Cable reel system

A cable reel assembly system in which a teach pendant cable can be removably installed. An insert is positioned in alignment with an aperture in a central spool cylinder, and an adapter is mounted to the insert. A teach pendant cable can be removably connected to the adapter.

Not Applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates to cable reel systems and more specifically to cable reel systems for use in connection with teach pendants in manufacturing and other industrial settings.

BRIEF SUMMARY OF THE INVENTION

Teach pendants, also referred to as teach boxes, are typically handheld devices that are used to program the motion of robotic devices. Teach pendants are typically interfaced with a control box using a teach pendant cable. Teach pendant cables vary in length and can typically range from 15 feet to 60 feet (or longer) in length. A teach pendant cable reel is typically mounted on or near the control box. When a user desires to program a robot, the user will typically pick up the teach pendant and unreel the teach pendant cable as the user walks over to the robot to be programmed.

Teach pendant cables can become damaged from a variety of causes. In conventional teach pendant cable reel systems, all or portions of the cable reel assembly typically must be disassembled to replace the damaged teach pendant cable. In some instances, the entire teach pendant cable system must be sent back to the manufacturer to replace a damaged teach pendant cable. These circumstances result in increased cost and increased downtime. A continuing need exists for a teach pendant cable reel system in which a damaged teach pendant cable reel can be replaced without the need to disassemble the entire cable reel unit or sending the entire cable reel unit back to the manufacturer.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIG. 1, a front view of cable reel unit10is shown. Cable reel unit10typically includes a spool assembly100having a first spool sidewall110and a second spool sidewall120and a central spool cylinder200. A cable500(shown inFIG. 2), such as a teach pendant cable, is typically wrapped around central spool200and retained in place by sidewalls110and120. Referring toFIG. 2, a first end510of cable500attaches to a teach pendant600, typically at teach pendant coupling610. A second end520of cable500is electrically connected to a control box (not shown). A connector525proximate end520typically is connected to the spool assembly100at adapter300, shown inFIG. 1. Adapter300is typically mounted in central spool cylinder200to permit cable500to interface with spool assembly100. Adapter300typically is a mating connector, but can likewise be any other component for electrically coupling cable500with spool assembly100. Adapter300can be selected from a variety of configurations to accommodate the wiring and pin configuration of a desired teach pendant cable500.

Referring back toFIG. 1, adapter300is typically interfaced with central spool cylinder200via insert400. As shown inFIG. 1, insert400typically includes a first surface402, second surface404, and side surfaces406and408. Insert400is typically positioned to be in alignment with an aperture202in central spool assembly200. Adapter300is typically inserted through an aperture (not shown) in the first surface402of insert400and held in place with a threaded collar302. Other suitable structures to affix adapter300to insert400can likewise be used.

Referring now toFIG. 3, a side view of insert400is shown as it is typically installed proximate the inner surface220of central spool cylinder200. As shown inFIGS. 1 and 3, insert400is typically affixed to the inner surface220of central spool cylinder200using fasteners422,424,426, and428, which are inserted through apertures in insert flange430and apertures in central spool200. Fasteners422,424,426, and428are typically screws, but any other suitable fastener can likewise be used to affix insert400to cylinder200. As shown inFIG. 3, insert flange430is typically configured with a curvature that generally matches the curvature of the inner surface220of spool assembly200, thereby permitting flange surface430to interface with the inner surface220of spool cylinder200.

Still referring toFIG. 3, insert400is typically shaped and positioned to minimize the stress at the interface of adapter300and cable500, thereby reducing the likelihood of damage to the electrical connection between the cable500and adapter300. The first surface402of insert400typically extends in a direction generally perpendicular to the inner surface220of spool cylinder200at the general location where these surfaces meet. This orientation typically reduces the amount of stress exerted on adapter300because it orients the interface of adapter300and cable500to be generally aligned with the central axis of cable500at this interface location as cable500is reeled and unreeled. This stress is typically reduced by causing the forces exerted by cable500as it is reeled and unreeled to be orthogonal to the surface of adapter300(i.e., primarily along the longitudinal axis of cable500at the location where it interfaces with adapter300). This orthogonal force is typically bore by the threaded interface connecting adapter300to cable500at connector525, and the lateral force that might cause damage to the electrical connection is typically minimized.

Still referring toFIG. 3, the first insert surface402typically has a length less than the radial distance between the inner surface220of spool cylinder200and the outer surface710of slip ring assembly700. This configuration typically enables surface402to extend in a generally perpendicular direction to the surface of central cylinder200at the general location where surface402meets with the inner surface220of central cylinder200. The second insert surface404typically has a sloped shape that provides a guide path for cable500as it passes from the outer surface210of central cylinder200and through aperture230in cylinder200.

Referring toFIG. 3, spool assembly100(seeFIG. 1) is shown facing the outer surface of spool sidewall110. A support arm150is interconnected with the inner hub140of spool assembly100and extends outward as shown. Support arm150can also be interconnected at other suitable locations within spool assembly100. A slip ring assembly700is likewise interconnected with spool assembly100. Slip ring assembly700typically rotates with the spool assembly100and maintains an electrical connection between teach pendant600and a cable (not shown), such as a pigtail cable, that interconnects with a control panel (not shown). A cable315is typically interconnected with slip ring assembly700and typically terminates at adapter300. Cable315is typically supported by support arm150. Adapter300can be removably interconnected, or mated, with connector525, which is interconnected with teach pendant cable500.

Referring toFIGS. 4 and 5, following is an illustrative, nonlimiting example of usage of the present invention. Step 1: Securely mount the reel assembly10in its desired position using bolts such as ⅜″ (M10) bolts. The spool centerline should be aligned with the cable guide800as shown inFIG. 5. Step 2: Position the cable guide800. The guide800should be oriented so that the cable500comes off the reel10in a straight line without bends. It should be noted that the reel10is typically pre-tensioned if the cable stop530and teach pendant cable500were factory installed on the cable reel10. Step 3: Adjust the cable stop530to the desired position. Step 4: Connect the reel pigtail connector (not shown) to the controller (not shown). Step 5: Connect the teach pendant cable connector525to the teach pendant600and re-spool the teach pendant cable500to a desired length by re-engaging the ratchet lock (not shown). Turn on power to the teach pendant600and check all electrical signals.

Spring Tension Procedure

The tension on reel10can be adjusted by adding wraps of cable500(increasing tension) or removing wraps of cable500(decreasing tension). Step 1: Pull about 10 feet of cable500from reel10, allowing spool100to rotate. Step 2: Test reel10operation for desired effect. Re-adjust as desired using the foregoing procedures.

Cable Removal Procedure

The following procedure can be used to remove a worn or damaged teach pendant cable500from the reel10prior to installation of a new teach pendant cable500. Step 1: Turn off all electrical power. Step 2: Disconnect the cable500from the teach pendant600. Step 3: Remove the cable stop530and allow the teach pendant cable500to retract on to the spool100. Ensure all tension is off the spring (not shown) by manually rotating the spool100(normally clockwise when viewed from the junction box side). Step 4: Remove the cable500from the spool100by looping the cable500over the spool sidewall110and large slip ring cover130. Step 5: Disconnect the teach pendant cable connector525from the adapter, or mating connector,300mounted in the center of the spool cylinder200. If a wire tie was used, carefully snip and remove the wire tie.

Cable Installation

Step 1: Unspool the new cable500and, if feasible, lay it out to eliminate any twists. This step typically assists in the winding operation of the reel10and prolongs cable500life. Step 2: Take the teach pendant connector525side of the teach pendant cable500and slide it through the cable guide800. Continue this process until all the teach pendant cable is through the cable gland, or cable stop,530and guide800except for approximately the last foot of cable500. Step 3: Plug the teach pendant cable connector525into the mating connector, or adapter,300that is mounted in the center of the spool100. Make sure that the cable connector525is aligned properly and threaded correctly on to the spool's connector, or adapter,300. If necessary a wrench may be used to tighten the cable connector300, but this should be done with caution to avoid over-tightening. As an extra precaution, gently wrap a wire tie around the last foot of the teach pendant cable500to the end of the cable500to keep the connector300from being pulled and damaged. The wire tie should not be over-tightened. Step 4: Wind the teach pendant cable500back on the reel spool100by hand rotating the spool100in direction it turns free of spring tension (normally clockwise when viewed from the junction box side.). Step 5: Install and adjust the cable stop530to the desired position. Step 6: Turn on power to the teach pendant600and check all electrical signals. Step 7: Pre-tension the reel100and complete the installation.

All patents, patent publications, and peer-reviewed publications (i.e., “references”) cited herein are expressly incorporated by reference to the same extent as if each individual reference were specifically and individually indicated as being incorporated by reference. In case of conflict between the present disclosure and the incorporated references, the present disclosure controls.

It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the claims.