Patent Grant
12319535
This application relates to U.S. patent application Ser. No. 17/220,164, filed Apr. 1, 2021, which is hereby incorporated by reference in its entirety.
The invention relates to cable winding machines generally and, more particularly, to a method and/or apparatus for implementing a reel take-up machine.
Because cable is generally purchased in bulk on large reels weighing as much as 20,000 pounds, it is generally necessary that cable handling equipment be capable of transferring the cable from a very large reel, as provided by the manufacturer, to a smaller reel which the end user can more easily transport for field applications and handle for use in manufacturing applications. This is particularly true where the cable is very large and bulky, such as copper electrical service cables installed in the field by electricians and electrical utilities.
It would be desirable to implement a reel take-up machine.
The invention concerns a reel take-up apparatus comprising a frame, a drive mechanism, a hydraulic counterbalance system, 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 hydraulic counterbalance system is generally configured to counterbalance a weight of the drive mechanism to allow the drive mechanism to float freely on the frame. The pair of positioning actuators may be configured to move a 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.
Embodiments of the invention will be apparent from the following detailed description and the appended claims and drawings.
Embodiments of the present invention include providing a reel take-up machine that may (i) allow a single operator to load and unload a reel, (ii) support a reel using flanges of the reel instead of an axle, (iii) allow a reel to be loaded from one side while the reel is sitting on a surface, (iv) lift a reel after being loaded for winding or unwinding, (v) be rolled up to a reel like a hand truck, and/or (vi) allow the operator to easily attach one or more cables to the reel in preparation for winding.
In various embodiments, a reel take-up apparatus is provided for handling a reel (or spool) having a barrel (or core) about which a wire or cable is wound and two flanges, one at each end of the barrel. The reel take-up apparatus generally includes a frame, a pair of roller assemblies, a drive mechanism, and a shaft that is connected at only one end. Each roller assembly is generally mounted to an elongated frame member. The roller assemblies are configured to be moved toward and away from one another. The shaft is connected at the one end to the drive mechanism for rotating the reel. An unconnected end of the shaft is configured to spear a center arbor hole of a reel. A roller of each roller assembly is rotatably supported at each end. The roller assemblies are arranged so that a rotational axis of each roller of each roller assembly is substantially parallel to one another and to a rotational axis of the reel. A positioning actuator (e.g., a scissor jack mechanism, etc.) may be coupled between each elongated frame member and each roller assembly. The positioning actuators are generally configured to move the rollers of each roller assembly toward and away from one another. By positioning the rollers adjacent to the flanges of the reel and then moving the rollers toward one another, the reel may be raised to an elevated position above the floor. The rollers allow the reel to be rotated by the drive mechanism.
Referring to
A right front caster 108a is generally attached to an end of the right bottom frame member 106a that is distal from the frame cross member 104. A left front caster 108b is generally attached to an end of the left bottom frame member 106b that is distal from the frame cross member 104. A right rear caster assembly 110a is generally attached to a second end of the right bottom frame member 106a adjacent to the frame cross member 104. A left rear caster assembly 110b (not visible) is generally attached to a second end of the left bottom frame member 106b adjacent to the frame cross member 104. The right rear caster assembly 110a and the left rear caster assembly 110b are generally configured as swivel casters to allow the reel take-up apparatus 100 to be easily maneuvered.
In various embodiments, the frame cross member 104, the right bottom frame 106a, and the left bottom frame member 106b are generally configured as non-moving structural components of a roller assembly of the reel take-up apparatus 100. In various embodiments, the roller assembly of the reel take-up apparatus 100 generally comprises the frame cross member 104, a right side roller sub-assembly, and a left side roller sub-assembly. The right side roller sub-assembly generally comprises the right bottom frame member 106a and a right push bar assembly 112a. The left side roller sub-assembly generally comprises the left bottom frame member 106b and a left push bar assembly 112b.
A first end of the right push bar assembly 112a and a first end of the left push bar assembly 112b are generally slidably attached to the frame cross member 104 by v-groove rollers 114. The right push bar assembly 112a generally extends away from the frame cross member 104 parallel with the right bottom frame member 106a. The left push bar assembly 112b generally extends away from the frame cross member 104 parallel with the left bottom frame member 106b. A second end of the right push bar assembly 112a that is distal from the frame cross member 104 is generally supported by a first swivel caster 116. Similarly, a second end of the left push bar assembly 112b that is distal from the frame cross member 104 is generally supported by a second swivel caster 116.
The right push bar assembly 112a is generally coupled to the right bottom frame member 106a by a positioning actuator assembly (e.g., a scissor jack mechanism, etc.). In an example, the positioning actuator assembly may comprise a hydraulic cylinder configured to move the right push bar assembly 112a relative to the right bottom frame member 106a. The positioning actuator assembly is generally configured, in a first mode, to move the right push bar assembly 112a away from the right bottom frame member 106a and, in a second mode, to move the right push bar assembly 112a toward the right bottom frame member 106a. The right push bar assembly 112a further comprises a roller 118a. The roller 118a is generally coupled to the right push bar assembly 112a such that an axis of the roller 118a is parallel to the right push bar assembly 112a.
The left push bar assembly 112b is generally coupled to the left bottom frame member 106b by a second positioning actuator assembly (e.g., a scissor jack mechanism, etc.). In an example, the second positioning actuator assembly may comprise a second hydraulic cylinder configured to move the left push bar assembly 112b relative to the left bottom frame member 106b. The positioning actuator assembly is generally configured, in a first mode, to move the left push bar assembly 112b away from the left bottom frame member 106b and, in a second mode, to move the left push bar assembly 112b toward the left bottom frame member 106b. The left push bar assembly 112b further comprises a roller 118b. The roller 118b is generally coupled to the left push bar assembly 112b such that an axis of the roller 118b is parallel to the left push bar assembly 112b.
In various embodiments, the reel take-up apparatus 100 generally further comprises a modular push handle assembly 120. The modular push handle assembly 120 generally provides a handle for use by an operator to maneuver the reel take-up apparatus 100 and encloses a drive mechanism that is slidably attached to the vertical frame member 102. The drive mechanism is further connected to a first end of a shaft 122. A second end of the shaft 122 is generally left unconnected and configured to be placed through a center arbor hole of a reel (not shown for clarity) upon which wire/cable is to be wound. The shaft 122 is generally further configured to allow the reel to be driven by the drive mechanism attached to the first end of the shaft 122.
In an example, a knuckle arm assembly 124 is attached (e.g., welded, splined, etc.) to the shaft 122 near the vertical frame member 102. The knuckle arm assembly 124 is generally configured to be coupled to a reel by a drive pin 126 (described below in connection with
In various embodiments, the reel take-up apparatus 100 further comprises a tool balancer 128. A frame 128a supporting the tool balancer 128 may be mounted at or near a top end of the vertical frame member 102. The tool balancer 128 is generally coupled to the drive mechanism slidably attached to the vertical frame member 102. The tool balancer 128 is generally configured to act as a counterbalance for the weight of the drive mechanism. The tool balancer 128 generally allows the drive mechanism to float freely on the vertical frame member 102, allowing the drive mechanism to move up and down as a reel attached to the reel take-up apparatus 100 moves up and down.
In various embodiments, the reel take-up apparatus 100 generally further comprises a hydraulic motor 130. The hydraulic motor 130 may be mounted at or near a rear right corner of the reel take-up apparatus 100. The hydraulic motor 130 is generally coupled to the positioning actuators of the right side and the left side roller sub-assemblies. The hydraulic motor 130 is generally configured to provide power to lift and lower the reel in a controlled manner.
In various embodiments, the reel take-up apparatus 100 may further comprise a slide wire traverse base (or wire traverse or carriage assembly or level wind) 132. In an example embodiment, the slide wire traverse base 132 may be mounted on a side of the left bottom frame member 106b opposite the left push bar assembly 112b. In an example, a wire handling assembly 134 is generally attached to the slide wire traverse base 132 by an extension arm 136. The slide wire traverse base 132 is generally configured to move the wire handling assembly 134 back and forth between flanges of a reel mounted on the reel take-up apparatus 100 to facilitate efficient winding of wire/cable on the barrel (or core) of the reel. In an example, the slide wire traverse base 132 may comprise a lead screw and square nut drive mechanism allowing the extension arm 136 to change direction as the wire/cable is being wound. In an example, the wire handling assembly 134 may comprise a wire clamp 140, a wire guide 142, and a wire measurement assembly 144. The slide wire traverse base 132, the extension arm 136, the wire clamp 140, the wire guide 142, the wire measurement assembly 144 may be implemented using conventional devices and/or techniques.
Referring to
When a reel is loaded onto the reel take-up apparatus 100, the modular push handle assembly 120, the enclosed drive mechanism, and the shaft 122 slide up the vertical frame member 102 as the reel is lifted off the floor by extension of the right and left push bar assemblies 112a and 112b away from the respective right and left bottom frame members 106a and 106b. In an example, the modular push handle assembly 120, the enclosed drive mechanism, and the shaft 122 are attached to a slide mount plate 148, which is slidably attached to the vertical frame member 102. In an example, the slide mount plate 148 may comprise four traverse bearings (e.g., one at each corner), which may be slidably attached to rail bearings on each vertical rail (or tube) of the vertical frame member 102. The four traverse bearings and two rail bearings generally allow the drive mechanism to float freely on the vertical frame member 102, allowing the bevel geared motor 160 to move up and down as a reel attached to the reel take-up apparatus 100 moves up and down. In an example embodiment, the right and left push bar assemblies 112a and 112b are extended away from the respective right and left bottom frame members 106a and 106b by expanding respective scissor jack mechanisms coupled (i) between the right push bar assembly 112a and the right bottom frame member 106a and (ii) between the left push bar assembly 112b and the left bottom frame member 106b. In an example embodiment, each scissor jack mechanism may comprise a hydraulic cylinder and eight spreader bars (described below in connection with
Referring to
When the reel 150 is loaded and locked onto the reel take-up apparatus 100, the right and left push bar assemblies 112a and 112b may be extended to force the respective rollers 118a and 118b under the flanges 156a and 156b of the reel 150. The reel 150 is lifted off a surface (e.g., a floor) by the rollers 118a and 118b moving under the flanges 156a and 156b. The rollers 118a and 118b generally support the flanges 156a and 156b of the reel 150 allowing the reel 150 to be driven (e.g., rotated) by the drive mechanism mounted on the vertical frame member 102. In various embodiments, the drive mechanism generally comprises a bevel geared motor 160. In an example, the bevel geared motor 160 generally comprises a motor and a gear box (hidden).
A detail A is shown highlighting an example embodiment of a positioning actuator assembly (e.g., a scissor jack mechanism) that may be coupled (i) between the right push bar assembly 112a and the right bottom frame member 106a and (ii) between the left push bar assembly 112b and the left bottom frame member 106b. In an example embodiment, each scissor jack mechanism may comprise eight spreader bars 162 and a hydraulic cylinder 164 (described below in connection with
Referring to
When the hydraulic cylinder 164 is extended, the eight spreader bars 162 are generally moved toward a perpendicular alignment that maximizes a separation between the left bottom frame member 106b and the left push bar assembly 112b. When the hydraulic cylinder 164 is contracted, the eight spreader bars 162 are moved toward forming acute angles with the left bottom frame member 106b and the left push bar assembly 112b, which minimizes the separation between the left bottom frame member 106b and the left push bar assembly 112b. The right bottom frame member 106a and the right push bar assembly 112a are similarly coupled and operated by another eight spreader bars 162 and another hydraulic cylinder 164.
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In general, the unconnected end of the shaft 122 is configured to go into (e.g., spear) the center arbor hole 152 of the reel 150. The shaft 122 is generally inserted into the center arbor hole 152 of the reel 150 until the flange 156b of the reel 150 (e.g., the flange nearest the vertical frame member 102) comes into contact with the knuckle arm assembly 124. The knuckle arm assembly 124 may then be attached to the reel 150 by passing the drive pin 126 through a hole in the knuckle arm assembly 124 and into one of the one or more drive holes 154 of the reel 150. The drive pin 126 is generally secured to the knuckle arm assembly 124 (e.g., using a cotter pin, etc.). The unconnected end of the shaft 122 is generally used to spear (or skewer) the reel 150. A locking collar 170 may then be placed on and fastened (e.g., using one or more set screws, etc.) to the unconnected end of the shaft 122 to lock the reel 150 onto the reel take-up apparatus 100. Instead of having to handle a separate shaft every time a reel is loaded as in traditional machines, the shaft 122 stays with the reel take-up apparatus 100 and is held in position at one end, while the unconnected end is used to spear the reel 150.
When the reel 150 is between the right roller sub-assembly and the left roller sub-assembly and the shaft 122 is extending past the flange 156a, which is more distal from the vertical frame member 102, the operator may assemble the knuckle arm 124 to the reel 150 such that drive pin 126 extends through the knuckle arm 124 toward the reel 150 and engages one of the one or more drive holes 154 in the flange 156b of the reel 150 (e.g., illustrated in
The rollers 118a and 118b generally support the flanges 156a and 156b of the reel 150 while the reel 150 is turned (rotated) by the drive mechanism using the knuckle arm 124 and the drive pin 126. The rollers 118a and 118b are generally constructed in terms of material strength and hardness to withstand significant loads associated with a fully laden reel 150. In an example, the fully laden reel 150 may weigh as much as 6,000 pounds. In an example, the reel take-up apparatus 100 may be configured to pull wire(s)/cable(s) with a force of as much as 20,000 pounds. In one example, the reel 150 may be forty-two inches wide and have a diameter of seventy-two inches. However, the reel take-up apparatus 100 may be scaled up or scaled down to accommodate larger or smaller, respectively, capacities.
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In general, a cable (or cables) may be attached to the reel 150 in several ways. Wooden reels 150 typically need cables to be stapled to a flange 156a or 156b, or to the core 158. Steel reels either have a securing hole (e.g., the hole 182), or a bar that is recessed into one of the flanges 156a and 156b. In an example, a steel reel with a recessed bar may have one end of a rope tied around the recessed bar and a second end of the rope secured to the cable(s) with tape and/or special knots. In various embodiments, an advantage of the reel take-up apparatus 100 is that an operator may get right to the reel 150 as soon as the group of wires (or cables) 180 is fed through the wire guide 144, the wire measuring assembly 142, and the wire clamp 140, and attach the group of wires (or cables) 180 to the reel 150. In contrast, with existing machines, the operator has to fish the wire over the entire machine and then attach the wire to the reel, which is very difficult. A significant benefit of the reel take-up apparatus 100 in accordance with embodiments of the invention is that loading the wire is much easier and saves a significant amount of time and, therefore, cost.
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In an example embodiment, the reel take-up apparatus 200 may comprise an attached pallet truck and a hydraulic counterbalance system instead of the modular push handle assembly 120 and the tool balancer 128, respectively. In an example, an electric pallet truck 202 may be attached to the frame cross member 104 (e.g., using the fork pockets 146a and 146b, etc.). The electric pallet truck 202 may allow an operator to maneuver loaded reels more easily and with more accuracy. In an example, the electric pallet truck 202 may be battery powered. In an example, a handle of the electric pallet truck 202 may provide greater operator comfort and reduced steering effort. In an example, the electric pallet truck 202 may provide electrical mechanical brakes to provide good stopping power.
In an example, the hydraulic counterbalance system may comprise a hydraulic cylinder 204, a horizontal lift tube 206, and a vertical lift tube 208. A first end of the hydraulic cylinder 204 is generally connected to the frame cross member 104. A second end of the hydraulic cylinder 204 is generally connected to a first end of the horizontal lift tube 206. A second end of the horizontal lift tube 206 is generally connected to a first end of the vertical lift tube 208. A second end of the vertical lift tube 208 is generally connected to the slide mount plate 148 and the drive mechanism comprising the bevel geared motor 160.
When the hydraulic cylinder 204 is extended, the slide mount plate 148 and the drive mechanism comprising the bevel geared motor 160 are generally moved upward along the vertical frame member 102. When the hydraulic cylinder 204 is contracted, the slide mount plate 148 and the drive mechanism comprising the bevel geared motor 160 are generally moved downward along the vertical frame member 102. In various embodiments, the hydraulic counterbalance system is generally configured to act as a counterbalance for the weight of the drive mechanism. The hydraulic counterbalance system generally allows the drive mechanism to float freely on the vertical frame member 102, allowing the drive mechanism to move up and down as a reel attached to the reel take-up apparatus 200 moves up and down. In various embodiments, the hydraulic motor 130 may be coupled to the positioning actuators of the right side and the left side roller sub-assemblies and the hydraulic cylinder 204. The hydraulic motor 130 is generally configured to provide power to lift and lower the reel and the drive mechanism in a controlled manner.
In various embodiments, the reel take-up apparatus 200 may further comprise the slide wire traverse base (or wire traverse or carriage assembly or level wind) 132. In an example embodiment, the slide wire traverse base 132 may be mounted on a side of the left bottom frame member 106b opposite the left push bar assembly 112b. In an example, the wire handling assembly 134 is generally attached to the slide wire traverse base 132 by the extension arm 136. The slide wire traverse base 132 is generally configured to move the wire handling assembly 134 back and forth between flanges of a reel mounted on the reel take-up apparatus 200 to facilitate efficient winding of wire/cable on the barrel (or core) of the reel. In an example, the slide wire traverse base 132 may comprise a lead screw and square nut drive mechanism allowing the extension arm 136 to change direction as the wire/cable is being wound. In an example, the slide wire traverse base 132 may be powered by an electric motor 132a. In an example, the electric motor 132a is generally attached to an end of the slide wire traverse base 132 that is distal from the frame cross member 104. In an example, the wire handling assembly 134 may comprise the wire clamp 140, the wire guide 142, and the wire measurement assembly 144. The slide wire traverse base 132, the extension arm 136, the wire clamp 140, the wire guide 142, the wire measurement assembly 144 may be implemented using conventional devices and/or techniques.
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In an example, mobile operator station 230 may be configured to allow an operator to control the reel take-up apparatus 200 at a safe distance from the moving parts of the reel take-up apparatus 200. In an example, the mobile operator station 230 may comprise a cabinet 232, a stand 234, a plurality of casters 236, and a foot pedal (or switch) 238. In an example, the cabinet 232 may enclose a human machine interface (HMI) for operating the reel take-up apparatus 200. In an example, the mobile operator station 230 may be configured to communicate with the reel take-up apparatus 200 using a wireless protocol (e.g., WiFi, BLUETOOTH, ZIGBEE, etc.). In an example, the foot pedal 238 may be configured to allow the operator to adjust a height of the mobile operator station 230. In another example, the foot pedal 238 may be configured to provide a safety interlock to ensure the operator is at the mobile operator station 230 and not near the reel take-up apparatus 200.
The terms “may” and “generally” when used herein in conjunction with “is(are)” and verbs are meant to communicate the intention that the description is exemplary and believed to be broad enough to encompass both the specific examples presented in the disclosure as well as alternative examples that could be derived based on the disclosure. The terms “may” and “generally” as used herein should not be construed to necessarily imply the desirability or possibility of omitting a corresponding element.
While the invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the scope of the invention.
| Number | Name | Date | Kind |
|---|---|---|---|
| 11643297 | Graham | May 2023 | B1 |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17220164 | Apr 2021 | US |
| Child | 18122402 | US |
