Retractable Cable Reel for Torsion-sensitive Cable

Abstract

A cable reel is disclosed having an outer deployment spool for deployment and retractive coiling of cable based on rotation about a central axis. The cable reel also has an inner, coaxial drum in which stored cable assumes tighter loops and relaxed loops responsive to the deployment or coiling of the cable on the outer spool. The cable extends from the inner drum through an opening in an axial tube and out of the drum orthogonally. The cable is contiguous from the deployable end on the outer spool, through the inner drum coils and through the axial tube. The reel may have a resistive spring or other means of retraction. The disclosed cable is not subject to acute bends, turns or torsion upon its long axis through deployed and retracted phases.

Claims

1. A cable reel comprising: an outer spool and inner drum, a longitudinally contiguous torsion-sensitive cable comprising a fixed end and a deployable end, sidewalls, and a fixed axial tube about which the sidewalls, inner drum and outer spool are rotatably attached, said outer spool and inner drum being bracketed by the sidewalls, a partition radially disposed about the axis of the tube between the sidewalls forming a radial base for the outer spool and a radial roof for the inner drum, the length of cable coilable about the outer spool, communicating with the inner drum through an annulus in the partition, looping about the axial tube, extending through an annulus in the tube and exiting axially through a second annulus, being fixed within the second annulus of the tube, the loops of the inner drum being of sufficient number to tensionally assume the rotation of the reel when the length of outer cable is deployed, and to relax when the outer cable is coiled.

2. The apparatus of claim 1, wherein the cable further comprises a plurality of individually sheathed conductors bundled in a unified outer sheath.

3. The apparatus of claim 1, wherein the cable further comprises a fiber optic waveguide.

4. The apparatus of claim 1, wherein the cable further comprises a fluid tube.

5. The apparatus of claim 2, wherein the cable comprises an ethernet cable and a plurality of electrical power wires, the outer sheath further comprising a metal flex conduit.

6. The apparatus of claim 1, wherein the cable comprises at least one electrically conductive wire and one tube.

7. A cable reel comprising: a rigid axial tube, a drum rotatably disposed axially about the axial tube, an outer spool disposed coaxially about the drum, a radial partition dividing the drum and the spool, a composite cable deployably disposed about the spool such that axial rotation of the spool alternatively deploys and coils the cable, an annulus in the partition through which the cable passes into the drum, slack cable loops in the drum about the axial tube such that when cable is coiled on the spool the loops are relaxed and when cable is deployed from the reel the coils tensionally assume the rotation and contract around the axial tube, and capture of a segment of the cable within the axial tube such that it does not rotate with respect to the reel.

8. The cable reel of claim 7, wherein the composite cable comprises a data wire and a power wire.

9. The cable reel of claim 7 wherein the composite cable comprises a cable conduit sheath, an electrically conductive wire and a fluid tube.

10. The cable reel of claim 7 wherein the composite cable comprises a fiber optic waveguide and an electric wire.

11. The cable reel of claim 7 wherein the composite cable comprises a fiber optic waveguide and a fluid tube.

12. The cable reel of claim 7 wherein the composite cable comprises an electric wire and a solid conveyance tube.

13. The cable reel of claim 9 wherein the electrically conductive wire comprises a data wire.

14. A cable reel comprising: a rigid axial tube, a drum rotatably disposed axially about the axial tube, an outer spool disposed coaxially about the drum, a radial partition dividing the drum and the spool, a composite cable deployably disposed about the spool such that axial rotation of the spool alternatively deploys and coils the cable, an annulus in the partition through which the cable passes into the drum, cable loops in the drum about the axial tube such that when cable is coiled on the spool the loops are relaxed and when cable is deployed from the reel the coils tensionally assume the rotation and contract around the axial tube, capture of the cable within the axial tube such that it does not rotate with respect to the reel, and a spring disposed between the axial tube and the drum.

15. The cable reel of claim 14 wherein the spring is a clock spring disposed about the axial tube having a first end affixed to the tube and a second end affixed to the spool.

16. The cable reel of claim 14 wherein the spring comprises the cable loops.

17. The cable reel of claim 14 wherein the composite cable comprises an electrically conductive sub-cable larger than 4 AWG, a fluid tube and a solid conveyance tube.

18. The cable reel of claim 16 wherein the composite cable further comprises a cable conduit sheath.

19. The cable reel of claim 14 wherein the composite cable comprises a fiber optic waveguide and an electrically conductive wire.

20. The cable reel of claim 14 wherein the composite cable comprises a plurality of data wires, a power wire and a metallic cable conduit sheath.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0027] FIG. 1 is a perspective view of the cable reel of the present invention generally in a coiled configuration.

[0028] FIG. 2 is an axially bifurcated section perspective of the cable reel of FIG. 1.

[0029] FIG. 3 is a perspective view of the cable reel of FIG. 1 having a sidewall removed and the cable generally coiled.

[0030] FIG. 4 is the view of FIG. 3, and the cable generally deployed.

[0031] FIG. 5 is a perspective cutaway view of the cable of FIGS. 1-4.

[0032] FIG. 6 is a perspective cutaway view of the cable of a second preferred embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Embodiments of the present disclosure now will be described more fully hereinafter with reference to the accompanying drawings. However, many different embodiments are contemplated, and the present disclosure should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and better convey the scope of the disclosure to those skilled in the art.

[0034] Referring now to FIGS. 1, 2 & 3, wherein is depicted the cable reel 10 of this embodiment. Cable reel 10 is comprised of spool 12, first mounting bracket 14, second mounting bracket 16, and baseplate 18. Brackets 14 & 16 are affixed to the baseplate 18 by rivet nuts 22a-d (rivet nuts 22e-f, are hidden in this perspective). Spool 12 is laterally bracketed on its sides by sidewalls 20a-b. Radial partition 24 is disposed between sidewalls 20a and 20b, a distance from an axial tube 26 (FIGS. 2-4). Radial partition 24, in this embodiment, is affixed to the sidewalls 20a-b by welds (not depicted). But it will be appreciated that a variety of affixation means may be employed (without limitation, screws, bolts, rivets, etc.).

[0035] Sidewalls 20a-b extend radially beyond the partition 24 thereby forming an outer spool well 28. The depth of the outer spool well 28, is a function of the radii of the sidewalls 22a-b, and the distance of the radial partition from the axial tube 26. It will be appreciated that the depth of the outer well 28, is designed as a function of the nature of the material to be spooled (described hereafter) and the overall space needed to accommodate the cable reel 10.

[0036] Axial tube 26 (FIGS. 2-4) is affixed to first and second mounting brackets 14 & 16 such that it does not rotate in respect thereto. In this embodiment nut 30 (FIG. 2) affixes to one side of the axial tube and compression nut 32 (FIGS. 1&2) affixes to the other side. This arrangement causes the axial tube 26, first mounting bracket 14, second mounting bracket 16 and baseplate 18 to be affixed together to form a mounting system for the reel. It will be appreciated that the mounting system will further be affixed to some other structure (building, cart, vehicle, etc. not depicted) such that the reel remains stationary. It will be appreciated that keyway means (not depicted) might be used to prevent rotation of axial tube 26 with respect to the mounting system, but in our experience it has not been necessary. Axial tube 26, is a typical steel pipe, in this instance. Axial tube 26, is sufficiently wear resistant such that rotation of the sidewalls 20a-b thereupon will not damage it. In an application with combinations of high loads and high cycle life requirement bushings or bearings could be utilized.

[0037] The inner surface (proximal to axial tube 26) of radial partition 24, sidewalls 20a-b, and outer surface of the axial tube 26, define an inner drum 36 (FIGS. 2-4).

[0038] Sidewalls 20a-b rest on the outer surface of the axial tube 26, in an axis-rotatable fashion.

[0039] A cable 40, is described herein having a first end 42 (FIGS. 1&3) and a second end 44. Cable 40 is homogenous from end 42 through end 44, except as described herein sheath 40, may terminate or change in substance.

[0040] Also provided is a bias clock spring 50 and a spring housing 52 (FIGS. 2&3). The spring housing is attached to the inner wall of a sidewall 20b by way of welds, studs or rivets (not depicted). Clock spring 50 resides over the axial tube 26 in a radial manner having an inner tab 54 (FIG. 2), affixed to the axial tube 26 and an outer tab (not depicted) affixed to the spool 12, such that when spool 12 rotates with respect to the tube 26, the spring 50 is wound and biases the spool 12 to a wound position. It will be appreciated that a variety of springs, motors or hand-cranks could be employed to accomplish the rotation described.

[0041] Now, turning to the dynamic relationship of cable 40 with respect to cable reel 10. Cable 40 has three longitudinal segments: an outer segment 46, an inner segment 47 (FIGS. 2-4) and an axial segment 48 (FIG. 2). The outer cable segment 46, is disposed about the outer spool well 28 when there is no demand for extended cable, such as when a tool (not depicted) is in a stored and unused condition. However, when there is a demand for extended cable 40, the reel 12 unwinds and cable is deployed from outer segment 46. In this condition the clock spring 50 tightens and creates a stored bias to rewind cable segment 46 when the demand is no longer needed.

[0042] Cable 40 travels through the radial partition 24 at a partition annulus 60 (FIGS. 2&4) therethrough. Several coil winds are placed on the inner cable segment 47 around the axial tube 26. These coils roughly correspond to the number of winds of the outer coil segment 46 on the outer spool well 28.

[0043] From the inner drum well 36, cable 40 then travels through an internal annulus 62 of the axial tube 26, through the lumen of the axial tube 26 and exits through a second axial annulus 64, thereby forming the axial cable segment 48. The second cable end 44 of the axial cable segment 46, is fixed in axial position by compression nut 32.

[0044] The condition of the inner cable segment 47 has hereto been described when cable is not deployed, i.e. the inner cable segment 47 is relaxed adjacent the inner wall of radial partition 24 (the outer wall of the inner spool well 36). See, FIGS. 1-3.

[0045] It will be appreciated that the coils of the inner cable segment 47 might be used in lieu of clock spring 50, to bias the cable reel 10 in a condition in which cable 40 is coiled upon spool 12. This would necessarily depend on selecting cable components that have a natural bias. The components of the cable will be chosen for function. However, design of sheath 74 (FIG. 5) will be made to accommodate this bias function in terms of composition and construction. For example, wall composition and thickness can be selected to yield the desired bias.

[0046] FIG. 4 depicts cable 40 deployed from spool 12 and the inner coil segment 47, consequently, tensionally assumed radially proximal to axial tube 26. That is to say; when spool 12 rotates to deploy outer cable segment 46, that rotation tensionally tightens coils of the inner cable segment.

[0047] In particular, when Cable 40 is coiled upon the outer spool well 28, it has five stored rotations (FIG. 3). When cable 40 is fully deployed (FIG. 4) it has one coil in retention. The diameter of the radial partition 24 (the base of well 28) is twelve and ? inches. Therefore, the length of cable deployed is just greater than one hundred sixty inches. The number of cable 40 loops in the drum 36 are three in coiled condition (FIG. 3). These three loops each have a nominal diameter of eight and ? inches (FIG. 3). When cable 40 is deployed (FIG. 4), the rotation necessary to accomplish that causes the coils to tensionally assume the rotation, changing the number of loops in the inner cable segment 47 of the drum 36 to seven, having a nominal diameter of just greater than three and ? inches.

[0048] FIG. 5 depicts cable 40, of FIGS. 1-4, generally broken out at second end 44. A category 5E ethernet cable is depicted 70. Power wires include DC Pos. 72a, DC Neg. 72b, and ground wire 72c. ethernet cable 70 carries data between the camera (not depicted) and a processor (not depicted). Power wires 72a-c are used to power the camera and whatever else may be employed at the tool end 42 of cable 40. Ethernet cable will be appreciated by one skilled in the art to be shielded and composed of stranded conductors to allow for continuous flexing. Power wires 72a-c are 16 AWG wire that consists of stranded conductors for continuous flexing.

[0049] A flexible cable conduit sheath 74 is disposed around the various cable components (ethernet cable 70 & power wires 72a-c) to encase and unify them. Sheath 74 in this preferred embodiment is a rolled flexible metal conduit, in other embodiments it may be desirable to encase the rolled metal in a flexible polymer to make it watertight. The sheath could also be a woven flexible polymer or other material. It will be appreciated that when sub-components of cable 40 (ethernet cable 70 & power wires 72a-c) are bound by sheath 74, the widely differing physical characteristics of the components formulate a cable 40 that acts in predictable ways. In particular, the loops of inner cable segment 47 as it resides in inner drum well 36 around axial tube 26, tightens and loosens in a far more predictable manner than would unsheathed components of the same cable.

[0050] It will further be appreciated that sheath 74 will guard cable components (ethernet cable 70 & power wires 72a-c) against abrasion and slippage as they travel through and bias against the partition annulus 60, internal annulus 62 and second axial annulus 64.

[0051] When the term composite cable as used herein, it is intended to mean a mixed-use cable bundled within a flexible conduit sheath. Mixed use means some combination of data wire, fiber optic waveguide, power wire, gas tube, liquid tube, and solid conveyance tube.

[0052] As used herein torsion sensitive means any elongate component which cannot withstand repeated tortious rotation. Fiber optic waveguides, as discussed elsewhere herein, are inherently sensitive. Insulation sheaths are subject to cracking under torsion and, thus separation and possible shorting. The sensitive conductors used for data can be inherently subject to these failure modes.

[0053] FIG. 6 illustrates a second preferred embodiment of cable reel 10 configured to operate and supply the welding head of a robotic arm (not depicted). Cable 80 is operative in the same manner upon the reel, 12, as in the first preferred embodiment illustrated in FIGS. 1-5, except that cable 80 is of somewhat different composition as will be described.

[0054] Cable 80 has the following components throughout its length: ethernet cable 70, power wires 72a-c, welding arc sub-cable 82, welding ground sub-cable 84, welding feed wire and tube 86, shield gas tube 87, pneumatic tube 88, and large cable conduit 90. ethernet cable 70 and power wires 72a-c are of the same composition and of similar purpose as previously described.

[0055] Welding sub-cables 82 & 84 are of a sufficiently large gauge to handle the current necessary to effect arcs and temperatures for welding; but, small enough to minimize the overall structure cable 80 and reel 10. The gauge of sub-cables 82 & 84 is, of course, a function of the length of the wire, the duty cycle of the welding unit and the nature of the substance being welded. Nevertheless, 2 AWG braided, extra flexible copper wire is generally considered sufficient in this application.

[0056] Welding filler is provided via welding feed wire and tube 86. Feed wire tube 86, is an example of solid conveyance tube as previously discussed. In this instance the feed wire is 0.030 solid-core wire. The outer tube guide of wire and tube 86, is 0.035 inch I.D. PVC sheath. Shield gas tube 87 delivers pressurized shield gas in accordance with good welding technique, often argon or a CO.sub.2/argon mix, depending on the application. Gas tube 87 is a ? inch I.D. styrene-butadiene rubber hose.

[0057] Lastly, pneumatic tube 88 provides pressurized gas to drive single-acting pneumatic rams (not depicted) to operate a pneumatic gripper used to manipulate workpieces. The tube 88 is one quarter inch polyurethane tubing, and its use and composition are well known. It will be appreciated that the pneumatic gripper and other attendant apparatus (valves, etc.) will be selected and disposed in accordance with one of ordinary skills in those arts.

[0058] Lastly, large cable conduit sheath 90, is of a one and ? inch in diameter and of ten inch bend radius to accommodate the previously described structure, It is of similar composition and configuration as cable conduit sheath 74, FIGS. 1-6, but larger.

[0059] From the foregoing, it will be appreciated that the above disclosed apparatus enables a cable reel that accommodates deployment of and service to a variety of tools remote from service components such as tubes, wires and wave guides and eliminates the need for unorganized slack and excessive connectors, bends, and torsional flex.

[0060] Although certain example apparatus and methods, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the claims of this patent.