Electrical Cable Reeling Apparatus

This invention relates to reeling apparatus for handling fixed lengths or sections of electrical cable.

There are reeling or spooling apparatus that have been described in the art for handling many types of flexible tubular members, such as electrical cable, flexible well tubing, flexible hose, and the like, so name a few. However, a problem is presented in the handling of electrical cable sections having substantially rigid connectors at the section ends, because the connectors of such cables interfere with the winding of the cable onto a drum of the reeling or spooling apparatus. Additionally, the substantially rigid terminal connectors may be subjected to excessive bending moments when wound on the drums of such apparatus which may cause damage thereto and to the electrical cable conductors. So far as is known, no one has previously provided a satisfactory reeling apparatus for storing and feeding an entire electrical cable section where the entire length of the electrical cable section, including the end connectors, is wound on and completely removed from the reel of the apparatus.

Accordingly, the present invention provides a new and improved electrical cable reeling apparatus for storing, receiving and feeding therefrom a complete section of an electrical cable having substantially rigid terminal connectors at the ends of each section which includes a rotatable reel provided with means for releasably securing at least one of the electrical cable terminal connectors for rotation therewith without interfering with the winding of the electrical cable on the reel and for releasing the terminal connector from the reel when the cable is unwound therefrom. The apparatus also includes means for transporting one end of the electrical cable to and from a remote location to facilitate the positioning and releasing of the releasably secured cable terminal connector relative to the reel.

A preferred embodiment of the apparatus of this invention is shown in the drawings, wherein:

FIG. 1 is a side view of the apparatus having an electrical cable section wound on the reel illustrating the positioning of the cable terminal connector with the reel for rotation therewith;

FIG. 2 is a view similar to FIG. 1 but illustrating the cable connector positioning and releasing means of the reel positioned for receiving the cable terminal connector for winding of the cable on the reel;

FIG. 3 is a plan view of the apparatus taken along line 3--3 of FIG. 2 shown in position for receiving the electrical cable terminal connector for cable winding;

FIG. 3A is an elevation of the reel as illustrated in FIG. 3;

FIG. 4 is a plan view of the apparatus showing the positioning of the electrical cable and its terminal connector on the reel as the reel is rotated from the position illustrated in FIGS. 3 and 3A when the cable is being wound thereon;

FIG. 4A is an elevation of the apparatus as shown in FIG. 4;

FIG. 5 is a plan view of the apparatus shown in position for releasing the electrical cable and its terminal connector therefrom when the cable is unwound; and

FIG. 5A is an elevation of the apparatus shown in FIG. 5.

In the drawings, the letter E generally designates a fixed length of electrical cable which includes one or more electrical conductors formed into an insulated conductor section C having a male terminal connector T1 connected at one end of the section C and a similar female terminal connector (not shown) connected at the opposite end of the section C. The terminal connectors are usually substantially rigid and have diameters greater than the conductor section C diameter to facilitate the coupling of a plurality of cables E. The electrical cable E may be of any desired length and size. However, as will become more readily apparent from the following description, the apparatus of the present invention is particularly adapted to handle relatively long lengths of cable sections, e.g. 1,000 to 5,000 ft., which are constructed of a plurality of relatively large diameter conductors suitable for installation in a well bore for transporting power, telemetry signals and the like between the surface and a down-hole electrically powered drilling apparatus or other electrical equipment.

Referring now to the drawings, the electrical cable supply and storage reel apparatus, generally designated as R, of the present invention includes a reel 60 having an axial shaft 60a which is mounted for rotation on a support frame 62 by conventional means such as pillow blocks 64a, 64b. The main part of the reel 60 is of conventional construction having a cylindrical drum 60b and circular end walls 60c, 60d with diameters greater than the cylindrical drum 60b so as to retain the electrical cable E on the cylindrical drum 60b as it is helically wound and unwound with respect thereto. However, the supply reel 60 is further provided with a releasable means, generally designated 70, for positioning the electrical cable terminal connector T1 on the reel 60 for rotation therewith and for releasing the terminal connector T1 when the cable E is unwound therefrom. The releasable means 70 protects the terminal connector T1 and the cable conductor C from excessive bending moments during cable winding and unwinding and thereby prevents damage thereto.

As illustrated, the releasable means 70 is mounted with the reel side wall 60c substantially adjacent its circumferential edge 60e for positioning the cable terminal connector T1 for rotation with the reel 60 outwardly adjacent the circular end wall outer surface 60f. More particularly, the releasable means 70 includes an outwardly extending flange member 71 fixedly mounted with the end wall outer surface 60f and a gate member 72 pivotally mounted with the end wall 60c. Also included is a cable connector catch plate 73 perpendicularly mounted between the end wall outer surface 60f and the outwardly extending flange 71 having a groove 73a for receiving the cable E.

As illustrated in FIGS. 3 and 3A, the outwardly extending flange 71 and pivotal gate member 72 are mounted substantially adjacent to the side wall upper edge 60e and to each other forming a space 78 therebetween for receiving a portion of the electrical cable E upon rotation of the reel 60 in the direction shown by the arrow 74.

The pivotal gate member 72 is adapted for pivotal movement between a first position in substantial alignment with the circular end wall circumferential edge 60e and a second position inwardly thereof over the cylindrical reel drum 60b (FIGS. 4, 4A). Additionally, the pivotal gate member 72 has an arcuate-shaped lower edge 72a (FIG. 4A) which is spaced from the cylindrical reel drum 60b a sufficient distance to permit the passage of the electrical cable conductor portion C thereunder. The gate member 72 is forcibly held in the aforementioned first position in alignment with the end wall edge 60e by means of a spring element 75 mounted with the end wall outer surface 60f and the gate member 72.

Additionally, a trigger member 76 having a protrusion 76a is pivotally mounted on the flange 71 adjacent a flange opening 71a which is adapted to engage the gate member 72 and move it from the aforementioned first aligned position to the aforementioned second inward position for releasing the electrical cable E and its terminal connector T from the reel 60 during unwinding (FIGS. 5 and 5A).

Further, a connector guide member 77 is mounted with the pivotal gate member 72 and the outwardly extending flange 71 has a curved lip portion 71b, both positioned adjacent the connector catch plate member 73, to facilitate the positioning of the cable terminal connector T1 for engagement with the grooved catch plate 73.

The cable supply and storage assembly R of the invention also includes a means, generally designated 66, for controlling the rotation of the supply reel 60 thereby controlling the rate at which the electrical cable E is wound onto and unwound from the reel 60. The rotation rate control means 66 may include any conventional power and braking apparatus, such as hydraulic motor and brake assembly of conventional design, positioned on the frame 62 which is connected with the supply reel 60 such as by sprocket 66a, 60g and chain 68.

The supply reel assembly R is also provided with a winch assembly 80, preferably mounted with the frame 52 adjacent the reel end wall 60c for transporting one end of the electrical cable E between the cable reel assembly R and a remote location. The winch assembly 80 includes a swivel connector 82 mounted with the winch cable 84 and adapted for connected by threads or the like with the electrical cable terminal connector T1 for extending over the threads of the connector T1 for thereby protecting them as the connector is transported between the supply reel assembly R and the remote location, such as a well, for insertion and removal of the cable E into and from the well bore. Further, the mounting of the winch assembly 80 adjacent the supply reel end wall 60c permits the electrical cable E and its terminal connector T1 to be positioned adjacent the end wall outer surface 60f whereby it can be automatically positioned on the reel 60 by rotation of the supply reel 60 in the direction of the arrow 74 illustrated in FIG. 3 during cable winching and can be substantially automatically removed from the supply reel 60 by rotation in the direction of the arrow 79, as illustrated in FIG. 5.

As illustrated in FIGS. 3-5A, and beginning with FIGS. 3 and 3A, in the operation of the cable supply and reel assembly R, the electrical cable E may be received and wound on the cylindrical reel 60 by initially positioning the cable terminal connector T1 adjacent the end wall outer surface 60f in alignment for engagement with the connector catch plate 73 between the flange 71 and the gate 72. As mentioned hereinbefore, where the cable E is initially remotely located, such positioning and alignment may be facilitated by threadably connecting the protective connector 82 of the winch assembly 80 with the terminal connector T1 and winching the cable E to the aforementioned position adjacent the reel end wall outer surface 60f. Upon rotation of the reel 60 in the direction of the arrow 74, such as by activating the power and braking apparatus of the reel rotation control means 66 in a known manner, the terminal connector engages the grooved catch plate 73 with the cable conductor C being received in the groove 73a, the positioning of which is facilitated by the positioning member 77 and the flange lip portion 71b. When the terminal connector T1 engages the grooved catch plate 73, the protective connector 82 may be disconnected from the electrical terminal connector T1 whereby any tension on the electrical cable E is transferred therefrom to the catch plate 73. Upon further rotation of the reel 60 in the direction of the arrow 74 (FIG. 3) the cable conductor section C is moved downwardly in the receiving space 78 between the outwardly extending flange 71 and the gate member 72 until it comes into engagement therewith. Further rotation forces the cable conductor section C downwardly between the gate member 72 and the flange 71 forcing the gate member to move from the aforementioned first position in alignment with the end wall edge 60e (FIGS. 3 and 3A) towards the second inward position until the cable conductor section C engages the reel cylindrical drum 60b as illustrated in FIGS. 4 and 4A. Upon such engagement, the cable conductor section C passes under the gate member lower edge 72a thereby permitting the gate member 72 to forcibly move back to the first aligned position under spring pressure. Further continued rotation of the reel 60 in the direction of the arrow 74 causes the electrical cable E to the helically wound on the reel cylindrical drum 60b between the end walls 60c and 60d with the cable terminal connector T1 being positioned outwardly therefrom adjacent the end wall outer surface 60f. It will be readily apparent that such positioning of the terminal connector T1 outwardly from the reel drum 60b prevents it from interfering with the orderly helical winding of the electrical cable conductor section C thereon. Additionally, such positioning protects the terminal connector T1 and the cable conductor C at an interfere therewith from excessive bending moments which in all probability would occur if the terminal connector T1 was positioned on the reel drum 60b which could cause damage thereto. Further, the positioning of the terminal connector T1 outwardly of the drum 60b permits access thereto so that the electrical continuity of the electrical cable E may be tested while helically wound and stored on the reel 60.

The electrical cable E and its terminal connector T1 may be completely removed from the reel 60 in the following manner. The electrical cable E is initially helically unwound from the drum portion 60b, such as by rotating the reel 60 in the direction indicated by the arrow 79 in FIG. 5 until only that portion of the cable conductor C extending under the gate member lower edge 72a outwardly from the reel drum 60b remains in contact therewith. At this point, if it is desired to employ the winch assembly 80 to control the movement of the electrical cable E from the supply reel assembly R to a remote location, the winch assembly protective connector 82 is threadably connected with the electrical cable terminal connector T1. Additionally, at this point, the trigger member 76 is moved to engage its protrusion 76a with the gate member 72 forcing it to the second inward position, as illustrated in FIGS. 5 and 5A. In the position illustrated, a portion of the electrical cable conductor C is disposed adjacent the reel end wall 60c. The cable E may then be moved upwardly between the gate member 72 and flange member 71 outwardly therefrom with simultaneous movement of the terminal connector T1 upwardly and outwardly from the grooved catch plate 73 thereby providing cable release from the reel 60. If desired, such release may be effected by holding the electrical cable E in a stationary position such as by braking the winch assembly 80 in a known manner and rotating the reel 60 in the direction indicated by the arrow 79 in FIG. 5. During reel rotation, the cable E is caused to pass between the gate member 72 and flange member 71 with simultaneous braking of contact between the terminal connector T1 and the grooved catch plate 73. During removal, either by moving the cable or by rotating the reel 60, the cable E contacts the trigger protrusion 76a and forces it from engagement with the gate member 72 permitting the gate member 72 to forcibly return under spring pressure from the inward second position to the first position in alignment with the reel end wall edge 60e, as illustrated in FIG. 3.

The apparatus of the present invention may be employed to supply, receive and store 9 sections of the above-described electrical cable for substantially any use. However, as disclosed in U.S. Pat. application Ser. No. 621,157 by Roy H. Cullen, Joshua M. Jackson and Jim Witovek, Jr., entitled "Electrical Cable Feeding And Removing Apparatus", filed Oct. 9, 1975, the apparatus of this invention may be used with the apparatus of said application, for positioning the entire length of one or more electrical cable sections in a well bore and removing same, as described in Unites States patent application Ser. No. 621,131 by Roy H. Cullen, Joshua M. Jackson, Jim Witovek, Jr. and Terry Jones, entitled "Method And Apparatus For Deployment And Retrieval Of Fixed Lengths Of Electrical Cable Into And From A Well Bore", also filed Oct. 9, 1975.

The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials as well as in the details of the illustrated construction may be made without departing from the spirit of the invention.