Patent Publication Number: US-2015076274-A1

Title: Centre Wheel for Winding Up a Duct or Cable on a Stabilizing Centre Core

Description:
TECHNICAL FIELD 
     The present invention relates to an arrangement and a method for winding up a duct or a cable. 
     BACKGROUND 
     Microducts are small ducts for the installation of fiber optic cables. They have a size ranging from typically 3 to 16 mm and are installed as bundles in ducts. The installation of fiber optic cables in ducts can be done by pulling or by cable jetting. Cable jetting is the process of blowing the fiber optic cable through the microduct. Ducts are sensitive to impacts and bending since this may harm the microduct inside the ducts. If the microducts inside the duct are harmed it may be impossible to blow the fiber optic cables through the microducts. 
     Ducts or cables for telecommunication use or power distribution are normally shipped on cable drums alternatively without drums, wrapped in coils. In many situations, it is advantageous to deliver ducts or cables in coils since the volume and weight of the product is significantly smaller. Cost for shipping will therefore be dramatically reduced, especially for overseas deliveries. In addition, customers may prefer coils since there is no need for waste handling of used cable drums. Cost for handling and installation for the customer will then be reduced. There are a lot to gain by using coils; however there are several fundamental problems associated to coiling of ducts or cables. Coiling of ducts or cables requires special and expensive machines not available at many duct or cable manufacturing plants. Many manufacturing plants are built around an infrastructure that handles reels only. Coils are also difficult to produce in vertical position. Ducts are heavy and handling of coils of these products is a problem due to their own weight. To optimize shipping, coils are stacked upon each other, preferably up to 4 coils. The weight of the upper coils may squeeze the ducts or cables in the lower coils. Stacked coils may also slip during transportation and it is not easy to stabilize stacked coils. 
     Handling of coils, e.g. lifting and shipping of coils is difficult. Several coils need to be stacked above each other and the pack of coils needs to be secured in a quick and easy way. Lifting of coils by crane requires lifting straps. The weight of the coil itself makes it hard to avoid damage of the product when lifting. 
     Ducts or cables in coils also need to be kept in coils even when the duct/cable is installed and the coil is unwound. A coil may collapse when starting to pull out the outer end. 
     There is therefore a need for an improved solution for handling coils of ducts or cable, which solution solves or at least mitigates at least one of the above mentioned problems. 
     SUMMARY 
     An object of the present invention is therefore to provide arrangements and methods which solve or at least mitigate at least one of the above mentioned problems. 
     In accordance with a first aspect the present invention relates to a centre wheel for winding up a duct or cable on a stabilizing center core. The centre wheel has a first and a second end. The centre wheel comprises a first plate element arranged at the first end of the centre wheel. The centre wheel further comprises at least three curved plate elements extending between the first plate element and the second end and arranged at angular distance around a centre axis of the centre wheel, so that the stabilizing center core can be fit in a space between the first plate element and the curved plate elements, whereby a duct or cable that is wound around the third plate elements is supported by the third plate elements and by the stabilizing centre core in gaps between the third plate elements. 
     The above stated object is thus achieved by means of a centre wheel for winding up a duct or cable on a stabilizing center core. The centre wheel has at least three curved plate elements extending between the first plate element and the second end and arranged at angular distance around a centre axis of the centre wheel. This arrangement allows the stabilizing center core to be fit in a space between the first plate element and the curved plate elements. A duct or cable that is wound around the third plate elements is thereby supported by the third plate elements and by the stabilizing centre core in gaps between the third plate elements. 
     An advantage of embodiments of the present invention is that it provides for manufacturing of a significant lighter package of duct or cable than a traditional reel. 
     A further advantage of embodiments of the present invention is that it provides for manufacturing of a package of duct or cable, where the stabilizing centre core is easier to assemble and disassemble than a traditional reel. 
     Another advantage of embodiments of the present invention is that it provides for manufacturing of a package of duct or cable which supports stacking of several packages above each other without the duct or cable that is wound around the stabilizing centre core is harmed. The stabilizing centre core relieves pressure loads on the duct or cable when several coils are stacked on each other, minimizing risk for damaged ducts or cables during transport. 
     A further advantage of embodiments of the present invention is that it provides for manufacturing of a package of duct or cable that can be unwound using the same equipment used for unwinding duct or cable on traditional reels. 
     Yet a further advantage of embodiments of the present invention is that it provides for manufacturing of a package of duct or cable where the design also supports mounting of lifting straps so that the stabilizing centre core can be lifted with e.g. a forklift or a crane. 
     Further features of embodiments of the present invention will become apparent when reading the following detailed description in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an exemplary embodiment of a stabilizing centre core according to the present invention. 
         FIG. 2  shows an exploded diagram of an exemplary embodiment of a stabilizing centre core according to the present invention. 
         FIG. 3  shows an exemplary embodiment of a centre wheel according to the present invention. 
         FIG. 4  shows an exemplary embodiment of a machine according to the present invention. 
         FIG. 5  shows an exemplary embodiment of a connector according to the present invention. 
         FIG. 6  shows an exemplary embodiment of a base plate according to the present invention. 
         FIG. 7  shows an exemplary embodiment of a claw according to the present invention. 
         FIG. 8  shows a flowchart of a method for winding up a duct or cable according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like reference signs refer to like elements. 
       FIG. 1  shows a stabilizing centre core  1  for stabilizing a coil of duct or cable, according to an exemplary embodiment of the present invention. As illustrated, the stabilizing centre core  1  comprises a centre tube  2  having a first  2   a  and a second end  2   b.  The centre tube  1  comprises a central opening  2   c  so that the stabilizing centre core  1  can be mounted on a machine (not shown) for winding up duct or cable on the stabilizing centre core  1 . The stabilizing centre core  1  further comprises a first plate element  3  arranged at the first end  2   a  of the centre tube  2  and a second plate element  4  arranged at the second end  2   b  of the centre tube  2 . In an exemplary embodiment of the stabilizing centre core  1  according to the present invention is the first and the second plate elements  3 ,  4  hexagonal as illustrated in  FIG. 1 . The first and second plate elements  3 ,  4  may however in other exemplary embodiments have other shapes. In the exemplary embodiment of the stabilizing centre core  1  illustrated in  FIG. 1  the first plate element  3  and the second plate element  4  each comprise a central opening  3   a,    4   a  of a dimension that corresponds to the dimension of the central tube  2 . The first and the second plate elements  3 ,  4  are thereby adapted to be thread on the centre tube  2  and can easily be removed there from. The stabilizing centre core  1  further comprises at least three third plate elements  5  extending between the first plate element  3  and the second plate element  4  and arranged at angular distances around a circumference of the centre tube  2 . The duct or cable that is wound around the stabilizing centre core  1  is thereby supported by the third plate elements  5 , which prevents the duct or cable from being bent and thereby from being harmed. 
     In another exemplary embodiment of the present invention are the at least three third plate elements wider at the first end than at the second end. Since the at least three third plate elements being wider at the first end than at the second end the stabilizing centre core gets cone-shaped form. The cone-shaped formed prevents the duct or cable from slip of when for instance the stabilizing centre core is lifted or moved. 
     In other exemplary embodiment of the stabilizing centre core  1  according to the present invention the stabilizing center core  1  comprising at least four third plate elements  5  at a maximum angular distance of 90 degrees. In this embodiment may the third plate elements also be rectangular or wider at the first end than at the second end. 
     In yet other exemplary embodiment of the stabilizing center core  1  according to the present invention the stabilizing centre core  1  comprises at least six evenly distributed third plate elements  5 . The third plate elements may also in this embodiment be rectangular or wider at the first end than at the second end. 
     Having more third plate elements  5  in the stabilizing centre core  1  results in that the duct or cable that is would around the stabilizing centre core  1  is given more support. As mention above ducts are sensitive to impacts and bending since this may harm the microducts inside the ducts. If the microducts inside the duct are harmed it may be impossible to blow the fiber optic cable through the microduct. It is therefore important that the duct is given enough support by the third plate elements  5  when the duct is wound around stabilizing centre core  1 . Depending of the size of the duct and the stabilizing centre core  1  different number of third plate elements  5  is required in order to give enough support to the duct in order to prevent the duct from being harmed. Using fewer third plate elements  5  makes the stabilizing centre core faster to assemble and disassemble. Yet an advantage with fever third plate elements  5  is lower cost and weight. 
     In another exemplary embodiment of the stabilizing centre core  1  according to the present invention  1  the at least three third plate elements  5  are detachably mounted on the first plate element  3  and the second plate element  4 , whereby the at least three third plate elements  5  easily can be removed from the first plate element  3  and the second plate element  4 . 
     In another exemplary embodiment of the stabilizing centre core  1  according to the present invention  1  surfaces on the third plate elements  5  which support the duct or cable have been treated in order to increase the friction against the duct or cable. The third plate elements  5  may for instance comprise furrows or grooves which increase the friction between the duct or cable and the third plate elements  5 . An advantage with increasing the friction between the duct or cable and the third plate elements is that the duct or cable is further prevented from slipping on the stabilizing centre core  1  during handling or transportation. In yet another exemplary embodiment of the stabilizing centre core  1  according to the present invention at least one of the centre tube  2 , the first plate element  3 , the second plate element  4  and the third plate elements  5  are made of a material that is substantially lighter than wood, for example cardboard, which is also recyclable. Traditional reels are made of structural timer which is a heavy type of tree. In this exemplary embodiment the weight of the stabilizing center core  1  is further reduced which makes the handling of the stabilizing centre core  1  even easier. Transportation costs for shipping the duct or cable wound up on the stabilizing centre core  1  is then also further reduced. Other advantages with using cardboard for at least one of the components  2 ,  3 ,  4 ,  5  is that the cost for the stabilizing centre core  1  is further reduced and the that it is easier to recycle the stabilizing centre core with minimum waste management compared to a complete cable reel. 
     In another exemplary embodiment of the stabilizing centre core  1  according to the present invention  1  the centre tube  2 , the first plate element  3 , the second plate element  4  and the third plate elements  5  are made of a plastic, wood, Styrofoam or metal. 
     Referring  FIG. 2 , the first and second plate elements  3 ,  4  comprise notches  3   b,    4   b  adapted to receive and hold the third plate elements  5 . In another exemplary embodiments the third plate elements  5  also comprises notched adapted to receive and hold the first and second plate elements  3 ,  4 . In the exemplary embodiment of the stabilizing centre core  1  in  FIGS. 1 and 2  the components  2 ,  3 ,  4 ,  5  are assembled in a form-fit manner, allowing all components to be easily disassembled. In the exemplary embodiment of the stabilizing centre core  1  illustrated in  FIG. 1  are all components  2 ,  3 ,  4 ,  5  of the stabilizing centre core  1  arranged radially inside a duct, or cable which is wound around the stabilizing centre core  1 . 
     In the exemplary embodiments of the stabilizing centre core  1  illustrated in  FIGS. 1 and 2  the duct centre core components  2 ,  3 ,  4 ,  5  are assembled in a form-fit manner, allowing all components to be easily disassembled. Therefore neither glue, nails nor screws are required in order to hold the components  2 ,  3 ,  4 ,  5  together, simply notches  3   b,    4   b,    5   b  that are dimensioned so that a component can be held by friction. In the exemplary embodiments of the stabilizing centre core  1  illustrated in  FIGS. 1 and 2  the first and second plate elements  3 ,  4  comprise a plurality of openings  3   c,    4   c  arranged between the central opening  3   a,    4   a  and the outer circumferential edge of the plate elements  3 ,  4 . Theses openings  3   c,    4   c  may be used for a securing element (not shown) which is arranged to secure the wound of duct or cable on the stabilizing centre core  1 . In an exemplary embodiment of the stabilizing centre core  1  according to the present invention the openings  3   c,    4   c  are placed between the centre tube  2  and the third plate elements  5 . An advantage of placing the openings  3   c,    4   c  at this position is that the bearing stresses at the openings  3   c,    4   c  caused by the a securing element is reduced. 
     In an exemplary embodiment of the stabilizing centre core  1  illustrated in  FIG. 1  and  FIG. 2  are a diameter of the centre tube  2  between 300-1500 mm, an outer diameter of stabilizing center core  2  between 500-2400 mm and a height of the stabilizing center core  2  between 300-2000 mm. 
     Another aspect of the present invention relates to a centre wheel  10  for winding up a duct or cable on a stabilizing center core  1 .  FIG. 3  illustrates the centre wheel  10  for winding up a duct or cable on the stabilizing center core  1 . The centre wheel  10  having a first and a second end. The centre wheel  10  comprises a first plate element  12  arranged at the first end of the centre wheel  10 . The centre wheel  10  further comprises at least three curved plate elements  13  extending between the first plate element  12  and the second end and arranged at angular distance around a centre axis of the centre wheel  10 . The stabilizing center core  1  can be fit in a space between the first plate element  12  and the curved plate elements  13 . A duct or a cable that is wound around the third plate elements  13  is thereby supported by the third plate elements  13  and by the stabilizing centre core  1  in gaps between the third plate elements  13 . 
     In another exemplary embodiment of the centre wheel  10  according to the present invention the centre wheel  10  further comprises a second plate element  14  removable arranged at the second end, whereby the duct or cable is further supported by the second plate element  14 . 
     In yet another embodiment of the centre wheel  10  according to the present invention, the first plate element  12  comprises slots  14  in a radial direction in the gaps between the third plate elements  13 . The slots  14  in the radial direction in the gaps between the third plate elements  13  give way for belts that are used to secure the duct or the cable in the stabilizing centre core  1 . 
     In a further embodiment of the centre wheel  10  according to the present invention the third plate elements  13  tilt from the first plate element  12  towards the centre axis of the center wheel  10 . Since the third plate elements  13  tilt from the first plate element  12  towards the centre axis of the center wheel  10  the third plate elements  13  gets a cone-shaped form. The cone-shaped formed makes it possible to use the centre wheel  10  together with a stabilizing centre core  1  that has a cone-shaped form. As mentioned before winding up the duct or cable on a cone shaped stabilizing centre core  1  further prevents the duct or cable to slip off from the stabilizing center core  1  when for instance the stabilizing centre core  1  is lifted or moved. 
     In other exemplary embodiment of the centre wheel  10  according to the present invention the centre wheel  10  comprises at least four curved plate elements  13  at a maximum angular distance of 90 degrees. In yet other exemplary embodiment of the centre wheel  10  according to the present invention the centre wheel  10  comprises at least six at least six evenly distributed curved plate elements  13 . 
     Having more curved plate elements  13  in the centre wheel  10  makes it possible to fit a stabilizing centre core  1  having more third plate elements  5  in the centre wheel  10 . Using a stabilizing centre core  1  having more third plate elements  5  results in that the duct or cable that is would around the stabilizing centre core  1  is given more support. As mention above ducts are sensitive to impacts and bending since this may harm the microducts inside the ducts. If the microducts inside the duct are harmed it may be impossible to blow the fiber optic cable through the microduct. It is therefore important that the duct is given enough support by the third plate elements  5  when the duct is wound around stabilizing centre core  1 . 
     In another exemplary embodiment of the centre wheel  10  according to the present invention surfaces on the curved plate elements  13  have been treated in order to increase the friction against the duct or cable. The curved plate elements  13  may for instance comprise furrows or grooves which increase the friction between the duct or cable and the curved plate elements  13 . 
     The first plate element  12 , the curved plate elements  13  and the second plate element  14  are preferably made of steel. 
       FIG. 4  shows another aspect of the present invention, which is a machine  20  for winding up a duct or a cable. The machine  20  comprises the centre wheel  10  according to previously described embodiments. In another exemplary embodiment of the machine  20  according to the present invention the machine  20  further comprises driving means  21  for rotating the centre wheel  10  in order to wind up the duct or cable on the centre wheel  10 . The driving means  21  can be a step motor or another type motor capable of rotating the centre wheel  10  in order to wind up the duct or cable on the centre wheel  10 . In yet another exemplary embodiment of the present invention the machine  20  further comprises guiding means  22  for guiding the cable or duct while the cable or duct is being wound up on the centre wheel  10 . In yet another exemplary embodiment of the machine  20  according to the present invention the guiding means  22  is arranged to move the cable or duct in an upward and downward direction substantially parallel to the centre axis. In yet another exemplary embodiment of the machine  20  according to the present invention the guiding means  22  comprises a step motor arranged to move the guiding means  22 . In yet another exemplary embodiment of the machine  20  according to the present invention the guiding means  22  further comprises breaking means  23  arranged to brake the cable or duct while the cable or duct is being wound up on the centre wheel  20 . 
       FIG. 5  shows another aspect of the present invention. Stabilizing centre cores  1  which comprise duct or cable that is wound up on the stabilizing centre cores  1  can preferably be stacked above each other during transportation. To avoid slipping of the stabilizing centre cores  1  during transport it is essential to secure the coils together.  FIG. 5  shows a connector  50 , preferably made of cardboard, plastic or wood that is inserted in between the stabilizing centre cores  1 . The bottom of stabilizing centre core  1  is stabilized towards a pallet with a base plate  60  as shown in  FIG. 6 . Several stabilizing centre cores  1  can then be held together with a strap attached to the base  60  and another plate mounted at the top stabilizing centre core  1 . A similar plate as the one shown in  FIG. 6  can be used at the top for attaching the strap. 
       FIG. 7  shows yet a further aspect of the present invention, which is a claw  70  that grips the stabilizing centre core  1  as shown in  FIG. 7 . The claw  70  is used for lifting the stabilizing centre core  1 . In the exemplary embodiment of the claw  70  shown in  FIG. 7 , the claw  70  comprises 3 arms  71 , but the claw  70  may in other exemplary embodiments have more that 3 arms. 
       FIG. 8  shows a flowchart of a method for winding up a duct or cable using the centre wheel  10  according to the present invention. In a step  810  a stabilizing centre core  1  is arranged in the space between the first plate element  12  and the curved plate elements  13 . Next in a step  820  is then the duct or cable wound up on the centre wheel  10 , whereby the duct or cable is supported by the third plate elements  13  and by the stabilizing centre core  1  in gaps between the third plate elements  13 . Further, in a step  830  is a securing element, which is arranged to secure the wound of duct or cable on the stabilizing centre core  1  applied. In a final step  840  is the centre wheel removed whereby the duct or cable is supported by the third plate elements  5 .