Cable Reel Machines

Project Summary

The reel machine design project included the design, analysis, testing, and production of two identical machines used to spin large, 2000lb, cable reels for loading and unloading of the cable. I designed the reel machine using open structural steel shapes and to be galvanized to reduce corrosion during prolonged usage at sea. I calculated the maximum stress on the structure and welded sub-components using the heaviest reel configuration through hand calculations and FEA, and determined appropriate weld and structural steel sizes accordingly. I calculated the maximum torque required to spin the largest reel at the required speed, and specified the motor size, gearbox ratio, and motor controller to handle this torque. I calculated the range of motion required to handle the largest reel and determined the hydraulic cylinder and pump that provided this while supporting the load of the reel. I calculated shear stresses, shear tear-out, and bearing stress for all bolted connections, and sized the hardware appropriately. After fabrication, I load tested the reel machine to ensure it could lift and spin the largest reel at the maximum speed required.  I also managed all material procurement and fabrication as well as assembly of the structures.

Implemented Skills

• CAD (PTC Creo)

• structural analysis using first principles hand calculations

• weldment design and analysis 

• finite element analysis using ANSYS

• drawing generation following GD&T standards

• material selection for rugged environments

• proof testing

• motor and gearbox selection

• bolted joint analysis

• design for manufacturing and assembly

• design for galvanizing