0.01012 0.01069 0.00209
Reel 100
Existing 0.04242 0.05799 0.05915 0.00682
Table 5: Normalized Wire Pull Data
The subject matter described above is provided by way of illustration only and
should
not be construed as limiting. Values disclosed may be at least the value
listed. Values may
also be at most the value listed. Various modifications and changes may be
made to the
subject matter described herein without following the example embodiments and
applications
illustrated and described, and without departing from the true spirit and
scope of the claimed
subject matter, which is set forth in the following claims.
