Winding and unwinding apparatus incorporating wrapping arms

Apparatus (10) for unwinding a flexible cable (C) from a storage reel (S) on which the cable is wound. The cable is wound onto a take-up drum (50). An arm mechanism (60) engages the cable and wraps it about the drum. A mechanism (64) is provided for continuously rotating the arm mechanism, this rotation unwinding a length of cable from the storage reel at the same time another length of cable is wound onto the take-up drum. In addition, a mechanism (66) is provided for simultaneously moving the arm mechanism longitudinally with respect to the drum for the cable to be wound onto the drum along the entire length thereof.

BACKGROUND OF THE INVENTION 
This invention relates to the underground laying of cables such as fiber 
optic cables in which the cable must be unwound from a reel when an 
obstruction is encountered and then rewound after an end of the cable is 
fed under or through the obstruction, and more particularly, to apparatus 
for automatically performing the unwinding operation in a rapid and 
efficient manner. 
A well-known problem in the laying of underground cables, including fiber 
optic cables, is how to lay the cable under an obstruction. Encountering a 
roadway or similar obstacle through which a trench could not be 
conveniently routed, has meant that a tunnel or bore has had to be driven 
under the obstacle. This further involved the necessity of unwinding the 
cable from a storage reel, feeding the free end of the cable through the 
tunnel, and then rewinding the cable back unto the reel on the other side 
of the obstruction. This operation has involved considerable man-hours of 
effort and the tortuous laying of cable on the ground in various patterns 
so that the cable could be more readily rewound. 
Different devices for handling cable are known in the art. See, for 
example, U.S. Pat. Nos. 4,744,696, 4,701,098, 4,568,035, 4,542,861, 
4,454,999, 4,447,013, and U.S. Pat. No. 4,338,059. In addition to these, 
there is also U.S. Pat. No. 4,871,127, which discloses a portable device 
for storing an endless cable. The device includes a slotted center tube in 
which the clack end of a cable is installed. The cable is also looped 
inside a reel and transversely inserted into a bail and snatch blocks. A 
drum is then rotated and reciprocates such that the cable is wound onto 
the reel. While the device does alleviate some of the problems described 
above, including reducing the time and man-hours required to unwind a 
cable, other apparatus should be available which is simpler to use, and as 
cost effective. Furthermore, it is a requirement of the shown device that 
the cable must always be centrally oriented, and threaded through the 
center of the device to operate. 
SUMMARY OF THE INVENTION 
Among the several objects of the present invention may be noted the 
provision of cable unwinding apparatus for in-ground cables such as fiber 
optic cables which eliminates the need to lay a cable out on the ground 
when the cable is to be routed through an obstacle; the provision of such 
apparatus which is portable for movement to a work site at which an 
obstacle is encountered; the provision of such apparatus by which cable 
being laid underneath an obstruction can be quickly and easily unwound 
from a storage reel for the free end of the cable to be routed through the 
obstruction with the cable then being easily rewound back onto the storage 
reel; the provision of such apparatus to which the cable is readily 
attached prior to beginning an unwinding operation; the provision of such 
apparatus for reciprocally winding the cable on a drum so long lengths of 
cable can be wound on a compact drum; the provision of such apparatus 
which is hydraulically operated; and, the provision of such apparatus 
which requires few people to operate so to substantially save on labor 
costs. 
In accordance with the invention, generally stated, apparatus for unwinding 
a flexible cable from a storage reel on which the cable is wound comprises 
a cable drum onto which the cable is wound. The cable is engaged by a 
series of wrapping arms which wrap the cable about the drum. The wrapping 
arms are continuously rotated about the drum, this rotation unwinding a 
length of cable from the reel at the same time another length of cable is 
wound onto the drum. The wrapping arms are simultaneously moved 
longitudinally with respect to the drum for the cable to be wound onto the 
drum along its entire length. Other objects and features will be in part 
apparent and in part pointed out hereinafter.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to the drawings, cable C such as a flexible, fiber optic cable is 
to be laid in a trench T. Although the description that follows is with 
regard to cable C, the cable can be any appropriate type of flexible 
in-ground cable. The depth to which the cable is laid is typically below 
the frost line to prevent damage to the cable during the winter. While not 
shown, it will be understood that trench T is created by a cable laying 
tractor, back hoe, or the like, R having a trenching implement I on its 
front end creating the furrow in ground G in which the cable is laid. 
Typically, the tractor also has a cable storage reel S on which the cable 
was initially wound. Several thousands of feet of cable may be wound on 
the drum. As the tractor proceeds across the surface, cable is unwound 
from the reel and deposited in the trench. Thereafter, the cable is 
covered by the soil displaced as the trench was formed. 
Throughout the course of a cable laying operation, an obstacle or 
obstruction, e.g. roadway O, may be encountered which the trenching 
implement cannot dig a channel across. When this happens, a tunnel or bore 
B is created beneath the obstacle. Now, the cable must be unwound from the 
storage reel. The free end of the cable is then fed through the tunnel and 
the cable rewound on the reel. Heretofore, this involved unwinding the 
cable from the reel and laying it out on the ground. The cable typically 
was laid on the ground in a series of loops or FIG. 8 pattern. When the 
cable was totally unwound and the end of the cable routed through the 
tunnel, the cable was rewound on the storage reel so the cable laying 
process could continue. Such an operation was both time consuming and 
involved substantial man-hours of effort; especially if there were 
thousands of feet of cable on the reel. Some improvements have previously 
been made in simplifying this operation and cutting down on both the labor 
and time involved. See, for example, U.S. Pat. No. 4,871,127 which 
presents one alternative to the previous manual methods. 
As shown in FIG. 1, apparatus of the present invention, indicated generally 
10, comprises a portable, wheeled vehicle 12 which has a tow bar 14 by 
which the vehicle can be hitched to a powered vehicle such as the truck K 
and towed along as the cable laying operation moves from place to place. 
The apparatus includes a generally rectangular frame 16 from which struts 
14a, 14b, diagonally, forwardly extend from the respective front corners 
of the frame to form tow bar 14. A pintle 18 is attached to the forward 
ends of the struts for connection to a hitch H on the back of truck K. A 
jack 20 is mounted along the length of strut 14a, when the apparatus is 
unhitched from truck K, to provide a support leg for the apparatus. 
Referring to FIGS. 2-4, it will be seen that frame 16 includes a pair of 
spaced apart, parallel, side members 22a, 22b. The frame also includes 
respective end members 24a, 24b, and intermediate lateral support members 
24c and 24d. Fenders 26a, 26b are affixed to the respective side members 
at a point intermediate the length of the side members. Wheels 28 are 
covered by these fenders and the wheels are mounted on the respective ends 
of a transversely extending axle 30. Spaced apart, parallel, longitudinal 
members 32a-32d extend between end member 24b and support member 24d. In 
addition, struts 34a, 34b angle upwardly and inwardly from the front end 
of the frame; as do respective parallel struts 36a, 36b. The respective 
upper ends of the struts are connected by lateral members 38 and 40. The 
sides of the resulting frame are covered with sheets of metal 42, and 44, 
as is the top of the frame by a sheet 46. Sheet 42, which comprises a 
control panel for the apparatus, as will be described hereinafter, extends 
from the top to the bottom of the struts 34a, 36a. Sheet 44 extends 
substantially, but not completely, from the top to the bottom of the 
struts 34b, 36b. 
A cable take-up drum 50 comprises a hollow cylinder 52, one end, the 
forward end of which is attached in any convenient manner to the struts 
36a, 36b. The drum may be of any convenient length, it being understood 
that up to several thousand feet of cable C may be wound about the outer 
surface of the cylinder. At each end of the drum are a series of radially 
extending spokes 54 which extend about the circumference of the ends of 
the drum. Respective bands 56a, 56b extend around the ends of the drum and 
the outer end of the spokes are attached to the inner face of the bands. 
The spokes and bands form respective end structures for the take-up drum 
and define the total diameter of the drum assembly about which the cable 
can be wound. Again, this may be any convenient diameter capable of 
permitting long lengths of cable to be wound onto the drum. The drum is 
rigidly attached to frame 16. A pair of supports 58a, 58b, extend 
transversely of the cylinder at the rear end of the drum and intermediate 
the length thereof respectively. The ends of the supports are attached to 
the inner wall of the cylinder and the supports are installed above the 
centerline L of the cylinder and parallel to the transverse axis of the 
cylinder. 
An arm means 60 is provided for engaging cable C and wrapping it about the 
outer surface 62 of cylinder 52. To perform this function and, further, to 
have the arm wrap the cable along the entire length of the drum, apparatus 
10 is also provided with a means 64 for continuously rotating the arm 
means as well as a means 66 for simultaneously moving the arm means 
longitudinally with respect to the drum. Means 64 is also designed to move 
the arm means in a reciprocal manner so the cable is wound over the drum 
in arranged and uniform layers, one layer of winding being formed when the 
arm means is moved longitudinally in one direction with respect to the 
drum and the next layer when the arm means is moved back in the opposite 
direction. Referring to FIG. 6, a shaft 68, whose length is substantially 
greater than that of the take-up drum has its forward end journalled in a 
bearing assembly 70. As shown in FIG. 4, a trapezoidal plate 72 extends 
between and is attached to struts 34a, 34b. A screen wire mesh 74 is 
installed above the plate. The side plates 42 and 44, the top plate 46, 
the plate 72 and the screen thus form a housing 76 immediately forward of 
the forward end of the drum. The plate has an opening 78 for the forward 
end of the shaft and the bearing assembly is mounted on the inside surface 
of the plate inside the housing. A sprocket assembly 82 is mounted to the 
shaft at point inside the housing. The assembly includes a hub 84 fitting 
over the shaft and a sprocket 86. A hydraulic drive motor 88 is mounted 
inside the housing. The motor has an output shaft 90 on the end of which a 
drive sprocket 92 is mounted. An endless chain 94 is installed over the 
sprockets for the motor to turn the shaft when the motor is running. 
A sleeve 96 is sized to fit on shaft 68 and slide thereover. The length of 
the sleeve is less than that of the shaft. Opposed longitudinal slots 98, 
only one of which is shown in FIG. 6, extend intermediate the length of 
the sleeve. The slots are identical in length and position. Pins 100 are 
insertable through the slots into the side of shaft 68. The pins serve 
both to capture the sleeve on the shaft and to limit the distance the 
sleeve can slide along the shaft. As will be described hereinafter, this 
determines the distance the arm means can move with respect to the take-up 
drum. Rearwardly of the rear end of the slots is a circular plate 102 
which extends radially outwardly from the side of the sleeve. Rearwardly 
of the plate is hub assembly 104. This hub assembly comprises a portion of 
the arm means 60. 
Referring to FIGS. 7 and 8, hub assembly 104 includes a collar 106 which 
fits over shaft 68 and attaches to the rear end of sleeve 96. For example, 
the collar is threadably received on the end of the sleeve. Opposed arms 
108, 110 extend radially outward from the collar. A counterweight assembly 
112 is attached to the outer end of arm 108. Assembly 112 includes a 
paddle-shaped weight 114 affixed on the end of a hollow arm 116. Arm 116 
is rectangular in cross-section and sized to be received on the end of arm 
108. Arm 108 has a series of linearly spaced holes 118 and the end of arm 
116 fitting onto arm 108 has a pair of corresponding holes. This allows 
the position of the counterweight on the end of arm 108 to be adjustable. 
Pins 120 are inserted through the corresponding openings in the arms 116 
and 108 when the counterweight assembly is properly positioned. 
Arm means 60 includes a plurality or series of spaced apart wrapping arms 
122a-122d. It will be understood that there can be more or fewer wrapping 
arms than the four shown in the drawings. The arms are spaced an angular 
distance from each other, the angle Q being equal in this instance; 
although the angle could vary. Further, the length of the arms becomes 
increasingly longer from are 122a through arm 122d. It will be noted, 
however, that arm 122a, the shortest arm, has a length generally 
corresponding to the radius from the centerline of the take-up drum to the 
circumference of the bands 56a, 56b. As shown in FIG. 7, arm 122a is 
comprised of an arm section 124. Arms 122b-122d are each comprised of arm 
sections 126b-126d all of which are of equal length but longer than 
section 124. Arms 122b-122d each further comprise a second arm segment 
128, 130, and 132 respectively. These second arm sections are located at 
the respective distal ends of the first arm sections and extend 
orthogonally thereto. As shown in FIGS. 1 and 2, the sections extend 
forwardly over the drum and are radially spaced outwardly therefrom. Arm 
section 130 is longer than section 128; while arm section 132 is longer 
than section 130. Tie bars 134a-134c interconnect adjacent arms to provide 
structural rigidity to the assembly. Tie bar 134a extends between arm 
sections 124 and 126b, tie bar 134b between sections 128 and 130, and tie 
bar 134c between sections 130 and 132. As best seen in FIG. 8, the tie 
bars are attached in a staggered arrangement to help improve the rigidity 
of the assembly. 
Respective cable guides 136a-136d are affixed to the respective outer ends 
of the wrapping arms 122a-122d. Each guide comprises a sheave 138 mounted 
in a rectangular frame 140. The sheaves are preferably of a low friction 
elastomeric material to facilitate movement of the cable through the 
guide. Further, each frame has an openable and closable section 142 (see 
guide 136d) to facilitate installation of a section of the cable in the 
respective guides at the beginning of a cable unwinding operation. Section 
142 may be of any convenient design which allows the section to be opened 
for installation of the cable in the guide and which can be thereafter 
closed and locked in place to prevent inadvertent dislodgement of the 
cable during the unwinding operation. Each cable guide is arranged at a 
particular angle as shown, to conveniently direct the cable onto or off of 
the drum during application. 
In addition to the cable guides 136a-136d, at the rear of vehicle 12 is a 
cable guide 144 (see FIGS. 1 and 2). The guide comprises a short hollow 
cylinder 146 having an openable and closeable section 148. Again, this 
section can be of any convenient design which will not inadvertently open 
during an unwinding operation. Guide 144 is aligned with the longitudinal 
centerline of drum 50, and is therefore mounted on the upper ends of 
respective struts 150a, 150b which extend diagonally upwardly from the 
rear end of respective frame side members 22a, 22b. In addition, a 
vertical support 152 extends upwardly from end frame member 24a. 
To obtain reciprocal longitudinal movement of the wrapping arm assembly, a 
hydraulic ram or cylinder 154 is mounted within cylinder 52. A support 
bracket 156 vertically depends from the forward, upper end of the 
cylinder, and the forward end of the cylinder is attached to this bracket 
by a pin 158. Hydraulic cylinder 154 extends lengthwise of cylinder 52 at 
a point above the transverse supports 58a, 58b. A piston rod 160 extends 
rearwardly from the rear of the hydraulic cylinder. A slide 162 is 
installed in a guide 164. The guide comprises a hollow tube which is 
rectangular in cross-section. The guide extends longitudinally of cylinder 
52 and the respective ends of the guide are supported on the upper faces 
of supports 58a, 58b. Further, the guide is parallel to the hydraulic 
cylinder. The length of slide 162 is approximately the same as the length 
of the take-up drum. The rear end of the slide is attached to the outer 
end of piston rod 160 by a connector 166. This connector is a vertically 
extending bracket which attaches to the outer end of the piston rod, at 
the upper end of the bracket, and to the rear end of the slide, at the 
lower end of the bracket. This connection can be achieved in any 
convenient manner such that as the piston rod moves into and out of the 
hydraulic cylinder, the slide moves with it. Depending beneath the slide, 
at the outer end thereof, as a pair of spaced apart pins are bearing 
members 168a, 168b. As seen in FIG. 6, the spacing between the pins is 
such that they straddle plate 102 on sleeve 96. 
Located beneath housing 76, and installed on the frame members 32a-32d are 
a battery 170, a gasoline powered hydraulic pump 172, and a hydraulic 
fluid reservoir 174. Mounted on side panel 42 are controls for operating 
motor 88 and the pump. Referring to FIG. 9, the various controls mounted 
on panel 42 are shown. An "On-Off" switch 176, a "Start" switch 178, and 
throttle and choke controls 180, 182 respectively are used to start the 
hydraulic pump and supply electrical current to the hydraulic controls 
184, 186 mounted behind panel 42 (see FIG. 3). Hydraulic fluid lines 
188-196 are routed between the pump, reservoir, controls, drive motor and 
ram for the apparatus to perform an unwinding operation. 
At the beginning of an unwinding operation, truck K backs vehicle 12 up to 
the location where the cable unwinding operation is to take place. A 
length of cable is unwound from drum S. The various cable guides 144 and 
136a-136d are opened, and the cable is installed in each guide which are 
then closed. Since there is usually no free end of the cable which could 
be attached to the take-up drum 50, a length of cable is routed between 
the spokes 54 at the forward end of the drum and the cable is inserted in 
a clamp 198 located on side panel 44. To further secure this section of 
the cable, it can further be routed through hooks 200 located on the inner 
face of fender 26b. This insures there will be no interference during the 
unwinding operation. Once the cable is installed in the various guides and 
a length clamped in place, the operator moves handle 202 on panel 42 to 
the "On" position. This activates hydraulic drive motor 88 to begin 
rotation of shaft 68 and, in turn, arm means 60. By rotating crank 204 on 
panel 42, the operator can speed up or slow down the rotation of the arm 
means. 
As arm means 60 rotates, cable is wrapped around take-up drum 50 and 
simultaneously unwound from reel S. Since the arm means rotates completely 
about drum 50, cable is wrapped completely about the drum. Because the 
cable is clamped in place by clamp 200, rotation of the arm means creates 
a pulling action by which the cable is unwound from reel S. It is then 
drawn through guide 144 and pulled successively outwardly from the center 
of the apparatus by the movement of the arms 122a-122d. From the outermost 
arm 122d, the cable is deposited on the outer surface 62 of the take-up 
drum. 
If only a small length of cable is to be unwound and wrapped onto the drum 
50, the longitudinal position of the arm means relative to the take-up 
drum can remain stationary. Where, however, a substantial length of cable 
is to be wrapped, it is preferable if the cable were wrapped onto the drum 
in layers. To accomplish this, the moving means 66 is activated to move 
the arm means longitudinally of the drum simultaneously with its rotation 
about the drum. The operator accomplishes this by moving lever 206 on 
panel 42 between the "In" and "Out" positions. Setting the lever to the 
"Out" position causes hydraulic fluid to be pumped into cylinder 154 to 
push the piston 160 to the left as viewed in FIG. 6. This moves arm means 
60 also to the left, via the force of the piston on plate 102 via slide 
162, so the cable is succeedingly deposited over the leftward or rearward 
portions of the take-up drum. When the cable is being deposited on the 
extreme rear portion of the drum, the operator moves lever 206 to the "In" 
position. Now piston 160 is drawn back into the cylinder and the arm means 
is moved to the right; again, by the force of the piston on plate 102 via 
slide 162. As the arm means now moves to the right, a new layer of cable 
is wrapped about the drum over the previously wrapped layers. The operator 
can also control the speed of this reciprocal movement of the arm means by 
adjusting the position of a crank 208 on panel 42. When the cable is 
completely unwound, so the end of the cable is now wrapped on the take-up 
drum, tractor R is moved to the other side of the obstacle. The end of the 
cable is now rerouted through the guides 136a-136d and 144 and connected 
to the reel S. The cable can now be pulled through the tunnel or bore 
beneath the obstacle and unwound from the take-up drum back onto the reel 
using the arm means to perform the unwinding operation. 
It will be understood that variations on the above components comprising 
apparatus 10 could be included without effecting the overall operation of 
the apparatus as described. For example, vehicle 12 could be a powered 
vehicle and not have to be hitched to another vehicle for movement from 
one place to another. Also, the arm rotating means 64 and arm moving means 
66 could be electrically rather than hydraulically driven. Further, rather 
than having the operator control the longitudinal movement of the arm 
means, a sensing means such as an optical sensor could be located inside 
cylinder 52, at each end of the cylinder. The sensors would detect the 
position of slide 162 and when the location of the slide indicated the 
arms means had reached the nearest or farthest end of its travel, the 
direction of movement could be automatically reversed. In addition, 
apparatus 10 has a protective guard 210 comprising a wire mesh screen 
formed in a semi-circular pattern and attached to a frame 212 that is 
attachable to frame 12. The guard could, instead be of a translucent sheet 
material or otherwise fabricated so as to permit the operator a clear view 
of the operation of the apparatus while safeguarding him and any other 
persons in the vicinity of the apparatus. 
In view of the foregoing, it will be seen that the several objects of the 
invention are achieved and other advantageous results are obtained. 
As various changes could be made in the above constructions without 
departing from the scope of the invention, it is intended that all matter 
contained in the above description or shown in the accompanying drawings 
shall be interpreted as illustrative and not in a limiting sense.