Pioneering Ground Support for High-Altitude Innovation
At Carousel USA, we take pride in building turntables that help power innovation across industries. One of our most exciting challenges to date was creating a custom industrial turntable for cable management, specifically for a company developing high-altitude balloons designed to deliver cell service to remote regions. These balloons, designed as floating cell towers, offered a lifeline for communities without traditional internet infrastructure. This was especially crucial during natural disasters and in hard-to-reach terrain.
Engineering a High-Performance Launch Station Pivot
To support the ground launch station for this groundbreaking technology, our team was tasked with designing and fabricating a custom industrial turntable system for cable management with unique demands. The launch station required a center pivot. It needed to rotate a 60,000-pound structure safely, while routing multiple high-voltage power cables, fiber optic lines, and helium gas pipes—all allowing for full 720° rotation.
A Smarter Cable Management System—Designed In-House
The solution? A rugged yet refined cable management system, engineered entirely in-house. Instead of relying on bulky and expensive cable chain systems with long lead times, we developed a simple vertical coiling mechanism. This mechanism allowed the heavy-duty cables to move freely and efficiently. Moreover, this approach minimized space requirements, reduced costs, and eliminated unnecessary moving parts—all without compromising on performance.
Optimized Design Through Advanced 3D Modeling
Every element of the turntable was optimized using advanced 3D modeling software. This ensured we could anticipate and resolve challenges before fabrication even began. Once built, our engineers ran extensive bench tests using scale models. They did this before fabricating and installing the full-size assembly. This custom industrial turntable for cable management was carefully tested and approved.
Exceeding Expectations with Precision and Durability
The result was a cost-effective, durable, and precise system that met—and exceeded—the project’s rigorous requirements. By combining smart design with hands-on craftsmanship, Carousel USA helped support a mission. This mission aimed to connect people across the globe.
Innovating at Every Turn
From residential builds to industrial breakthroughs, we’re proud to help bring bold ideas to life—one rotation at a time.
