CA2271600A1 - Collapsible reel and method of assembly - Google Patents
Collapsible reel and method of assembly Download PDFInfo
- Publication number
- CA2271600A1 CA2271600A1 CA002271600A CA2271600A CA2271600A1 CA 2271600 A1 CA2271600 A1 CA 2271600A1 CA 002271600 A CA002271600 A CA 002271600A CA 2271600 A CA2271600 A CA 2271600A CA 2271600 A1 CA2271600 A1 CA 2271600A1
- Authority
- CA
- Canada
- Prior art keywords
- spokes
- reel
- plugs
- side wall
- rim
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
- B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
- B65H75/18—Constructional details
- B65H75/20—Skeleton construction, e.g. formed of wire
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
- B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
- B65H75/18—Constructional details
- B65H75/22—Constructional details collapsible; with removable parts
- B65H75/2236—Collapsible flanges
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
- B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
- B65H75/04—Kinds or types
- B65H75/08—Kinds or types of circular or polygonal cross-section
- B65H75/14—Kinds or types of circular or polygonal cross-section with two end flanges
Landscapes
- Storage Of Web-Like Or Filamentary Materials (AREA)
Abstract
The present invention relates to a collapsible reel for shipping and storage of flexible cables, pipes, and other elongate articles, the reel comprising a pair of side wall members having a plurality of spokes extending radially outwardly from a center connector, and a transverse generally cylindrical structure formed between the side wall members using a plurality of transverse bars mounted between adjacent pairs of spokes. The diameter of the transverse generally cylindrical structure is adjustable by mounting the transverse bars to the spokes at a set radial distance from the center.
Optionally, a plurality of receptacles may be adjustably mounted onto the spokes to receive the ends of the transverse bars. Optionally, dividers may be mounted onto the transverse bars to facilitate the winding of more than one type of cable or pipe onto the same reel.
Optionally, a plurality of receptacles may be adjustably mounted onto the spokes to receive the ends of the transverse bars. Optionally, dividers may be mounted onto the transverse bars to facilitate the winding of more than one type of cable or pipe onto the same reel.
Description
Title: Collapsible Reel and Method of Assembly FIELD OF THE INVENTION
The present invention relates to a collapsible reel for shipping and storage of flexible cables, pipes, and other elongate articles, and to a method of assembly of such a reel.
BACKGROUND OF THE INVENTION
Various designs for reels which may be used for shipping and storage of flexible cables, pipes, and other elongate articles, and which may be collapsed for storage and assembled for reuse, are known in the art.
One example is U.S. Patent No. 4,620,676 issued to Missalla which discloses a dismountable reel having two circular side members with inside and outside faces. The circular side members have attachment rings on the inside faces of the side members, with openings around the attachment rings. A core member is formed from a strip of sheet metal, the strip having junctions at the ends so that the strip may be formed into a generally cylindrical shape, and attachment tongues on the edges of the strip are interengagable with the attachment rings. While this design provides a functional collapsible reel, the wire rod structure forming the circular side members may be time consuming to manufacture, likely requiring extensive soldering. Also, the solid core member, while functional, would add significantly to the weight of the reel.
Other reel designs propose solid side members including U.S.
Patent No. 5,806,788 issued to Witwer et al.; U.S. Patent No. 5,588,628 issued to Sachleben; and U.S. Patent No. 4,066,224 issued to Hargreaves et al. While such solid side wall designs provide strength, again the additional material likely adds significantly to the weight of the reels.
Yet another example is U.S. Patent No. 5,242,129 issued to Bailey et al., which discloses a knockdown cable reel including a central drum with radially extending flanges positioned on each end to form circular side members. The flanges are formed from a plurality of segments to facilitate assembly and disassembly. A flange ring encircles the outer periphery of each flange to stabilize the flange during use. Again, the amount of material used to form the solid side flanges and the solid central drum will add weight to the cable reel. Furthermore, because the central drum is not collapsible, the central drum will still occupy significant space when the reel is knocked down.
OBJECTS OF THE INVENTION
With the foregoing in mind, a primary objective of the present invention is to provide a relatively light weight reel assembly which is inexpensively manufactured and which is readily collapsible for storage and which is readily assembled for reuse.
Another objective of the present invention is to provide a reel assembly in which the diameter of the cylindrical structure between the side wall members may be adjusted to one of a number of possible diameters so as to increase or decrease the capacity of the reel.
A further object of the present invention is to provide a method of manufacturing side wall members and forming a central cylindrical structure for a reel quickly and inexpensively.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a reel for winding flexible cables, pipes and the like, comprising:
a) a pair of side wall members, each side wall member having:
i) a center hub connector, the center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of the annular axle sleeve, the plugs lying in a common plane;
ii) a plurality of spokes having a cavity at an inner end for receiving one of the plugs therein, the spokes lying in the plane and extending radially outwardly;
The present invention relates to a collapsible reel for shipping and storage of flexible cables, pipes, and other elongate articles, and to a method of assembly of such a reel.
BACKGROUND OF THE INVENTION
Various designs for reels which may be used for shipping and storage of flexible cables, pipes, and other elongate articles, and which may be collapsed for storage and assembled for reuse, are known in the art.
One example is U.S. Patent No. 4,620,676 issued to Missalla which discloses a dismountable reel having two circular side members with inside and outside faces. The circular side members have attachment rings on the inside faces of the side members, with openings around the attachment rings. A core member is formed from a strip of sheet metal, the strip having junctions at the ends so that the strip may be formed into a generally cylindrical shape, and attachment tongues on the edges of the strip are interengagable with the attachment rings. While this design provides a functional collapsible reel, the wire rod structure forming the circular side members may be time consuming to manufacture, likely requiring extensive soldering. Also, the solid core member, while functional, would add significantly to the weight of the reel.
Other reel designs propose solid side members including U.S.
Patent No. 5,806,788 issued to Witwer et al.; U.S. Patent No. 5,588,628 issued to Sachleben; and U.S. Patent No. 4,066,224 issued to Hargreaves et al. While such solid side wall designs provide strength, again the additional material likely adds significantly to the weight of the reels.
Yet another example is U.S. Patent No. 5,242,129 issued to Bailey et al., which discloses a knockdown cable reel including a central drum with radially extending flanges positioned on each end to form circular side members. The flanges are formed from a plurality of segments to facilitate assembly and disassembly. A flange ring encircles the outer periphery of each flange to stabilize the flange during use. Again, the amount of material used to form the solid side flanges and the solid central drum will add weight to the cable reel. Furthermore, because the central drum is not collapsible, the central drum will still occupy significant space when the reel is knocked down.
OBJECTS OF THE INVENTION
With the foregoing in mind, a primary objective of the present invention is to provide a relatively light weight reel assembly which is inexpensively manufactured and which is readily collapsible for storage and which is readily assembled for reuse.
Another objective of the present invention is to provide a reel assembly in which the diameter of the cylindrical structure between the side wall members may be adjusted to one of a number of possible diameters so as to increase or decrease the capacity of the reel.
A further object of the present invention is to provide a method of manufacturing side wall members and forming a central cylindrical structure for a reel quickly and inexpensively.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a reel for winding flexible cables, pipes and the like, comprising:
a) a pair of side wall members, each side wall member having:
i) a center hub connector, the center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of the annular axle sleeve, the plugs lying in a common plane;
ii) a plurality of spokes having a cavity at an inner end for receiving one of the plugs therein, the spokes lying in the plane and extending radially outwardly;
iii) an outer rim, the rim securely connecting an outer end of the spokes, the rim lying in the plane; and b) a transverse generally cylindrical structure formed between the pair of side wall members, the generally cylindrical structure causing the pair of sidewall members to be substantially parallel and axially aligned along the axis of rotation of the reel.
In an alternative embodiment, the spokes may comprise a plurality of pairs of adjacently fixed spokes formed from the ends of a continuous, bent, elongate member which substantially defines a sector of a circle.
Preferably, the cavities in each of the spokes have a cross-section substantially matching the cross-section of the plugs, whereby the plugs closely fit inside the cavities.
Optionally, the side walls of the plugs are tapered and the cross-section of the plugs progressively broadens towards the base of the plugs, whereby the plugs tightly fit in the cavities when the spokes are driven down onto the plugs.
In one embodiment, the spokes are crimped onto the plugs, so as to lock the spokes onto the plugs.
Advantageously, the rim of the reel is formed from an appropriate length of a U-shaped channel curved substantially into a broken ring, the opening of the U-shaped channel facing radially inward, the rim being flexible so as to allow the rim to be enlarged to receive all of the outer ends of the spokes within the U-shaped channel, the parallel side portions near the outer ends of the spokes closely fitting between the side walls of the U-shaped channel, the rim then being closeable to form an unbroken ring.
Preferably, the outer rim is crimped to the outer ends of the spokes so as to lock the spokes in position.
In a preferred embodiment, the transverse generally cylindrical structure comprises a plurality of transverse bars mounted between a pair of correspondingly aligned spokes of each of the side wall members, the bars being mounted at generally the same radial distance from the center of each of the side wall members.
Advantageously, the radial distance from the center of the side wall members to the transverse bars is adjustable, whereby the diameter of the transverse generally cylindrical structure may be adjusted, so as to adjust the capacity of the reel.
More advantageously, radial distance margins are provided on the spokes so as to facilitate even adjustment of the transverse bars.
In another aspect, the present invention provides a method of assembling a reel, the method comprising the steps of:
a) providing a center hub connector, the center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of the annular axle sleeve, the plugs lying in a common plane;
b) providing a plurality of spokes having a cavity at one end for receiving one of the plugs therein, the spokes lying in the plane and extending radially outwardly;
c) providing an outer rim for connecting an outer end of each of the spokes, the rim being formed from an appropriate length of an U-shaped channel;
d) inserting the plugs into the cavities to connect the spokes to the center hub connector and connecting the outer end of the spokes to the outer rim to form a sidewall member; and e) providing a plurality of transverse bars and mounting each of the transverse bars between a pair of correspondingly aligned spokes of each of a pair of the sidewall members, the transverse bars forming a transverse generally cylindrical structure between the side wall members, the generally cylindrical structure causing the pair of side wall members to be substantially parallel and axially aligned along the axis of rotation of the reel.
Preferably, the method further comprises the step of crimping the spokes over the plugs so as to lock the spokes in position.
More preferably, the method further comprises the step of mounting the transverse bars to the spokes using adjustable U-bolts.
In another aspect, the present invention provides an apparatus for assembling a side wall member, the apparatus comprising:
a) a platform having a defined center position for receiving a center hub connector having plugs;
b) a center crimping tool assembly mounted to the platform at the defined central position, the central crimping tool assembly providing means for crimping an inner end of a spoke onto each of the plugs;
c) a plurality of telescopic arms mounted to the platform and extending radially outwardly from the defined central position, the length of the telescopic arms being adjustable to receive different sizes of the spokes; and d) a plurality of outer rim crimping tool assemblies, each outer rim crimping tool assembly being mounted at an outer end of each telescopic arm, and receiving an outer end of the spokes together with a portion of an outer rim, the outer rim crimping tool providing means for crimping the outer ends of the spokes into the outer rim, the number of outer crimping tool assemblies corresponding to the number of rim-spoke connection points in the side wall member.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A shows a plan view of a first embodiment of a side wall member in accordance with the present invention;
Figure 1B shows a plan view of a second embodiment of a sidewall member in accordance with the present invention;
Figure 2A shows a plan view of a center hub connector for the side wall member of Figure 1A; ' Figure 2B shows a side view of the center hub connector of Figure 2A;
Figure 2C shows an enlarged view of a tapered plug for the center hub connector of Figures 2A and 2B;
Figure 2D shows a first embodiment of a pair of separate spokes for the side wall member of Figure 1A;
Figure 2E shows a second embodiment of a pair of spokes which are formed from the ends of a continuous, bent member;
Figure 2F shows a third embodiment of a pair of separate spokes having bent outer ends;
Figure 3A shows an enlarged partially hidden plan view of a joint connection, between an outer rim and an outer edge of a spoke, on the side wall member of Figure lA;
Figure 3B shows a length of U-shaped channel curved substantially into a ring for the side wall member of Figure lA;
Figure 3C shows a cross-sectional view of the joint connection in Figure 3A, taken along the line A--A of Figure 3A;
Figure 4 shows a top view of an assembly apparatus for assembling the side wall member of Figure 1A;
Figure 5A shows a partially hidden front view of one of the outer rim crimping tools shown in Figure 4;
Figure 5B shows a bottom view of the outer rim crimping tool of Figure 5A;
Figure 5C shows a side view of the outer rim crimping tool of Figure 5A;
Figure 6 shows a side view of a telescopic tool support arm for supporting the outer rim crimping tool of Figures 5A-5C;
Figure 7A shows an enlarged top view of the center hub connector crimping tool shown in Figure 4, together with a center hub connector and spokes for the side wall member of Figure 1;
Figure 7B shows the same components as in Figure 7A but with _7_ the center hub connector and spokes rotated clockwise into position for crimping;
Figure 8A shows a side view of the center hub bottom crimping tool assembly mounted onto a platform, for assembling the side wall member of Figure 1A;
Figure 8B shows an enlarged view of the center hub bottom crimping tool assembly of Figure 8A;
Figure 9A shows a detailed bottom view of a center hub bottom crimping die retaining plate assembly, for assembling the side wall member of Figure 1A;
Figure 9B shows a side view of the assembly of Figure 9A;
Figure 10A shows a transverse bar mounted between two correspondingly aligned spokes of a pair of side wall members;
Figure 10B shows a transverse bar inserted into an optional receptacle mounted onto each spoke;
Figure lOC is a top view of the assembly shown in Figure 10B;
Figure 10D is an end view of the assembly shown in Figure lOB;
Figure 10E shows a plan view of one embodiment of a receptacle which receives one end of a transverse bar;
Figure 10F shows a plan view of optional divider bars which are adjustably mounted onto a transverse bar;
Figure lOG shows a bottom view of the assembly shown in Figure lOF;
Figure 10H shows a detailed plan view of the mounting portion of the divider bar;
Figure 10I shows a bottom view of the mounting portion of the divider bar shown in Figure lOF;
Figure 11A shows an exploded view of one embodiment of the reel of the present invention; and Figure 11B shows an exploded isometric view of another embodiment of the reel of the present invention.
_8_ DETAILED DESCRIPTION OF THE INVENTION
Referring to Figure 1A, a first embodiment of a side wall member 1 of the present invention is shown. Each side wall member comprises a center hub connector 10 connecting a plurality of spokes 20 at their inner ends 21 and an outer rim 30 connecting the spokes 20 at their outer ends 22.
Now referring to Figure 1B, another embodiment of a side wall member 1 of the present invention is shown. Each side wall member 1 comprises a center connector 11 connecting a plurality of spokes 20b at their inner ends 21 and an outer rim 30b connecting the spokes 20b at their outer ends 22b. In Figure 1B each of the spokes 20b are welded at their inner ends 21 to a plate 11a. Advantageously, the outer ends 22b of each of the spokes 20b are bent at their outer ends 22b to allow for a filler joint weld between the outer ends 22b and the outer rim 30b. This detail is illustrated in Figure 1C. It will be appreciated that the center hub connector 10 of Figure 1A may be used instead of the center connector 11 shown in Figure 1B and vice versa. Various other embodiments for the side wall member 1 are possible but each embodiment should include a plurality of spokes extending radially outwardly from a center.
Now referring to Figure 2A, an enlarged plan view of the center hub connector 10 of Figure 1 A is shown. Each center hub connector 10 is formed from a generally annular axle sleeve 12 having a plurality of plugs 14 distributed around and extending radially outwardly from the outer surface of the annular axle sleeve 12. As shown in Figure 2B, the plugs 14 are aligned and lie in a plane which is perpendicular to the axis of rotation of the center hub connector 10. The plugs 14, shown by way of example in Figures 2A and 2B, are generally elongate bars having a square cross-section. However, it will be appreciated that the plugs can have a cross-section of virtually any shape that facilitates mating with an appropriately shaped cavity. For example, the cross-section of the plugs 14 may be circular, rectangular, hexagonal, or another polygonal shape. The length of the plugs 14 is not critical but preferably should be at least as long as the width of the plugs 14 so as to provide adequate support for the spokes 20.
The plugs may be shorter than their width provided that there is still sufficient space for crimping, as described further below.
Optionally, as shown in Figure 2C, a plug 14a may be tapered such that its cross-section progressively broadens towards its base. This tapered plug 14a is designed to fit tightly into an appropriately shaped cavity at the inner end 21 of a spoke 20 when the spoke 20 is driven down onto the plug 14a.
As shown in Figure 2D, individual spokes 20 of generally equal length may be mounted onto the plugs 14,14a by their inner ends 21 which have appropriately shaped cavities (not shown) to receive the plugs 14, 14a. The outer ends 22 may be connected to the rim 30 as described below.
In an alternative embodiment, as shown in Figure 2E, a pair of adjacently fixed spokes 20a are formed from the ends of a continuous, bent, elongate member which substantially defines a sector of a circle. The fixed spokes 20a have a common outer end 22a which is analogous to the outer end 22 of an individual spoke 20. In one possible embodiment, the outer end 22a has substantially the same curve as the rim. Preferably, the fixed spokes 20a form substantially the same angle (angle A° in Figure 2E) as two adjacent individual spokes 20 would when mounted onto two adjacent plugs 14,14a (angle A° in Figure 2D). Note that the tapered plugs 14a are designed to make it easier to mount the inner ends 21 of the fixed spokes 20a onto adjacent plugs 14a, as the ends of the fixed spokes 20a will approach the plugs 14a at an angle.
Now referring to Figure 2F, another embodiment of a pair of spokes 20b is shown. The spokes 20b of Figure 2E have their outer ends bent at substantially 90° which allow them to either fit within a rim formed from a U-shaped channel (described below) or be welded to a rim formed from a tube using a filler joint weld (Figure 1C). Advantageously, a filler joint weld will provide greater strength at the spoke-rim joints.
It will be appreciated that each of the inner ends of the spokes 20, 20a, 20b may also be mounted and/or welded onto a center hub connector as shown in Figures 2A-2C or, alternatively, be welded to a plate lla as shown in Figure 1B.
Now referring to Figure 3A, an enlarged partially hidden view of a rim 30 connected to the outer end of a spoke 20 is shown. In one 5 embodiment shown in Figure 3B, the outer rim 30 is formed from an appropriate length of a U-shaped channel curved substantially into a ring having a break 31. As shown in Figure 3B, the opening of the U-shaped channel is facing radially inwardly. Before the break 31 is closed, the outer rim 30 is flexible so as to allow the diameter of the outer rim 30 to be 10 enlarged to receive all of the outer ends of the spokes 20 which are mounted on the plugs 14,14a within the U-shaped channel of the rim 30.
As shown in Figure 3C, the outer end 22 of a spoke 20 may be secured to the outer rim 30 by means of a crimping connection which partially punctures the side walls of the U-shaped channel and sides of the spokes 20 so that flaps of material 25, 35 are bent inwardly. Once the connections have been made, the break 31 can be closed so that the rim 30 is a continuous ring. The break may be closed in any one of a number of conventional methods, for example, by welding the break 31 together, or by placing a bridge piece (not shown) extending between the two sides of the break 31 and fastening the ends of the break 31 onto the bridge piece by welding, crimping, adhesive, etc. A device for forming a connection at all rim-spoke connection points at the same time is described further below.
For additional strength at the rim-spoke connection points, it is possible to use adhesives or induction welding in conjunction with this type of crimping connection. Alternatively, adhesives or welding could be used instead of crimping.
It will be appreciated that the same type of rim-spoke connection as described above may be formed between an outer rim 30 and the outer end 22a of the fixed spokes 20a shown in Figure 2E. Advantageously, the outer end 22a of the fixed spokes 20a provides additional structural strength between the adjacent fixed spokes 20a and to the outer rim 30 since the entire outer end 22a is received within the U-shaped channel of the rim 30.
As discussed above, in an alternative embodiment (Figure 1B), the rim may be formed from a metal tube which is formed into a ring of suitable diameter for a given set of spokes 20, 20a, 20b. Preferably, the metal tubing used to form the rim 30b has either a square or rectangular cross-section and will allow the outer ends of spokes 20, 20a, 20b to be securely welded to it.
Figure 4 shows a top view of the side wall member 1 of Figure 1 in an apparatus for crimping the spokes 20 onto the center hub connector 10 and for crimping the outer ends of the spokes 20 onto the outer rim 30.
As shown in Figure 4, a center hub connector crimping tool 70 shown in dotted outline is mounted on a platform 40 which supports the center hub connector 10. Extending radially outwardly from the platform 40 are telescopic tool support arms 60 each of which support an outer rim crimping tool 50. The telescopic function is described further below.
Now referring to Figures 5A-5C, an enlarged view of the outer rim crimping tool 50 is shown. The outer rim crimping tool 50 comprises opposing puncture dies 102t, 102b which are retained on die retaining plates 55a, 56a. The puncture dies 102t, 102b are positioned over and under, respectively, each rim-spoke connection point (Figure 3A) and are urged toward each other to form a locked rim-spoke connection as shown in Figure 3C. As illustrated in Figure 5C, the puncture dies 102 are substantially wedge-shaped such that a puncture can be made in the outer rim 30 and spokes 20 and flaps of material 25, 35 are bent inwards to form a locked connection (Figure 3A and 3C). Supporting the top die retaining plate 55a is a top plate 53. A spacer plate 52 of appropriate width to accept a rim 30 is positioned between the top plate 53 and a bottom plate 51 which provides a supporting surface for the rim 30. The plates 51, 52, 53 are secured together, for example, by bolts and nuts (not shown). The bottom plate 51 has an orifice 51a through which the bottom puncture die 102 and die retaining plate 56a can pass in order to urge the bottom puncture die 102 towards the top puncture die 102. The bottom die retaining plate 56a is fastened to the end of a hydraulic cylinder 57 which is extended for the puncturing operation and which is withdrawn for removal of the rim 30 upon completion of the puncturing operation.
Now referring to Figure 6, a partially hidden side view of the telescopic tool support arm 60 is shown. The telescopic tool support arm 60 comprises an outer rim crimping tool mount 62 on top of which the outer rim crimping tool 50 is mounted. The outer rim crimping tool mount 62 may be of tubular structure which partially overlaps with one end of an elongate arm 64. The outer rim crimping tool mount 62 may be adjustable relative to the elongate arm 64 over a limited distance by means of a hydraulic cylinder 68 having one end connected to the elongate arm 64 and the other to the outer rim crimping tool mount 62. The action of the hydraulic cylinder 68 allows the outer rim crimping tool mount 62 to extend outwardly, in order to allow a rim 30 to be positioned in place for connection to the spokes 20, then contract inwardly to secure the rim 30 and position the outer rim crimping tool 50 for the crimping operation, and finally extend outwardly once more to allow the fully assembled side wall member 1 to be removed.
Still referring to Figure 6, another end of the elongate arm 64 is inserted into a tubular elongate arm table mount 66. Optionally, the elongate arm 64 includes a pin hole 64a which can be aligned with one of a plurality of pin holes 66a in the elongate arm table mount 66 and a pin (not shown) can be placed through the aligned pin holes 64a,66a so as to adjust the overall length of the telescopic tool support arm 60.
Alternatively, the elongate arm 64 may be adjusted relative to the elongate arm table mount 66 by means of a hydraulic cylinder (not shown) similar to the actin of the hydraulic cylinder 68 discussed above. This telescopic action further accommodates side wall members 1 having various diameters. Also shown in Figure 6 is a center hub connector 10 in position to receive spokes 20.
Now referring to Figure 7A, a top view of a center hub connector 10 is shown with spokes 20 mounted onto plugs 14 which extend radially outwardly from an annular axle sleeve 12. Still referring to Figure 7A, a center hub connector crimping tool assembly 70 is shown in dotted outline underneath the platform 40. Mounted on top of the platform 40 are center hub top crimping die retaining plates 72 which have an overhang portion 72a holding crimping dies 100 in position with the die tips pointed downwards. The center hub top crimping die retaining plate 72 may be bolted down onto the platform 40 using bolts 73 or other fastening means.
In Figure 7A, the spokes 20 are shown in between the center hub top crimping die retaining plates 72. In this position, an operator or a machine can mount the spokes 20 easily over the plugs 14 during the initial part of the assembly operation.
Now referring to Figure 7B, the spokes 20 and the center hub connector 10 are shown rotated clockwise into position, automatically or manually, for the crimping operation. In Figure 7B, the spokes 20 now abut the center hub top crimping die retaining plates 72 and the overhang portion 72a positions the top crimping dies 100t directly over the spokes 20 and the plugs 14 inserted into the spoke 20.
Now referring to Figure 8A, a side view of the platform 40 is shown with a representative center hub top crimping die retaining plate 72 mounted on top of the platform 40. For clarity, the other die retaining plates 72 are not shown. The platform 40 may be supported by legs 42 or by other means. Also shown in Figure 8A is the overhang portion 72a which allows the top crimping dies 100t to be positioned over the spokes 20 and the plugs 14 of the center hub connector 10. Furthermore, a center hub crimping tool assembly 80 is shown mounted underneath the platform 40 by means of a hanging support base 46 which is secured to the platform 40 by means of support columns 44.
Now referring to Figure SB, an enlarged view of the center hub bottom crimping tool assembly 70 is shown. The center hub bottom crimping tool assembly 70 comprises a center hub bottom crimping die retaining plate assembly 76 and a hydraulic cylinder 75 which lifts or lowers the die retaining plate assembly 76. The die retaining plate assembly 76 holds bottom crimping dies 100b in position directly underneath opposing top crimping dies 100t which are fastened to the bottom of the overhang portion 72a of the die retaining plate 72.
Referring back to Figures 7A and 7B, once the spokes 20 and the center hub connector 10 are automatically or manually rotated into position, the crimping dies 100t, 100b are positioned directly above and below the end of the spokes 20 and the plugs 14. In the position shown in Figure 7B, the center hub bottom crimping die retaining plate assembly 86 is urged upwards by means of the hydraulic cylinder 75 to push the crimping dies 100t, 100b into the spokes 20 and plugs 14 simultaneously from the top and bottom, respectively. The reverse operation of the hydraulic cylinder 75 releases the hold of the crimping dies 100t, 100b and the spokes 20 can be automatically or manually rotated back to the position in Figure 7A for removal of the completely assembled side wall members.
Now referring to Figures 9A and 9B, an enlarged detailed view of the die retaining plate assembly 76 is shown. The center hub bottom crimping die retaining plate assembly 76 includes a center hub bottom crimping die retaining plate 76a which holds the crimping dies 100 in position. The die retaining plate 76a may be supported by gussets 76b which are also braced against hydraulic cylinder mounts 76c for additional stability. Dowel guide openings 76d are shown in Figure 9A and dowel guides (not shown) help to keep the die retaining plate assembly 76 properly aligned during a crimping operation.
While the above discussion in relation to Figures 4-7B have been described with reference to individual spokes 20 of the type shown in Figure 2D, it will be appreciated that, with a modification of the relative positioning of the telescopic tool support arms 60 and the outer rim crimping tools 50, the discussion would apply equally to the alternative spoke arrangement (fixed spokes 20a) shown in Figure 2E above. The modification would involve repositioning (i.e. rotating) the telescopic tool support arms relative to the platform 40 such that the outer rim crimping tools 50 are appropriately aligned to crimp the outer ends 22a of the fixed spokes 20a to the outer rim 30. Similarly, a minor modification (i.e.
repositioning of the telescopic tool support arms) may be made to accommodate spokes 20b as shown in Figure 2F.
Now referring to Figure 10A, a transverse bar 90 is shown fastened to correspondingly aligned spokes 20 of a pair of side wall members 1. Preferably, the transverse bars 90 are bent at substantially 90°
at either end and these bent portions are fastened onto the corresponding spokes 20 by means of one or more U-bolts 92, plates 33, and nuts 94. More than one U-bolt 92 may be used per connection to provide additional strength. The transverse bars may be of any cross-section, but are preferably square or rectangular. Also, the bars are preferably made of tubing so as to be relatively light weight.
Figure 10B shows the bent end of a transverse bar 90 mounted into an optional receptacle 100. The receptacle 100 is mounted to a spoke 20. In one embodiment, the receptacle 100 is mounted to the spoke 20 by means of a U-bolt 92, plate 93, and nuts 94. Advantageously, the U-bolt may be loosened to reposition the receptacle 100 and then retightened to secure the receptacle 100 in place. The receptacle 100 may be fashioned from a short length of tubing having a cross-section corresponding to the cross-section of the transverse bar 90 being used. In Figures lOB-10D, a transverse bar 90 and receptacle 100 having a square cross-section are shown. The receptacle 100 has suitable inner dimensions which allow the bent end of the transverse bar 90 to fit snugly into the receptacle 100. Now also referring to Figure lOC, it is shown that the bent corner 91 of a transverse bar 90 has a tendency to deform and widen so that the bent ends of the transverse bar 90 will fit snugly into the receptacle 100. Optionally, the receptacle 100 has a bevelled opening 102 to better accommodate the curved portion of the transverse bar 90. Furthermore, the receptacle 100 may be provided with an opening 104 at the opposite end of the opening 102 to allow the outermost portion of the bent end of transverse bar 90 to extend through the receptacle 100. In use, this outermost portion of the transverse bar 90 which extends through the receptacle 100 allows an operator to easily disassemble the reel by tapping out the transverse bar 90 with a hammer or similar tool.
Now referring to Figures 10F-10I, a transverse bar 90 is shown with optional divider bars 110 mounted along its length. The divider bars 110 may be used to divide the reel into two or more segments such that different types of flexible cables, pipes, and the like may be wound on the same reel. The divider bars 110 have a mounting portion 112 which allow the divider bars 110 to be adjustably mounted to a transverse bar 90. The mounting portion 112 provides a ledge 113 which is substantially perpendicular to the divider bar 110. This ledge 113 abuts the transverse bar 90 and allows the divider bars 110 to be mounted to the transverse bars 90 at substantially right angles.
In one embodiment, a U-bolt 92, plate 93 and nuts 94 may be used for mounting. In use, the divider bars 110 would be mounted so that they extend radially outwardly from the center axis of the reel. The length of the divider bars 110 may be selected based on the dimensions of the side wall members 1A, 1B and the radius at which the transverse bars 90 or the receptacle 100 are mounted to the spokes 20.
Now referring to Figure 11A, an exploded plan view of one embodiment of a reel assembly of the present invention is shown. A
plurality of transverse bars 90 are shown between corresponding pairs of receptacles 100 which may be adjustably mounted to corresponding pairs of spokes 20 (not shown) of each side wall member 1. Advantageously, the receptacles 100 may be pre-mounted onto the spokes 20 of each side wall member 1 so that the only step required to assemble the reel is to insert each bent end of the transverse bars 90 into corresponding pairs of receptacles 100. Furthermore, once flexible cables, pipes, and the like have been unwound from the reel, the reel can be easily knocked down by removing the transverse bars 90 from the receptacles 100. As discussed previously, removal may be facilitated by providing an open bottom end 104 to each receptacle 100 so that the transverse bar 90 may be tapped out using a hammer or similar tool.
Now also referring to Figure 11B, when the transverse bars 90 or receptacles 100 are fastened to the spokes 20 at substantially the same radius R from the axial centers of the side wall members 1, a transverse generally cylindrical structure is formed by the transverse bars 90. The cylindrical structure causes the pair of side wall members to be substantially parallel and axially aligned along the axis of rotation of the reel.
The radial distance R of the transverse bar 90 or receptacle 100 from the axial center of the side wall members may be adjusted by loosening the U-bolts 92, plates 93, and nuts 94, aligning the transverse bars 90 to a new radial distance R' (not shown), and then retightening the U-bolts 92, plates 93, and nuts 94. Optional radial distance markings 93 are provided on the spokes 20 to facilitate even adjustment of the transverse bars 90 or receptacles 100 (Figure 10). It will be appreciated that this adjustment may increase or decrease the capacity of the reel which is formed. Advantageously, this adjustment allows cables or pipes which are less flexible to be wound around a generally cylindrical structure which has a larger diameter such that the bending stress put on the cable or pipe is reduced. Alternatively, the capacity of the reel may be increased when the cable or pipe to be wound on the reel can withstand a tighter bend.
The foregoing is a description of various embodiments of the invention which are provided by way of example. It will be appreciated that the invention is not limited to any of the specific features as described, but comprehends all variations which come within the scope of the appended claims.
In an alternative embodiment, the spokes may comprise a plurality of pairs of adjacently fixed spokes formed from the ends of a continuous, bent, elongate member which substantially defines a sector of a circle.
Preferably, the cavities in each of the spokes have a cross-section substantially matching the cross-section of the plugs, whereby the plugs closely fit inside the cavities.
Optionally, the side walls of the plugs are tapered and the cross-section of the plugs progressively broadens towards the base of the plugs, whereby the plugs tightly fit in the cavities when the spokes are driven down onto the plugs.
In one embodiment, the spokes are crimped onto the plugs, so as to lock the spokes onto the plugs.
Advantageously, the rim of the reel is formed from an appropriate length of a U-shaped channel curved substantially into a broken ring, the opening of the U-shaped channel facing radially inward, the rim being flexible so as to allow the rim to be enlarged to receive all of the outer ends of the spokes within the U-shaped channel, the parallel side portions near the outer ends of the spokes closely fitting between the side walls of the U-shaped channel, the rim then being closeable to form an unbroken ring.
Preferably, the outer rim is crimped to the outer ends of the spokes so as to lock the spokes in position.
In a preferred embodiment, the transverse generally cylindrical structure comprises a plurality of transverse bars mounted between a pair of correspondingly aligned spokes of each of the side wall members, the bars being mounted at generally the same radial distance from the center of each of the side wall members.
Advantageously, the radial distance from the center of the side wall members to the transverse bars is adjustable, whereby the diameter of the transverse generally cylindrical structure may be adjusted, so as to adjust the capacity of the reel.
More advantageously, radial distance margins are provided on the spokes so as to facilitate even adjustment of the transverse bars.
In another aspect, the present invention provides a method of assembling a reel, the method comprising the steps of:
a) providing a center hub connector, the center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of the annular axle sleeve, the plugs lying in a common plane;
b) providing a plurality of spokes having a cavity at one end for receiving one of the plugs therein, the spokes lying in the plane and extending radially outwardly;
c) providing an outer rim for connecting an outer end of each of the spokes, the rim being formed from an appropriate length of an U-shaped channel;
d) inserting the plugs into the cavities to connect the spokes to the center hub connector and connecting the outer end of the spokes to the outer rim to form a sidewall member; and e) providing a plurality of transverse bars and mounting each of the transverse bars between a pair of correspondingly aligned spokes of each of a pair of the sidewall members, the transverse bars forming a transverse generally cylindrical structure between the side wall members, the generally cylindrical structure causing the pair of side wall members to be substantially parallel and axially aligned along the axis of rotation of the reel.
Preferably, the method further comprises the step of crimping the spokes over the plugs so as to lock the spokes in position.
More preferably, the method further comprises the step of mounting the transverse bars to the spokes using adjustable U-bolts.
In another aspect, the present invention provides an apparatus for assembling a side wall member, the apparatus comprising:
a) a platform having a defined center position for receiving a center hub connector having plugs;
b) a center crimping tool assembly mounted to the platform at the defined central position, the central crimping tool assembly providing means for crimping an inner end of a spoke onto each of the plugs;
c) a plurality of telescopic arms mounted to the platform and extending radially outwardly from the defined central position, the length of the telescopic arms being adjustable to receive different sizes of the spokes; and d) a plurality of outer rim crimping tool assemblies, each outer rim crimping tool assembly being mounted at an outer end of each telescopic arm, and receiving an outer end of the spokes together with a portion of an outer rim, the outer rim crimping tool providing means for crimping the outer ends of the spokes into the outer rim, the number of outer crimping tool assemblies corresponding to the number of rim-spoke connection points in the side wall member.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A shows a plan view of a first embodiment of a side wall member in accordance with the present invention;
Figure 1B shows a plan view of a second embodiment of a sidewall member in accordance with the present invention;
Figure 2A shows a plan view of a center hub connector for the side wall member of Figure 1A; ' Figure 2B shows a side view of the center hub connector of Figure 2A;
Figure 2C shows an enlarged view of a tapered plug for the center hub connector of Figures 2A and 2B;
Figure 2D shows a first embodiment of a pair of separate spokes for the side wall member of Figure 1A;
Figure 2E shows a second embodiment of a pair of spokes which are formed from the ends of a continuous, bent member;
Figure 2F shows a third embodiment of a pair of separate spokes having bent outer ends;
Figure 3A shows an enlarged partially hidden plan view of a joint connection, between an outer rim and an outer edge of a spoke, on the side wall member of Figure lA;
Figure 3B shows a length of U-shaped channel curved substantially into a ring for the side wall member of Figure lA;
Figure 3C shows a cross-sectional view of the joint connection in Figure 3A, taken along the line A--A of Figure 3A;
Figure 4 shows a top view of an assembly apparatus for assembling the side wall member of Figure 1A;
Figure 5A shows a partially hidden front view of one of the outer rim crimping tools shown in Figure 4;
Figure 5B shows a bottom view of the outer rim crimping tool of Figure 5A;
Figure 5C shows a side view of the outer rim crimping tool of Figure 5A;
Figure 6 shows a side view of a telescopic tool support arm for supporting the outer rim crimping tool of Figures 5A-5C;
Figure 7A shows an enlarged top view of the center hub connector crimping tool shown in Figure 4, together with a center hub connector and spokes for the side wall member of Figure 1;
Figure 7B shows the same components as in Figure 7A but with _7_ the center hub connector and spokes rotated clockwise into position for crimping;
Figure 8A shows a side view of the center hub bottom crimping tool assembly mounted onto a platform, for assembling the side wall member of Figure 1A;
Figure 8B shows an enlarged view of the center hub bottom crimping tool assembly of Figure 8A;
Figure 9A shows a detailed bottom view of a center hub bottom crimping die retaining plate assembly, for assembling the side wall member of Figure 1A;
Figure 9B shows a side view of the assembly of Figure 9A;
Figure 10A shows a transverse bar mounted between two correspondingly aligned spokes of a pair of side wall members;
Figure 10B shows a transverse bar inserted into an optional receptacle mounted onto each spoke;
Figure lOC is a top view of the assembly shown in Figure 10B;
Figure 10D is an end view of the assembly shown in Figure lOB;
Figure 10E shows a plan view of one embodiment of a receptacle which receives one end of a transverse bar;
Figure 10F shows a plan view of optional divider bars which are adjustably mounted onto a transverse bar;
Figure lOG shows a bottom view of the assembly shown in Figure lOF;
Figure 10H shows a detailed plan view of the mounting portion of the divider bar;
Figure 10I shows a bottom view of the mounting portion of the divider bar shown in Figure lOF;
Figure 11A shows an exploded view of one embodiment of the reel of the present invention; and Figure 11B shows an exploded isometric view of another embodiment of the reel of the present invention.
_8_ DETAILED DESCRIPTION OF THE INVENTION
Referring to Figure 1A, a first embodiment of a side wall member 1 of the present invention is shown. Each side wall member comprises a center hub connector 10 connecting a plurality of spokes 20 at their inner ends 21 and an outer rim 30 connecting the spokes 20 at their outer ends 22.
Now referring to Figure 1B, another embodiment of a side wall member 1 of the present invention is shown. Each side wall member 1 comprises a center connector 11 connecting a plurality of spokes 20b at their inner ends 21 and an outer rim 30b connecting the spokes 20b at their outer ends 22b. In Figure 1B each of the spokes 20b are welded at their inner ends 21 to a plate 11a. Advantageously, the outer ends 22b of each of the spokes 20b are bent at their outer ends 22b to allow for a filler joint weld between the outer ends 22b and the outer rim 30b. This detail is illustrated in Figure 1C. It will be appreciated that the center hub connector 10 of Figure 1A may be used instead of the center connector 11 shown in Figure 1B and vice versa. Various other embodiments for the side wall member 1 are possible but each embodiment should include a plurality of spokes extending radially outwardly from a center.
Now referring to Figure 2A, an enlarged plan view of the center hub connector 10 of Figure 1 A is shown. Each center hub connector 10 is formed from a generally annular axle sleeve 12 having a plurality of plugs 14 distributed around and extending radially outwardly from the outer surface of the annular axle sleeve 12. As shown in Figure 2B, the plugs 14 are aligned and lie in a plane which is perpendicular to the axis of rotation of the center hub connector 10. The plugs 14, shown by way of example in Figures 2A and 2B, are generally elongate bars having a square cross-section. However, it will be appreciated that the plugs can have a cross-section of virtually any shape that facilitates mating with an appropriately shaped cavity. For example, the cross-section of the plugs 14 may be circular, rectangular, hexagonal, or another polygonal shape. The length of the plugs 14 is not critical but preferably should be at least as long as the width of the plugs 14 so as to provide adequate support for the spokes 20.
The plugs may be shorter than their width provided that there is still sufficient space for crimping, as described further below.
Optionally, as shown in Figure 2C, a plug 14a may be tapered such that its cross-section progressively broadens towards its base. This tapered plug 14a is designed to fit tightly into an appropriately shaped cavity at the inner end 21 of a spoke 20 when the spoke 20 is driven down onto the plug 14a.
As shown in Figure 2D, individual spokes 20 of generally equal length may be mounted onto the plugs 14,14a by their inner ends 21 which have appropriately shaped cavities (not shown) to receive the plugs 14, 14a. The outer ends 22 may be connected to the rim 30 as described below.
In an alternative embodiment, as shown in Figure 2E, a pair of adjacently fixed spokes 20a are formed from the ends of a continuous, bent, elongate member which substantially defines a sector of a circle. The fixed spokes 20a have a common outer end 22a which is analogous to the outer end 22 of an individual spoke 20. In one possible embodiment, the outer end 22a has substantially the same curve as the rim. Preferably, the fixed spokes 20a form substantially the same angle (angle A° in Figure 2E) as two adjacent individual spokes 20 would when mounted onto two adjacent plugs 14,14a (angle A° in Figure 2D). Note that the tapered plugs 14a are designed to make it easier to mount the inner ends 21 of the fixed spokes 20a onto adjacent plugs 14a, as the ends of the fixed spokes 20a will approach the plugs 14a at an angle.
Now referring to Figure 2F, another embodiment of a pair of spokes 20b is shown. The spokes 20b of Figure 2E have their outer ends bent at substantially 90° which allow them to either fit within a rim formed from a U-shaped channel (described below) or be welded to a rim formed from a tube using a filler joint weld (Figure 1C). Advantageously, a filler joint weld will provide greater strength at the spoke-rim joints.
It will be appreciated that each of the inner ends of the spokes 20, 20a, 20b may also be mounted and/or welded onto a center hub connector as shown in Figures 2A-2C or, alternatively, be welded to a plate lla as shown in Figure 1B.
Now referring to Figure 3A, an enlarged partially hidden view of a rim 30 connected to the outer end of a spoke 20 is shown. In one 5 embodiment shown in Figure 3B, the outer rim 30 is formed from an appropriate length of a U-shaped channel curved substantially into a ring having a break 31. As shown in Figure 3B, the opening of the U-shaped channel is facing radially inwardly. Before the break 31 is closed, the outer rim 30 is flexible so as to allow the diameter of the outer rim 30 to be 10 enlarged to receive all of the outer ends of the spokes 20 which are mounted on the plugs 14,14a within the U-shaped channel of the rim 30.
As shown in Figure 3C, the outer end 22 of a spoke 20 may be secured to the outer rim 30 by means of a crimping connection which partially punctures the side walls of the U-shaped channel and sides of the spokes 20 so that flaps of material 25, 35 are bent inwardly. Once the connections have been made, the break 31 can be closed so that the rim 30 is a continuous ring. The break may be closed in any one of a number of conventional methods, for example, by welding the break 31 together, or by placing a bridge piece (not shown) extending between the two sides of the break 31 and fastening the ends of the break 31 onto the bridge piece by welding, crimping, adhesive, etc. A device for forming a connection at all rim-spoke connection points at the same time is described further below.
For additional strength at the rim-spoke connection points, it is possible to use adhesives or induction welding in conjunction with this type of crimping connection. Alternatively, adhesives or welding could be used instead of crimping.
It will be appreciated that the same type of rim-spoke connection as described above may be formed between an outer rim 30 and the outer end 22a of the fixed spokes 20a shown in Figure 2E. Advantageously, the outer end 22a of the fixed spokes 20a provides additional structural strength between the adjacent fixed spokes 20a and to the outer rim 30 since the entire outer end 22a is received within the U-shaped channel of the rim 30.
As discussed above, in an alternative embodiment (Figure 1B), the rim may be formed from a metal tube which is formed into a ring of suitable diameter for a given set of spokes 20, 20a, 20b. Preferably, the metal tubing used to form the rim 30b has either a square or rectangular cross-section and will allow the outer ends of spokes 20, 20a, 20b to be securely welded to it.
Figure 4 shows a top view of the side wall member 1 of Figure 1 in an apparatus for crimping the spokes 20 onto the center hub connector 10 and for crimping the outer ends of the spokes 20 onto the outer rim 30.
As shown in Figure 4, a center hub connector crimping tool 70 shown in dotted outline is mounted on a platform 40 which supports the center hub connector 10. Extending radially outwardly from the platform 40 are telescopic tool support arms 60 each of which support an outer rim crimping tool 50. The telescopic function is described further below.
Now referring to Figures 5A-5C, an enlarged view of the outer rim crimping tool 50 is shown. The outer rim crimping tool 50 comprises opposing puncture dies 102t, 102b which are retained on die retaining plates 55a, 56a. The puncture dies 102t, 102b are positioned over and under, respectively, each rim-spoke connection point (Figure 3A) and are urged toward each other to form a locked rim-spoke connection as shown in Figure 3C. As illustrated in Figure 5C, the puncture dies 102 are substantially wedge-shaped such that a puncture can be made in the outer rim 30 and spokes 20 and flaps of material 25, 35 are bent inwards to form a locked connection (Figure 3A and 3C). Supporting the top die retaining plate 55a is a top plate 53. A spacer plate 52 of appropriate width to accept a rim 30 is positioned between the top plate 53 and a bottom plate 51 which provides a supporting surface for the rim 30. The plates 51, 52, 53 are secured together, for example, by bolts and nuts (not shown). The bottom plate 51 has an orifice 51a through which the bottom puncture die 102 and die retaining plate 56a can pass in order to urge the bottom puncture die 102 towards the top puncture die 102. The bottom die retaining plate 56a is fastened to the end of a hydraulic cylinder 57 which is extended for the puncturing operation and which is withdrawn for removal of the rim 30 upon completion of the puncturing operation.
Now referring to Figure 6, a partially hidden side view of the telescopic tool support arm 60 is shown. The telescopic tool support arm 60 comprises an outer rim crimping tool mount 62 on top of which the outer rim crimping tool 50 is mounted. The outer rim crimping tool mount 62 may be of tubular structure which partially overlaps with one end of an elongate arm 64. The outer rim crimping tool mount 62 may be adjustable relative to the elongate arm 64 over a limited distance by means of a hydraulic cylinder 68 having one end connected to the elongate arm 64 and the other to the outer rim crimping tool mount 62. The action of the hydraulic cylinder 68 allows the outer rim crimping tool mount 62 to extend outwardly, in order to allow a rim 30 to be positioned in place for connection to the spokes 20, then contract inwardly to secure the rim 30 and position the outer rim crimping tool 50 for the crimping operation, and finally extend outwardly once more to allow the fully assembled side wall member 1 to be removed.
Still referring to Figure 6, another end of the elongate arm 64 is inserted into a tubular elongate arm table mount 66. Optionally, the elongate arm 64 includes a pin hole 64a which can be aligned with one of a plurality of pin holes 66a in the elongate arm table mount 66 and a pin (not shown) can be placed through the aligned pin holes 64a,66a so as to adjust the overall length of the telescopic tool support arm 60.
Alternatively, the elongate arm 64 may be adjusted relative to the elongate arm table mount 66 by means of a hydraulic cylinder (not shown) similar to the actin of the hydraulic cylinder 68 discussed above. This telescopic action further accommodates side wall members 1 having various diameters. Also shown in Figure 6 is a center hub connector 10 in position to receive spokes 20.
Now referring to Figure 7A, a top view of a center hub connector 10 is shown with spokes 20 mounted onto plugs 14 which extend radially outwardly from an annular axle sleeve 12. Still referring to Figure 7A, a center hub connector crimping tool assembly 70 is shown in dotted outline underneath the platform 40. Mounted on top of the platform 40 are center hub top crimping die retaining plates 72 which have an overhang portion 72a holding crimping dies 100 in position with the die tips pointed downwards. The center hub top crimping die retaining plate 72 may be bolted down onto the platform 40 using bolts 73 or other fastening means.
In Figure 7A, the spokes 20 are shown in between the center hub top crimping die retaining plates 72. In this position, an operator or a machine can mount the spokes 20 easily over the plugs 14 during the initial part of the assembly operation.
Now referring to Figure 7B, the spokes 20 and the center hub connector 10 are shown rotated clockwise into position, automatically or manually, for the crimping operation. In Figure 7B, the spokes 20 now abut the center hub top crimping die retaining plates 72 and the overhang portion 72a positions the top crimping dies 100t directly over the spokes 20 and the plugs 14 inserted into the spoke 20.
Now referring to Figure 8A, a side view of the platform 40 is shown with a representative center hub top crimping die retaining plate 72 mounted on top of the platform 40. For clarity, the other die retaining plates 72 are not shown. The platform 40 may be supported by legs 42 or by other means. Also shown in Figure 8A is the overhang portion 72a which allows the top crimping dies 100t to be positioned over the spokes 20 and the plugs 14 of the center hub connector 10. Furthermore, a center hub crimping tool assembly 80 is shown mounted underneath the platform 40 by means of a hanging support base 46 which is secured to the platform 40 by means of support columns 44.
Now referring to Figure SB, an enlarged view of the center hub bottom crimping tool assembly 70 is shown. The center hub bottom crimping tool assembly 70 comprises a center hub bottom crimping die retaining plate assembly 76 and a hydraulic cylinder 75 which lifts or lowers the die retaining plate assembly 76. The die retaining plate assembly 76 holds bottom crimping dies 100b in position directly underneath opposing top crimping dies 100t which are fastened to the bottom of the overhang portion 72a of the die retaining plate 72.
Referring back to Figures 7A and 7B, once the spokes 20 and the center hub connector 10 are automatically or manually rotated into position, the crimping dies 100t, 100b are positioned directly above and below the end of the spokes 20 and the plugs 14. In the position shown in Figure 7B, the center hub bottom crimping die retaining plate assembly 86 is urged upwards by means of the hydraulic cylinder 75 to push the crimping dies 100t, 100b into the spokes 20 and plugs 14 simultaneously from the top and bottom, respectively. The reverse operation of the hydraulic cylinder 75 releases the hold of the crimping dies 100t, 100b and the spokes 20 can be automatically or manually rotated back to the position in Figure 7A for removal of the completely assembled side wall members.
Now referring to Figures 9A and 9B, an enlarged detailed view of the die retaining plate assembly 76 is shown. The center hub bottom crimping die retaining plate assembly 76 includes a center hub bottom crimping die retaining plate 76a which holds the crimping dies 100 in position. The die retaining plate 76a may be supported by gussets 76b which are also braced against hydraulic cylinder mounts 76c for additional stability. Dowel guide openings 76d are shown in Figure 9A and dowel guides (not shown) help to keep the die retaining plate assembly 76 properly aligned during a crimping operation.
While the above discussion in relation to Figures 4-7B have been described with reference to individual spokes 20 of the type shown in Figure 2D, it will be appreciated that, with a modification of the relative positioning of the telescopic tool support arms 60 and the outer rim crimping tools 50, the discussion would apply equally to the alternative spoke arrangement (fixed spokes 20a) shown in Figure 2E above. The modification would involve repositioning (i.e. rotating) the telescopic tool support arms relative to the platform 40 such that the outer rim crimping tools 50 are appropriately aligned to crimp the outer ends 22a of the fixed spokes 20a to the outer rim 30. Similarly, a minor modification (i.e.
repositioning of the telescopic tool support arms) may be made to accommodate spokes 20b as shown in Figure 2F.
Now referring to Figure 10A, a transverse bar 90 is shown fastened to correspondingly aligned spokes 20 of a pair of side wall members 1. Preferably, the transverse bars 90 are bent at substantially 90°
at either end and these bent portions are fastened onto the corresponding spokes 20 by means of one or more U-bolts 92, plates 33, and nuts 94. More than one U-bolt 92 may be used per connection to provide additional strength. The transverse bars may be of any cross-section, but are preferably square or rectangular. Also, the bars are preferably made of tubing so as to be relatively light weight.
Figure 10B shows the bent end of a transverse bar 90 mounted into an optional receptacle 100. The receptacle 100 is mounted to a spoke 20. In one embodiment, the receptacle 100 is mounted to the spoke 20 by means of a U-bolt 92, plate 93, and nuts 94. Advantageously, the U-bolt may be loosened to reposition the receptacle 100 and then retightened to secure the receptacle 100 in place. The receptacle 100 may be fashioned from a short length of tubing having a cross-section corresponding to the cross-section of the transverse bar 90 being used. In Figures lOB-10D, a transverse bar 90 and receptacle 100 having a square cross-section are shown. The receptacle 100 has suitable inner dimensions which allow the bent end of the transverse bar 90 to fit snugly into the receptacle 100. Now also referring to Figure lOC, it is shown that the bent corner 91 of a transverse bar 90 has a tendency to deform and widen so that the bent ends of the transverse bar 90 will fit snugly into the receptacle 100. Optionally, the receptacle 100 has a bevelled opening 102 to better accommodate the curved portion of the transverse bar 90. Furthermore, the receptacle 100 may be provided with an opening 104 at the opposite end of the opening 102 to allow the outermost portion of the bent end of transverse bar 90 to extend through the receptacle 100. In use, this outermost portion of the transverse bar 90 which extends through the receptacle 100 allows an operator to easily disassemble the reel by tapping out the transverse bar 90 with a hammer or similar tool.
Now referring to Figures 10F-10I, a transverse bar 90 is shown with optional divider bars 110 mounted along its length. The divider bars 110 may be used to divide the reel into two or more segments such that different types of flexible cables, pipes, and the like may be wound on the same reel. The divider bars 110 have a mounting portion 112 which allow the divider bars 110 to be adjustably mounted to a transverse bar 90. The mounting portion 112 provides a ledge 113 which is substantially perpendicular to the divider bar 110. This ledge 113 abuts the transverse bar 90 and allows the divider bars 110 to be mounted to the transverse bars 90 at substantially right angles.
In one embodiment, a U-bolt 92, plate 93 and nuts 94 may be used for mounting. In use, the divider bars 110 would be mounted so that they extend radially outwardly from the center axis of the reel. The length of the divider bars 110 may be selected based on the dimensions of the side wall members 1A, 1B and the radius at which the transverse bars 90 or the receptacle 100 are mounted to the spokes 20.
Now referring to Figure 11A, an exploded plan view of one embodiment of a reel assembly of the present invention is shown. A
plurality of transverse bars 90 are shown between corresponding pairs of receptacles 100 which may be adjustably mounted to corresponding pairs of spokes 20 (not shown) of each side wall member 1. Advantageously, the receptacles 100 may be pre-mounted onto the spokes 20 of each side wall member 1 so that the only step required to assemble the reel is to insert each bent end of the transverse bars 90 into corresponding pairs of receptacles 100. Furthermore, once flexible cables, pipes, and the like have been unwound from the reel, the reel can be easily knocked down by removing the transverse bars 90 from the receptacles 100. As discussed previously, removal may be facilitated by providing an open bottom end 104 to each receptacle 100 so that the transverse bar 90 may be tapped out using a hammer or similar tool.
Now also referring to Figure 11B, when the transverse bars 90 or receptacles 100 are fastened to the spokes 20 at substantially the same radius R from the axial centers of the side wall members 1, a transverse generally cylindrical structure is formed by the transverse bars 90. The cylindrical structure causes the pair of side wall members to be substantially parallel and axially aligned along the axis of rotation of the reel.
The radial distance R of the transverse bar 90 or receptacle 100 from the axial center of the side wall members may be adjusted by loosening the U-bolts 92, plates 93, and nuts 94, aligning the transverse bars 90 to a new radial distance R' (not shown), and then retightening the U-bolts 92, plates 93, and nuts 94. Optional radial distance markings 93 are provided on the spokes 20 to facilitate even adjustment of the transverse bars 90 or receptacles 100 (Figure 10). It will be appreciated that this adjustment may increase or decrease the capacity of the reel which is formed. Advantageously, this adjustment allows cables or pipes which are less flexible to be wound around a generally cylindrical structure which has a larger diameter such that the bending stress put on the cable or pipe is reduced. Alternatively, the capacity of the reel may be increased when the cable or pipe to be wound on the reel can withstand a tighter bend.
The foregoing is a description of various embodiments of the invention which are provided by way of example. It will be appreciated that the invention is not limited to any of the specific features as described, but comprehends all variations which come within the scope of the appended claims.
Claims (30)
1. A reel for winding flexible elongate articles, comprising:
a) a pair of side wall members, each side wall member having:
i) a center hub connector, said center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of said annular axle sleeve, said plugs lying in a common plane;
ii) a plurality of spokes having a cavity at an inner end for receiving one of said plugs therein, said spokes lying in said plane and extending radially outwardly;
iii) an outer rim, said rim securely connecting an outer end of said spokes, said rim lying in said plane; and b) a transverse generally cylindrical structure formed between said pair of side wall members, said generally cylindrical structure causing said pair of sidewall members to be substantially parallel and axially aligned along the axis of rotation of said reel.
a) a pair of side wall members, each side wall member having:
i) a center hub connector, said center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of said annular axle sleeve, said plugs lying in a common plane;
ii) a plurality of spokes having a cavity at an inner end for receiving one of said plugs therein, said spokes lying in said plane and extending radially outwardly;
iii) an outer rim, said rim securely connecting an outer end of said spokes, said rim lying in said plane; and b) a transverse generally cylindrical structure formed between said pair of side wall members, said generally cylindrical structure causing said pair of sidewall members to be substantially parallel and axially aligned along the axis of rotation of said reel.
2. The reel recited in claim 1, wherein, said spokes comprise a plurality of pairs of adjacently fixed spokes formed from the ends of a continuous, bent, elongate member which substantially defines a sector of a circle.
3. The reel recited in claim 1 or 2, wherein, said cavity in each of said spokes has a cross-section substantially matching the cross-section of said plugs, whereby said plugs closely fit inside said cavities.
4. The reel recited in claim 3, wherein, the side walls of said plugs are tapered and the cross-section of said plugs progressively broadens towards the base of said plugs, whereby said plugs tightly fit in said cavities when said spokes are driven down on said plugs.
5. The reel recited in claim 4, wherein, said spokes are crimped onto said plugs, so as to lock said spokes on said plugs.
6. The reel recited in claim 1 or 2, wherein, said spokes have substantially flat, parallel side portions near the outer end of said spokes, said parallel side portions being substantially coplanar with the corresponding side portions of said other spokes.
7. The reel recited in claim 6, wherein, the rim is formed from an appropriate length of a U-shaped channel curved substantially into a broken ring, the opening of said U-shaped channel facing radially inward, said rim being flexible so as to allow said rim to be enlarged to receive all of the outer ends of said spokes within said U-shaped channel, said parallel side portions near the outer ends of said spokes closely fitting between the side walls of said U-shaped channel, said rim then being closeable to form an unbroken ring.
8. The reel recited in claim 7, wherein, said outer rim is crimped to the outer ends of said spokes so as to lock said spokes in position.
9. The reel recited in claim 1 or 2, wherein, said transverse generally cylindrical structure comprises a plurality of transverse bars mounted between a pair of correspondingly aligned spokes of each of said side wall members, said bars being mounted at generally the same radial distance from the center of each of said side wall members.
10. The reel recited in claim 9, wherein, the radial distance from the center of said side wall members to said transverse bars is adjustable, whereby the diameter of said transverse generally cylindrical structure may be adjusted, so as to adjust the capacity of said reel.
11. The reel recited in claim 10, wherein radial distance markings are provided on said spokes so as to facilitate even adjustment of said transverse bars.
12. The reel recited in claim 11, wherein said transverse bars are formed from square metal tubing having each end bent substantially at a right angle, said bent ends of said transverse bars being substantially parallel to said spokes and being directed radially inwardly, said bent ends being mounted to said spokes.
13. The reel recited in claim 12, wherein, said bent ends are mounted to said spokes by means of U-bolts.
14. A method of assembling a reel, the method comprising the steps of:
a) providing a center hub connector, said center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of said annular axle sleeve, said plugs lying in a common plane;
b) providing a plurality of spokes having a cavity at one end for receiving one of said plugs therein, said spokes lying in said plane and extending radially outwardly;
c) providing an outer rim for connecting an outer end of each of said spokes, said rim being formed from an appropriate length of an U-shaped channel;
d) inserting said plugs into said cavities to connect said spokes to said center hub connector and connecting the outer end of said spokes to said outer rim to form a sidewall member;
and e) providing a plurality of transverse bars and mounting each of said transverse bars between a pair of correspondingly aligned spokes of each of a pair of said sidewall members, said transverse bars forming a transverse generally cylindrical structure between said side wall members, said generally cylindrical structure causing said pair of side wall members to be substantially parallel and axially aligned along the axis of rotation of said reel.
a) providing a center hub connector, said center hub connector being formed from an annular axle sleeve having a plurality of plugs distributed around and extending radially outwardly from the outer surface of said annular axle sleeve, said plugs lying in a common plane;
b) providing a plurality of spokes having a cavity at one end for receiving one of said plugs therein, said spokes lying in said plane and extending radially outwardly;
c) providing an outer rim for connecting an outer end of each of said spokes, said rim being formed from an appropriate length of an U-shaped channel;
d) inserting said plugs into said cavities to connect said spokes to said center hub connector and connecting the outer end of said spokes to said outer rim to form a sidewall member;
and e) providing a plurality of transverse bars and mounting each of said transverse bars between a pair of correspondingly aligned spokes of each of a pair of said sidewall members, said transverse bars forming a transverse generally cylindrical structure between said side wall members, said generally cylindrical structure causing said pair of side wall members to be substantially parallel and axially aligned along the axis of rotation of said reel.
15. The method of claim 14, further comprising the step of crimping said spokes over said plugs so as to lock said spokes in position.
16. The method of claim 15, further comprising the step of mounting said transverse bars to said spokes using U-bolts.
17. The method of claim 16, further comprising the step of adjusting the radial distance of said transverse bars from the center of said center hub connector by adjusting said U-bolts, so as to adjust the diameter of the generally cylindrical structure.
18. The method of claim 17, further comprising the step of providing radial distance markings on said spokes, so as to facilitate even adjustment of said transverse bars.
19. The method of any of claims 14-18, further comprising the step of crimping the side walls of the U-shaped channel forming said outer rim, so as to lock the outer end of said spokes in position in said outer rim.
20. An apparatus for assembling a side wall member, said apparatus comprising:
a) a platform having a defined central position for receiving a center hub connector having plugs;
b) a center crimping tool assembly mounted to said platform at said defined central position, said center crimping tool assembly providing means for crimping an inner end of a spoke onto each of said plugs;
c) a plurality of telescopic arms mounted to said platform and extending radially outwardly from said defined central position, the length of said telescopic arms being adjustable to receive different sizes of said spokes; and d) a plurality of outer rim crimping tool assemblies, each outer rim crimping tool assembly being mounted at an outer end of each telescopic arm, and receiving an outer end of said spokes together with a portion of an outer rim, said outer rim crimping tool providing means for crimping said outer ends of said spokes into said outer rim, the number of outer crimping tool assemblies corresponding to the number of rim-spoke connection points in said side wall member.
a) a platform having a defined central position for receiving a center hub connector having plugs;
b) a center crimping tool assembly mounted to said platform at said defined central position, said center crimping tool assembly providing means for crimping an inner end of a spoke onto each of said plugs;
c) a plurality of telescopic arms mounted to said platform and extending radially outwardly from said defined central position, the length of said telescopic arms being adjustable to receive different sizes of said spokes; and d) a plurality of outer rim crimping tool assemblies, each outer rim crimping tool assembly being mounted at an outer end of each telescopic arm, and receiving an outer end of said spokes together with a portion of an outer rim, said outer rim crimping tool providing means for crimping said outer ends of said spokes into said outer rim, the number of outer crimping tool assemblies corresponding to the number of rim-spoke connection points in said side wall member.
21. A reel for winding flexible elongate articles, comprising:
a) a pair of side wall members, each side wall member having:
i) a center connector;
ii) a plurality of spokes each having an inner end and an outer end, the inner ends of each spoke being connected to the center connector;
iii) an outer rim, said rim securely connecting said outer ends of said spokes, said outer rim and said spokes lying in a common plane; and b) a transverse generally cylindrical structure formed between said pair of side wall members, said generally cylindrical structure comprising a plurality of transverse bars mounted between a pair of correspondingly aligned spokes of each of said side wall members, said bars being mounted at generally the same radial distance from the center of each of said side wall members.
a) a pair of side wall members, each side wall member having:
i) a center connector;
ii) a plurality of spokes each having an inner end and an outer end, the inner ends of each spoke being connected to the center connector;
iii) an outer rim, said rim securely connecting said outer ends of said spokes, said outer rim and said spokes lying in a common plane; and b) a transverse generally cylindrical structure formed between said pair of side wall members, said generally cylindrical structure comprising a plurality of transverse bars mounted between a pair of correspondingly aligned spokes of each of said side wall members, said bars being mounted at generally the same radial distance from the center of each of said side wall members.
22. The reel recited in claim 21, wherein, a plurality of receptacles are mounted to said spokes to receive each end of said transverse bars between a pair of correspondingly aligned spokes of each of said side wall members, said receptacles being mounted at generally the same radial distance from the center of each of said side wall members.
23. The reel recited in claim 22, wherein, said transverse bars are formed metal tubing having each end bent substantially at a right angle, said bent ends of said transverse bars being substantially parallel to said spokes and being directed radially inwardly, said bent ends being received in said receptacles.
24. The reel recited in claim 22, wherein, the radial distance from the center of said side wall members to said receptacles is adjustable, whereby the diameter of said transverse generally cylindrical structure may be adjusted, so as to adjust the capacity of said reel.
25. The reel recited in claim 24, wherein, radial distance markings are provided on said spokes so as to facilitate even adjustment of said receptacles mounted to said spokes.
26. The reel recited in claim 22, wherein, said receptacles are mounted to said spokes by means of U-bolts.
27. The reel recited in claim 21, wherein, dividers are mounted onto said transverse bars, for dividing the types of cable or pipe that may be wound onto the same reel.
28. The reel recited in claim 27, wherein, said dividers comprise divider bars having a mounting portion, forming a ledge substantially perpendicular to said divider bars to allow said divider bars to be mounted to said transverse bars at substantially right angles.
29. The reel recited in claim 28, wherein, said divider bars are adjustably mounted to each of said transverse bars at said mounting portion.
30. The reel recited in claim 29, wherein, said divider bars are mounted to said transverse bars by means of U-bolts, said divider bars extending radially outwardly from the center axis of said reel.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002271600A CA2271600A1 (en) | 1999-02-26 | 1999-05-13 | Collapsible reel and method of assembly |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2,263,058 | 1999-02-26 | ||
| CA002263058A CA2263058A1 (en) | 1999-02-26 | 1999-02-26 | Collapsible reel and method of assembly |
| CA002271600A CA2271600A1 (en) | 1999-02-26 | 1999-05-13 | Collapsible reel and method of assembly |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2271600A1 true CA2271600A1 (en) | 2000-08-26 |
Family
ID=29712996
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002271600A Abandoned CA2271600A1 (en) | 1999-02-26 | 1999-05-13 | Collapsible reel and method of assembly |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2271600A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8371659B2 (en) | 2007-06-13 | 2013-02-12 | Royal College Of Art | Spoked wheel |
| WO2022069889A1 (en) * | 2020-09-30 | 2022-04-07 | Hs Products Ltd | Wire treatment method and apparatus |
| US11485604B2 (en) | 2020-09-23 | 2022-11-01 | Mmg Industries, Inc. | Disassembable reel apparatus and method |
-
1999
- 1999-05-13 CA CA002271600A patent/CA2271600A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8371659B2 (en) | 2007-06-13 | 2013-02-12 | Royal College Of Art | Spoked wheel |
| US11485604B2 (en) | 2020-09-23 | 2022-11-01 | Mmg Industries, Inc. | Disassembable reel apparatus and method |
| WO2022069889A1 (en) * | 2020-09-30 | 2022-04-07 | Hs Products Ltd | Wire treatment method and apparatus |
| GB2599638A (en) * | 2020-09-30 | 2022-04-13 | Hs Products Ltd | Wire treatment method and apparatus |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |