Abstract:
A parallel conductor spool can support multiple independently rotating bays. The parallel conductor spool may be used to hold and pay-out materials. The parallel conductor spool can support independent rotation of the bays at differing rates to provide for paying-out conductors of varying sizes at different speeds. The parallel conductor spool may be modular and expandable to support various configurations. The parallel conductor spool may be formed of disposable or recyclable materials to reduce the cost and logistical complexity of returning the spool. The bays within the parallel conductor spool can be configured to accommodate changes in product size, type, lengths, and the number of items on, or bays within, the spool.

Description:
BACKGROUND 
       [0001]    During installation, wires, conductors, or cables may be dispensed from the spools upon which they are provided to the installer. The spools may be mounted on an axle to support rotation of the spools during the dispensing process. For example, a 48 inch heavy wooden reel may be used to transport and provide conductors to an installation site. 
         [0002]    Often, more than one conductor or wire may be installed simultaneously. The simultaneous installation of multiple conductors may be referred to as paralleling. Paralleling may be achieved by providing multiple conductors on a spool or reel. However, when paralleling conductors of differing sizes, the conductors may be dispensed at varying rates leading to the accumulation of slack in one or more of the conductors as they are dispensed. Furthermore, mechanical interference between the conductors may be caused by accumulated slack or other interactions between the conductors as they are dispensed. Such accumulated slack, mechanical interference, or other interactions may result in entanglement or damage of the conductors during installation. These installation complications may result in wasted materials or wasted labor time leading to higher costs and delays. 
         [0003]    Larger spools and reels used for wires and conductors are often returnable to vendors or manufactures for reuse. Returnable materials, such as these, often result in losses, additional costs, and various logistical complications. 
       SUMMARY 
       [0004]    It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended for use in limiting the scope of the claimed subject matter. 
         [0005]    Apparatus, systems, and methods are described herein for parallel conductor spools having multiple independently rotating bays. The parallel conductor spool may also be referred to as a multi-bay reel. The parallel conductor spool is used to hold and pay-out, or dispense, materials. The parallel conductor spool can support independent rotation of the bays at differing rates to provide for paying-out conductors of varying sizes at different speeds. The parallel conductor spool may be modular and expandable to support various configurations. The parallel conductor spool may be formed of disposable or recyclable materials to reduce the cost and logistical complexity of returning the spool. The bays within the parallel conductor spool can be configured to accommodate changes in product size, type, lengths, and the number of items on, or bays within, the spool. 
         [0006]    According to at least one embodiment, a spooling system includes a reel. The reel comprises two fixed end flanges, two or more independently rotatable bays disposed along a common axis of rotation between the two fixed end flanges, and a rotation lock for temporarily fixing the rotation of the bays to the two fixed end flanges. 
         [0007]    According to further embodiments, a method for spooling provides a parallel conductor spool having multiple independently rotating bays. The bays can be temporarily locked to prevent independent rotation. The parallel conductor spool rotates to take-up conductors onto one or more of the bays. 
         [0008]    According to further embodiments, a parallel conductor spool is configured to provide multiple independently rotating bays. The spool can be configured to support modularity of the bays. Furthermore, the spool is configured to pay-out multiple conductors from the bays in parallel. Also, the spool is configured to support the pay-out of the multiple conductors at differing rates. 
         [0009]    Other apparatus, systems, and methods according to embodiments will be or become apparent to one with skill in the art upon review of the following drawings and Detailed Description. It is intended that all such additional methods, apparatus, and/or systems be included within this description, be within the scope of the present invention, and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is an elevation view showing details of a parallel conductor spool having multiple independent bays, according to various embodiments presented herein; 
           [0011]      FIG. 2  is a perspective view showing details of a parallel conductor spool upon a pallet platform, according to various embodiments presented herein; 
           [0012]      FIG. 3  is a context diagram showing details of take-up and pay-out of parallel conductors from a parallel conductor spool, according to various embodiments presented herein; 
           [0013]      FIG. 4  is a flow diagram illustrating a process for take-up of conductors onto a parallel conductor spool having multiple independently rotating bays, according to various embodiments presented herein; and 
           [0014]      FIG. 5  is a flow diagram illustrating a process for pay-out of conductors from a parallel conductor spool having multiple independently rotating bays, according to various embodiments presented herein. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    The following detailed description is directed to parallel conductor spools having multiple independently rotating bays for parallel pay-out of multiple conductors with reduced tangling, damage, or slack accumulation. In the following detailed description, references are made to the accompanying drawings that form a part hereof, and which are shown by way of illustration, specific embodiments, or examples. 
         [0016]    Referring now to the drawings, in which like numerals represent like elements through the several figures, aspects of a parallel conductor spool having multiple independently rotating bays will be described.  FIG. 1  illustrates an elevation view of a parallel conductor spool  100  having multiple independent bays  120 A- 120 D according to one or more embodiments presented herein. The multiple independent bays  120 A- 120 D may be referred to generically or collectively as bays  120 . The bays  120  may operate as individual or smaller reels or spools within the larger parallel conductor spool  100 . The parallel conductor spool  100  may be made up of two outer flanges  110  and a central hub  125 . The outer flanges  110  may remain fixed or stationary while the bays  120  independently rotate around the central hub  125 . Independent rotation of each of the respective bays  120  can support pay-out of conductors from each bay  120  at varying rates. Pay-out of conductors at differing rates may prevent tangles, slack, or damage from occurring during installation of the parallel conductors at a jobsite. 
         [0017]    The parallel conductor spool  100  is modular and may be expanded or variably configured by adding or removing bays  120 . The bays  120  may be of varying sizes and may support conductors of various dimensions and configurations. According to one embodiment, four bays  120 A- 120 D may be configured to dispense a parallel set of conductors for alternating current or direct current power of any voltage range. Three of the bays  120 A- 120 C may support insulated conductors, while a fourth bay  120 D may support a ground wire or other conductor of a smaller or larger size. The fourth bay  120 D may pay-out at a different rate due to the difference in conductor diameter. The independently rotating bays  120  of the parallel conductor spool  100  supports this variable rate pay-out of the conductors. 
         [0018]    The parallel conductor spool  100  may be constructed such that the outer flanges  110  form a dimension similar to a traditional 48 inch heavy wood reel. Alternatively, the parallel conductor spool  100  may be of varying dimensions according to various other embodiments. The bays  120  may be made of disposable material such as wood, plastic, cardboard, or metal. According to one embodiment, one of the bays  120  is constructed of a steel hub  170  and two flanges  160 . The flanges  160  may be made of wood, cardboard, plastic, metal, any other material, or any combination thereof. 
         [0019]    A spacer  150  may be provided between each neighboring pair of the bays  120 . The spacer  150  may also be positioned between the outer flanges  110  of the parallel conductor spool  100  and the bays  120  adjacent to the flanges. According to some embodiments, the spacer  150  is formed as a ring or washer for positioning over the central hub  125  between the bays  120 . According to some other embodiments, the spacer  150  is formed onto each of the bay  120  as part of the hub  170  or the flange  160  of the respective bay. The spacers  150  may serve to mechanically isolate each of the bays  120  from its neighboring bay or outer flange  110 . Further, the spacers  150  may serve to prevent friction, catching, or interference between the outer surfaces of the flanges  160  of neighboring bays  120 . As such, the spacers  150  may aid in the independent rotation of the bays  120  within the parallel conductor spool  100 . 
         [0020]    A locking rod  130  may be inserted through the outer flanges  110  and voids or holes within the bays  120  such that the bays are locked stationary within the parallel conductor spool  100 . Insertion of the locking rod  130  temporarily prevents the independent rotation of the bays  120 . Such locking may support take-up of conductors onto the bays  120  by rotating the parallel conductor spool  100  with the bays  120  locked into place. The locking rod  130  may also be used during shipping of the parallel conductor spool  100  to temporarily prevent the independent rotation of the bays  120 . 
         [0021]    According to exemplary embodiments, shipping clips  140  are applied to the flanges  160  of the bays  120  and to the outer flanges  110  of the parallel conductor spool  100 , as discussed further below in view of  FIG. 2 . The shipping clips  140  temporarily prevent rotation of the bays  120  within the parallel conductor spool  100  during shipping, transport, or manufacture. The shipping clips  140  may be removed from the parallel conductor spool  100  to allow independent rotation of the bays  120  during pay-out of conductors spooled onto the bays  120 . 
         [0022]    Either the locking rod  130  or the shipping clips  140  may be used to restrict rotation of the bays  120  within the outer flanges  110  of the parallel conductor spool  100 . According to some embodiments the locking rod  130  may be stronger to support locking of the bays  120  while the parallel conductor spool  100  is rotated for the purpose of taking-up conductors during a manufacturing or assembly process. In contrast, the shipping clips  140  may be lightweight, disposable elements for affixing the bays  120  during storage or transit. 
         [0023]    The parallel conductor spool  100  may be supported by a pallet platform  190 . According to exemplary embodiments, the parallel conductor spool  100  is affixed to the pallet platform  190  using reel clamps  180 . Rotation of the parallel conductor spool  100  may be restricted by fixing the outer flanges  110  of the parallel conductor spool to the pallet platform  190  using the reel clamps  180 , a chock, or slots  230  within the pallet platform  190 , as discussed further below in view of  FIG. 2 . The outer flanges  110  of the parallel conductor spool  100  may be held into the slots  230  within the pallet platform  190  by gravity, friction, or compression. Forklift provisions  195  may be provided within the pallet platform  190  to allow a forklift or pallet jack to lift and maneuver the pallet platform along with the attached parallel conductor spool  100 . 
         [0024]    The bays  120 , given their modular nature, may be loaded or spooled separately and then assembled onto the parallel conductor spool  100 . The bays  120  may also be locked within the parallel conductor spool  100  using the locking rod  130 . Locking of the bays  120  allows loading of the bays  120  by rotating the entire parallel conductor spool  100  similar to rotating a traditional 48 inch heavy wood reel for take-up or spooling of conductors. Take-up of conductors, wires, or cables may also be performed sequentially on separate bays  120 . For example, a first bay, such as the bay  120 A, may be spooled with a first conductor to completion and then the rotation of the parallel conductor spool  100  may be continued while a second conductor is spooled onto a second bay, such as the bay  120 B. 
         [0025]    While the parallel conductor spool  100  is used for the spooling of wire or cable as discussed herein, the parallel conductor spool  100  may also be used for tubing, hoses, or any other elements that may be rolled onto the bays  120  for parallel pay-out. Such parallel pay-out can support transportation and installation of the individual conductors, tubes, or other rolled elements together. 
         [0026]    According to exemplary embodiments, the parallel conductor spool  100  and the bays  120  within the parallel conductor spool are constructed of low-cost, disposable materials such as wood, cardboard, or metals. Such low-cost construction supports field disposal or material recycling of the parallel conductor spool  100 . Field disposal of the parallel conductor spool  100  or other recycling options may reduce expense and logistical complications associated with returning spools or spooling assemblies to vendors or manufacturers. The pallet platform  190  may be constructed of wood, metal, or any other rigid material. The pallet platform  190  may be reusable, recyclable, or disposable. 
         [0027]    Turning now to  FIG. 2 , further details of the parallel conductor spool  100  having multiple independently rotating bays  120 , according to various embodiments presented herein, will be described.  FIG. 2  is a perspective view illustrating the parallel conductor spool  100  upon the pallet platform  190  according to one or more embodiments presented herein. As discussed above, the parallel conductor spool  100  may be affixed to the pallet platform  190  by one or more of the reel clamps  180 . The parallel conductor spool  100  may also be held stationary upon the pallet platform  190  using a chock, other clamping, or other locking mechanisms. 
         [0028]    In addition to affixing the parallel conductor spool  100  to the pallet platform  190  via one or more of the reel clamps  180 , the outer flanges  110  of the parallel conductor spool  100  may be placed into slots  230  within the pallet platform to support locking and transporting of the parallel conductor spool upon the pallet platform. According to exemplary embodiments, the reel clamp  180  provides a locking element  224  that may be rotated using a lock handle  222 . When rotated, the locking element  224  can engage into a void  220  provided within one or more of the outer flanges  110  of the parallel conductor spool  100 . 
         [0029]    As discussed with respect to  FIG. 1 , the shipping clips  140  may be attached to the bays  120  and the outer flanges  110  of the parallel conductor spool  100  for further prevention of rotation of the bays within the parallel conductor spool during shipping, transport, or manufacture. According to exemplary embodiments, notches  215  within the flanges  160  of the bays  120  are provided for attaching the shipping clips  140 . Similarly, end flange notches  210  within the end flanges  110  may also support the shipping clips  140 . The shipping clips  140  may be blocks, rods, staples, wires, clamps or any other elements used to fix the rotation of the bays  120  within the parallel conductor spool  100 . Alternatively, a bar may be placed between the end flange notches  210  across the bays  120  to engage the bay notches  215  and restrict the individual rotation of the bays  120  within the parallel conductor spool  100 . Furthermore, as discussed with respect to  FIG. 1 , the locking rod  130  may be used to restrict rotation of the bays  120  within the parallel conductor spool  100 . 
         [0030]    Turning now to  FIG. 3 , further details of the parallel conductor spool  100  having the multiple independently rotating bays  120 , according to various embodiments presented herein, will be described.  FIG. 3  is a context diagram  300  illustrating take-up and pay-out of parallel conductors  310  from the parallel conductor spool  100 , according to one or more embodiments presented herein. A source  320  of the conductors  310  may be a manufacturing facility or storage facility of the conductors  310 . The parallel conductor spool  100  may be mounted within a take-up system  330 . The take-up system  330  may rotate the parallel conductor spool  100 . The conductors  310  may be taken up upon the parallel conductor spool  100  mounted within the take-up system  330  as the parallel conductor spool  100  is rotated. A rotating element within the take-up system  330  may engage the parallel conductor spool  100  at the central hub  125 ; or at one, or both, of the outer flanges  110 . The rotating element within the take-up system  330  may be driven by an electric motor or any other mechanism for driving rotations of the parallel conductor spool  100  within the take-up system  330 . 
         [0031]    As discussed further below in view of  FIG. 4 , the conductors  310  may be taken-up from the source  320  all at the same rate or at individually varying rates, according to embodiments. The conductors  310  may be taken-up from the source  320  in parallel, in separate sequential stages, or as separate operations according to various embodiments or applications. 
         [0032]    When the conductors  310  are taken-up from the source  320  separately onto the individual bays  120 , the parallel conductor spool  100  may then be assembled to include the bays  120  that have been independently loaded with conductor in a separate initial operation. 
         [0033]    The parallel conductor spool  100 , once loaded with the conductors  310 , may be removed from the take-up system  330  and deployed to the field. Once deployed, the parallel conductor spool  100  may be supported within a pay-out system  350 . The pay-out system  350  may include a pallet platform, such as the pallet platform  190 ; a reel support structure; or other conductor reel mechanism. The conductors  310  may be paid-out from the parallel conductor spool  100  into an installation  360 . The installation  360  may be a building, cabinet, closet, vehicle, or any other location or object where the parallel conductors  310  are being installed. The independent rotation of the bays  120  can support paying-out the conductors at differing rates. Paying-out conductors at varying rates can be advantageous when conductors having different sizes are involved. The parallel pay-out of conductors is discussed in additional detail with respect to  FIG. 5 . 
         [0034]    According to various embodiments, the parallel conductors  310  may be used for power delivery such as alternating current or direct current electricity. The conductors  310  may also be used for DC or low voltage applications. The conductors  310  may also be used for communication applications such a coaxial cable, video, fiber optics, data networks, telephones, grounding systems, control systems, automation systems, water tubing, heater tubing, or any other application where wires, cables, conductors, or other rolled elements may be used. 
         [0035]    Turning now to  FIG. 4 , additional details will be provided regarding the embodiments presented herein for the parallel conductor spools  100  having the multiple independently rotating bays  120 . In particular,  FIG. 4  is a flow diagram illustrating a process  400  for take-up onto the parallel conductor spool  100  having the multiple independently rotating bays  120  according to at least some embodiments presented herein. 
         [0036]    It should be appreciated that the operations described herein are implemented as a sequence of operational or manufacturing acts, as a sequence of computer implemented acts or program modules running on a computing system, or as interconnected machine logic circuits or circuit modules within the computing system. The implementation is a matter of choice dependent on the performance and other requirements of the various embodiments. Some of the logical operations described herein are referred to variously as state operations, structural devices, acts, or modules. It should also be appreciated that more or fewer operations may be performed than shown in the figures and described herein. These operations may also be performed sequentially, in parallel, or in a different order than those described herein. 
         [0037]    The process  400  begins at operation  405  where a parallel reel or the parallel conductor spool  100  is provided having the multiple independently rotating bays  120 . At operation  410 , the locking rod  130  is inserted into the parallel conductor spool  100  through the bays  120  to prevent rotation of the bays within the parallel conductor spool  100 . The shipping clips  140  may also be used to prevent rotation of the bays  120  instead of, or in addition to, the locking rod  130 . 
         [0038]    Continuing to operation  415 , the parallel conductor spool  100  is mounted within the take-up system  330 . At operation  420 , the take-up system  330  may rotate the parallel conductor spool  100  such that conductors may be taken-up into each of the respective multiple bays  120  at the same time or in sequence. 
         [0039]    According to an exemplary embodiment where the conductors are taken-up into the bays  120  in sequence, a first conductor is taken-up into the independent bay  120 A during rotation of the parallel conductor spool  100 . Once the independent bay  120 A is completely spooled with the first conductor, the parallel conductor spool is rotated such that a second conductor is then taken-up into the independent bay  120 B. This process continues until the conductors are taken-up into all, or a portion of, the independent bays  120 A- 120 D. 
         [0040]    According to an exemplary embodiment where the conductors are taken-up into the bays  120  simultaneously, conductors are taken-up into two or more of the bays  120  in parallel. For example, during rotation of the parallel conductor spool  100 , a first conductor is taken-up into the independent bay  120 A while a second conductor is simultaneously taken-up into the independent bay  120 B. 
         [0041]    According to further embodiments, before the independent bays  120 A- 120 D are assembled together into or onto the parallel conductor spool  100 , a conductor is taken-up into each of the independent bays. The separately spooled bays  120  are then assembled into or onto the parallel conductor spool  100 . 
         [0042]    At operation  425 , the locking rod  130  is removed from the bays  120  and the parallel conductor spool  100 . Alternatively, the locking rod  130  may remain within the parallel conductor spool  100  to lock the parallel conductor spool  100  during shipping. 
         [0043]    At operation  430 , the shipping clips  140  are applied to the parallel conductor spool  100 . The shipping clips  140  are applied to the bay notches  215  that are disposed within the flanges  160  of the bays  120 . The shipping clips  140  may also interface to the end flange notches  210  within the end flanges  110  of the parallel conductor spool  100 . The shipping clips  140  may be applied when the locking rod  130  has been removed or even if the locking rod  130  remains within the parallel conductor spool  100 . 
         [0044]    At operation  435 , the parallel conductor spool  100  is placed upon the pallet platform  190 . The parallel conductor spool  100  may be placed within the slots  230  disposed within the pallet platform  190 . The parallel conductor spool  100  may be affixed to the pallet platform  190  for storage or transport. The parallel conductor spool  100  may be fixed against rotation onto the pallet platform  190  using one or more reel clamps, such as the reel clamps  180 . According to exemplary embodiments, the reel clamps  180  lock into the voids  220  disposed within the parallel conductor spool  100 . The parallel conductor spool  100  may also be fixed against rotation using a chock or any other locking or breaking mechanism. 
         [0045]    Turning now to  FIG. 5 , additional details will be provided regarding the embodiments presented herein for the parallel conductor spools  100  having the multiple independently rotating bays  120 . In particular,  FIG. 5  is a flow diagram illustrating a process  500  for pay-out of conductors from the parallel conductor spool  100  having the multiple independently rotating bays  120  according to at least some embodiments presented herein. The process  500  may begin at operation  505  where the shipping clips  140  and the locking rod  130 , if inserted, are removed from the parallel conductor spool  100 . 
         [0046]    Continuing to operation  510 , the parallel conductor spool  100  is mounted within the pay-out system  350 . The pay-out system  350  may include the pallet platform  190  or other mechanism for supporting the parallel conductor spool  100  during pay-out of the conductors  210 . 
         [0047]    At operation  515 , the multiple conductors  310  can be paid-out in parallel. Paying-out the conductors  310  in parallel can support efficient installation of the conductors at a jobsite or assembly facility where the conductors  310  are being installed. 
         [0048]    The parallel pay-out of the conductors  310  may be supported by varying rates of rotation of the independent bays  120 . Allowing the individual bays  120  to rotate at varying rates can support the parallel pay-out of differently sized conductors without accumulation of slack, tangles, or other complications. 
         [0049]    Moreover, parallel pay-out of the conductors  310  from the independently rotating bays  120  can support reduced tangling of the conductors  310 . Supporting varying rates of rotation among the bays  120  can support the parallel pay-out of conductors with significantly reduced tangling. 
         [0050]    Further, parallel pay-out of the conductors  310  from the independently rotating bays  120  can support reduced accumulation of slack in one or more of the conductors  310 . Supporting varying rates of rotation among the bays  120  can support the parallel pay-out of conductors with significantly reduced slack accumulation. 
         [0051]    Parallel pay-out of the conductors  310  from the independently rotating bays  120  can also support reduced damage to the conductors  310 . The independent rotation of bays  120  may support pay-out at varying speeds thus supporting a reduction of interference between the conductors  310  along with a reduction of tangling or damage related to the interference between conductors  310 . 
         [0052]    It should be appreciated that the conductors may be paid-out of each of the respective multiple bays  120  separately or individually. For example, a first conductor may be paid-out of the independent bay  120 A, and once the independent bay  120 A is completely unspooled, a second conductor may be paid-out of the independent bay  120 B. This process may be continued until the conductors are all paid-out of all, or a portion of, the independent bays  120 A- 120 D. 
         [0053]    At operation  520 , the parallel conductor spool  100  is disposed in the field. Construction of the parallel conductor spool  100  of disposable or recyclable material such as wood, metal, cardboard or any combination thereof may allow disposal or recycling of the parallel conductor spool in the field. Field disposal or recycling of the parallel conductor spool  100  may support a reduction in transportation costs, management, and logistical complications associated with the returning of a spool or spooling system. The modular design of the bays  120  and outer flanges  110  of the parallel conductor spool  100  may be well suited for construction of disposable or recyclable materials. 
         [0054]    The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims.