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Wooden Cable Drum Manufacturing

Prepared by:
EEG Metal Products Research, Technology, and Productivity Improvement
Group

Feb. 2016 E.C

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Contents
1. Introduction ......................................................................................................................................... 1
2. Wooden Spool Drums Basic Product Description............................................................................ 1
3. Wooden Spool Drum Dimensions ...................................................................................................... 2
4. Wooden cable drums basic specifications ......................................................................................... 3
5. Main Parts of Wooden Cable Drums/reels ....................................................................................... 3
6. Tooling and Equipment ...................................................................................................................... 3
7. Human resource .................................................................................................................................. 4
8. Supply (BOQ For 1250mm flange diameter).................................................................................... 5
9. Quality.................................................................................................................................................. 5
10. General Manufacturing Process: ................................................................................................... 5
11. Cable Drum production process and methodology...................................................................... 6
12. Working drawings ........................................................................................................................ 10

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Wooden Cable Drum

1. Introduction
Cable reels are commonly used for storing and transporting ropes, chains, and conduits as well as
electrical cables and optical fibers. They come in many different sizes and materials, usually
plastic, wood, and chosen wood composites (plywood) or steel. They are designed to be reusable
and returnable. Cable reels are made of two flanges and a core/barrel that comes in between. In the
case of cable drums, these parts are joined together with the use of long, metal bolts/studs placed
around the rotation axis of the drum. Cable drums are of various sizes, however, the diameters of
flanges in our case (Power Equipment Manufacturing Industry) are usually within the range of
1000 to 2000 mm. Drums for multiple uses and big cable drums can be additionally reinforced
with fittings protecting the edges of flanges while drums exceeding the diameter of 1000 mm have
additional metal elements which protect the central hole. Drums are constructed in resinous wood.
The most popular material for cable drums is pine lumber, but spruce wood is also used.

2. Wooden Spool Drums Basic Product Description

As the name suggests, wooden cable reels are made from wood. Wooden cable reels are used in applications
where heavy loads are to be carried. The wooden reels can be used to reel in wires, ropes, and electrical
cables. Depending on the product to be transported, they can be tailored to a variety of traverse lengths and
flange diameters.

Cable drums are used for carrying different types of electrical wires. The drum is also used for
shipping different cables/wires. Cable drums are manufactured in different sizes and materials
depending on their usage. The material choice depends on the weight and which support it is being
used for. It also depends on how the drum is supposed to be stored, whether it is indoors or
outdoors. The cable drum dimension consists of a drum diameter (A), drum core/ barrel (B), drum
width (2D+C), and inside width (C), as seen in Figure 1.1 below.

Fig 1. Basic Product Description

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3. Wooden Spool Drum Dimensions

Fig 2. Solid wood drum detail dimensions

Table 1: Wooden cable drum varieties and their detail dimensions
Diameter Flanges/boards Bores Dia
Spool Flange Core Flange Core Central Drive Cable Distance Winding Overall Threaded
Drum Thickness bars bore hole passage b/n Width width rod
Type width D&C (Stud)
d1 d2 K G C D F I L2 L1 M/St.
8 800 400 36 22 85 40 40 100 400 480 10/4
9 900 450 36 22 85 50 50 160 560 650 10/4
10 1000 500 36 22 85 50 50 160 560 650 10/4
12 1250 630 50 22 85 65 60 160 710 800 12/4
14 1400 700 64 27 85 65 65 300 710 850 16/4
15 1500 800 64 27 85 65 65 300 710 850 16/4
16 1600 800 64 27 85 65 80 300 900 1040 16/4
18 1800 1000 64 32 100 65 80 300 900 1080 16/6
20 2000 1200 76 32 100 65 100 300 900 1100 16/6
22 2200 1200 90 38 125 65 120 300 1100 1340 20/8
24 2400 1400 90 38 125 65 130 600 1210 1450 20/8
25 2500 1600 100 38 125 65 130 600 1250 1510 20/8
Optionally with K1-middle chaplet. K2- side chaplet K3- inner cable passage. a metal plate with a socket, g- -
metal plate thickness

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4. Wooden cable drums basic specifications

Table 2: Wooden cable drum varieties and their basic specification
Sn. Flange Thickness Remark
Types (Mm) Carrying Capacity (Kg)
(mm)
1 800*400*400 36 700
2 900*450*560 36 900
3 1000*500*560 36 900
4 1250*630*650 50 3000
5 1400*700*710 64 3000
6 1500*800*710 64 2500
7 1600*800*900 64 2500
8 1800*1000*900 64 3000
9 2000*1200*900 76 6000
10 2200*1200*1100 90 6100
11 2400*1400*1210 90 6300
12 2500*1600*1250 100 6500

5. Main Parts of Wooden Cable Drums/reels

A wooden drum is made up of two flanges joined with screws/studs and there is a core/barrel
between them, on which a cable is wound. Drums with big diameters are fitted with sockets or
double metal plates with sockets. The flanges and cores of drums are made of wood. Parts of
Wooden Cable Drums are listed in the table below.

Table 3: Lists of Parts of Wooden Cable Drums/reels

Sn. Part Description UOM QTY Remark
1 Flange (Sub-assembly) Dia. 1250 Pieces 2
2 Barrel (Sub-assembly) Dia. 550-630 Pieces 1
3 Barrel seat (Barrel fixing sub-assembly) Pieces 3
4 Stud (M12*1.75) Pieces 4
5 Steel socket (Sheet metal and pipe sub- Pieces 2
assembly(143*143*3.0)
6 M6 Bolt with nut (Standard) Pieces 8
7 M12*1.75 nut Pieces 8
8 Washer (ID13, OD 50 & thickness 3mm) Pieces 8
Total Number of Pieces 36

6. Tooling and Equipment

The following list of tools and equipment are required for spool drum production at Saris wood
workshop. (Most of the equipment and tools are available in the works shop)

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Table 4: List of Tooling and Equipment Required

Sn. Machinery List (Description) UOM Qty. REMARK
Required

1 Table Saw Pieces 1

2 Band Saws Pieces 1
3 Thickness Planer Pieces 1
4 Wood planning Machine Pieces 1
5 Drilling Machine Pieces 1
6 Hand saw Pieces 2
7 Welding Machine Pieces 1 Outsource to MFI
8 Shearing Machine Pieces 1 Outsource to MFI or
AMSMI
9 Chipping hammer Pieces 1 Outsource to MFI
10 Adjustable tap Die Kit (Metric) Pieces 1 Min (M12 Die holder)
11 Claw hammer, 450 g, Pieces 2
12 Combination wrench (M12) Pieces 2
13 Combination wrench (M6) Pieces 2
14 Forstner Drill Bit Diameter (12,50,60 and Set 1 To be purchase
80mm)
15 Hammer Nail Guns (Pneumatic Brad Pieces 1 Available
Nailer)
16 Compressor Pieces 1 Available

7. Human resource
Table 5: List of Man-power required
Sn. Manpower qualification Job Grade Qty. Remark
Required
1 Carpenter (Senior Woodwork technician) 7 2
2 Carpenter (Woodwork technician) 6 1
3 Senior Welder 7 1
4 Machinist 6 1
5 Helper 3 1

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8. Supply (BOQ For 1250mm flange diameter)

Table 5: Supply (BOQ For 1250mm flange diameter)
Item Description Unit Qty. Unit Total Remark
No. Rate Amount
1 Pine (200x4000x25) Pcs 6.5 Flange Raw Material
2 Pine (150x4000x25) Pcs 2.0 “
3 Pine (75x700x25) Pcs 2.3 Barrel Raw Material
4 Nail (12Dx3.75x82.87) Kg 1.0 Flange Raw Material
5 Nail (80Dx3.40*50.63) kg ½ Barrel socket Material
Steel socket Raw
6 Sheet Metal (143x143x3) Pcs 2
Material
M6 Bolt ((M6x0.75)50m Steel socket Raw
7 Pcs 8
lost Material
Tube (ID 80mm dia.) Steel Tap Raw
8 shell thickness 3mm and Pcs 2 Material
length 45mm
Stud (840x12dia) Barrel Raw Material
9 M12x1.75 thread length Pcs 4
95mm
Washer ID 13, OD 5D “
10 Pcs 4
thickness 3mm
M12x1.75 nut (standard) “
11 Pcs 8
1.6 barrel
Nameplate (Tag) (30*60*1mm) thick
12 Pcs 1
aluminum

9. Quality
1) After the sub-assembling process at each stage, check the liner and geometrical dimensions.
2) Check if the measuring results comply with requirements.
3) If the test results are not acceptable do the necessary corrections accordingly.
4) Final check-up of assemblies of all sub-assemblies and linear and geometrical dimensions, joining
nails, and internal barrel and flange surfaces.

10.General Manufacturing Process:

The flanges are made first. The circular portions on either end of the core are the flanges. Two layers of
lumber are attached perpendicular to each other, making one solid piece, to make a square flange. The
square flange is cut into a circular shape with a band saw, which removes the edges. The circular flange is
next rubbed to ensure a flat surface along the freshly cut edges.

Second, the flanges are tailored to the needs of the user. The diameters of the start hole and arbor hole, the
number of bolt holes, and the angles of numerous holes are all common adjustments.

Third, the staves for the reel's core/barrels are formed from pine or lumber. Because the core, also known
as the drum, must form a circular, straight-edged lumber and must be rounded before being employed in
this operation. Regular lumber is fed into a machine that shaves the edges off and produces a curved board
known as a stave that will be used in the reel's drum. The flanges and staves are finally bolted together.

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11.Cable Drum production process and methodology
Step 1
Main assembly Description Flange assembly

Sub assembly description Reference

Documents
Sketches Step Process Description Note
1 Cut-out all lumber with specified dimension,
drill central part for the flange section (central
e
bore) with a specified hole size, and lay up all
parts perpendicular to each other.
2 Two layers of lumber are attached Use Nail (12Dx3.75x82.87) in a
perpendicular to each other, making one solid circular pattern.
piece, to make a square flange.
3 The square flange is cut into a circular shape Follow the scribed flange diameter
with a band saw, which removes the edges. The
circular flange is next rubbed to ensure a flat
surface along the freshly cut edges.
4 Drill the cable passage hole and make it sloped
for smooth cable rolling.

Step 2
Main assembly Description Barrel assembly

Sub assembly description Barrel fixing sub- Reference

Documents
assembly
Sketches Step Process Description Note
1 Cut out lumber with specified dimensions and A total of 12 pieces (3 sets)
make a square part bay joining 45 45-degree
e
connection.
2 Scribe the part with a divider and The square
edge is cut into a circular shape with a band
saw, which removes the edges.

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Step 3

Main assembly Description Barrel and Flange

assembly Reference
Sub assembly description Long bolt (Stud) Documents
Sketches Step Process Description Note
1 Cutting with specified length
e

2 Chamfering both ends

3 Thread making (both ends)

Step 4

Main assembly Description Barrel assembly

Sub assembly description Barrel fixing sub- Reference
Documents
assembly with flange
Sketches Step Process Description Note
1 Nailed at the center of the inner face of The inner face of the flanges
both flanges to fix the barrel in position should be markede on the side of
nail heads (The nail which is
used to attach both sides of the
flange layers perpendicularly)
2 Drill 4 holes with specific whole sizes for The hole must be drilled
stud bolt passage. throughout the flange faces and
aligned to a smooth stud bolt
connection.
3 Drill 2 Drive holes with specified sizes for
stud bolt passage.

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Step 5

Main assembly Description Barrel assembly

Sub assembly description Barrel sub-assembly Reference
Documents
(Core bars)
Sketches Step Process Description Note
1 Nailed on barrel fixing sub-assemblies at Keep the stud bolt passage holes
three positions. aligned and placee all studs in
positions and tight with the
required torque.

2 Flatten the sharp edges of the barrel

segments to bring a cylindrical profile.

3 Check all sides of the flanges' position at

equal spacing.

Step 6

Main assembly Description Center bore ass.

Sub assembly description Steel Tap (Central Reference
Documents
Bore Reinforcement)
Sketches Step Process Description Note
1 Cutting with specified dimensions and
ready for tube joining(welding) process e

2 Drilling 4 holes with specific whole sizes

for fixing bolt passage.

3 Welding both prepared steel sheets and Make sure that the pipe is
pipes. perpendicular and inscribed with
steel sheet

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Step 7
Main assembly Description Barrel assembly
Sub assembly description Final Assembly Reference
Documents

Sketches Step Process Description Note

1 Tapping steel tap sub-assembly at central
borehole at four places for each. e

2 Tightening long bolts/studs. The hole must be drilled

throughout the flange faces and
aligned to a smooth stud bolt
connection.
3 Checking all geometrical and linear
dimensions accordingly.

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12.Working drawings

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