Reel with manually actuated retraction system

• US 10,370,218 B2
• Filed: 09/11/2017
• Issued: 08/06/2019
• Est. Priority Date: 07/20/2012
• Status: Active Grant

• Current Assignee: Great Stuff, Inc.
• Original Assignee: Great Stuff, Inc.
• Inventors: Tracey, James B. A., Hill, III, Joseph M., Tracey, Johnathan R.
• Primary Examiner(s): Luo, David
• Application Number:
  US15/701,299
• Publication Number:
  US 20170369273A1
• Time in Patent Office: 694 Days
• Field of Search: 318 3, 318 34
• CPC Class Codes: B65H 75/4484 Electronic arrangements or adaptations for controlling the winding or unwinding process, e.g. with sensors
• CPC Class Codes: B65H 75/4486 Electric motors

Abstract

A reel has a spool member on which the linear material is spooled, an electric motor that rotates the spool member, and a controller that controls the operation of the motor. The controller monitors an unwound length of the linear material based on sensed rotation of the spool member by one or more sensors. The controller causes the electric motor to wind the linear material around the spool member, for example, upon detection of a pulling force on the linear material over a pull distance within a predetermined range, but, for example, does not trigger the winding of the linear material if the pull distance is greater than the predetermined range. The controller can cause the electric motor to stop winding of the linear material upon detection of a force on the linear material that holds the linear material in place.

Claims

1. A method for spooling linear material on an automatic reel device, the method comprising:

monitoring an amount of a linear material unwound from a rotatable spool member of the automatic reel device with one or more sensors;

sensing a pulling action on the linear material in a payout direction of the linear material;

controlling an electric motor to wind the linear material onto the rotatable spool member;

controlling the electric motor to stop rotating the rotatable spool member when the linear material is obstructed from being wound onto the rotatable spool member;

determining, with one or more sensors, whether a pull distance of said pulling action falls within a predetermined range based at least in part on sensed rotation of the rotatable spool member;

controlling the electric motor to wind the linear material onto the rotatable spool member when said pull distance falls within the predetermined range; and

controlling the electric motor to not wind the linear material when said pull distance is greater than the predetermined range.

2. The method of claim 1, further comprising engaging a power relay between a power source and the electric motor when said pull distance falls within the predetermined range.

3. The method of claim 1, wherein the one or more sensors comprise one or more Hall Effect sensors configured to measure one or more counts indicative of one or more revolutions of the rotatable spool member, each of said one or more counts corresponding to an amount of linear material unspooled from the rotatable spool member.

4. The method of claim 3, wherein controlling the electric motor to stop rotating the rotatable spool member when the linear material is obstructed from being wound onto the rotatable spool member comprises sensing when a time period between measured counts is greater than a maximum count timeout.

5. The method of claim 1, wherein controlling the electric motor to stop rotating the rotatable spool member when the linear material is obstructed from being wound onto the rotatable spool member comprises sensing when electric current draw of the electric motor is greater than a current spike limit or a maximum current limit.

6. The method of claim 1, further comprising:

determining when the linear material passes a docking point location at which the linear material loses contact with a ground surface based at least in part on a sensed change in winding speed of the linear material; and

adjusting power to the electric motor to maintain winding speed of an end of the linear material through the docking point location generally constant.

7. A method for spooling linear material on an automatic reel device, the method comprising:

monitoring an amount of a linear material unwound from a rotatable spool member of the automatic reel device with one or more sensors;

sensing a pulling action on the linear material in a payout direction of the linear material;

controlling an electric motor to wind the linear material onto the rotatable spool member;

determining when the linear material passes a docking point location at which the linear material loses contact with a ground surface based at least in part on a sensed change in winding speed of the linear material; and

adjusting power to the electric motor to maintain winding speed of an end of the linear material through the docking point location generally constant.

8. The method of claim 7, further comprising setting the docking point location by sensing a pulling force on the linear material a first predetermined number of times while the end of the linear material is held in a first generally fixed position proximate the ground surface.

9. The method of claim 7, further comprising determining when the linear material passes the docking point location via one or more sensors that measure one or more counts indicative of one or more revolutions of the rotatable spool member, each of said one or more counts corresponding to an amount of linear material spooled or unspooled on the rotatable spool member, and wherein adjusting power to the electric motor to maintain winding speed through the docking point location generally constant is based at least in part on maintaining a time period between said one or more counts generally constant.

10. The method of claim 7, further comprising disengaging a power relay between a power source and the electric motor after winding the linear material around the rotatable spool member to a predetermined docking amount of the linear material.

11. The method of claim 7, further comprising disengaging a power relay between a power source and the electric motor after winding the linear material around the rotatable spool member to a last stop point corresponding to a complete spooling of the linear material.

12. The method of claim 7, further comprising setting a predetermined grasping length of the linear material by sensing a pulling force on the linear material while an end of the linear material is held in a second generally fixed position corresponding to a desired grasping length to facilitate grasping of the linear material for the pulling action.

13. The method of claim 7, further comprising controlling the electric motor to wind the linear material below a maximum translational velocity of the linear material by decreasing rotational velocity of the rotatable spool member as more linear material is spooled onto the rotatable spool member during winding, thereby increasing a winding diameter of the linear material around the rotatable spool member.

14. The method of claim 7, further comprising:

determining, with one or more sensors, whether a pull distance of said pulling action falls within a predetermined range based at least in part on sensed rotation of the rotatable spool member;

controlling the electric motor to wind the linear material onto the rotatable spool member when said pull distance falls within the predetermined range; and

controlling the electric motor to not wind the linear material when said pull distance is greater than the predetermined range.

15. An automatic reel apparatus for spooling linear material, the apparatus comprising:

a spool member configured to rotate bi-directionally to spool and unspool the linear material with respect to the spool member;

an electric motor having an output shaft and configured to rotate the spool member via the output shaft;

one or more sensors configured to generate one or more signals indicative of rotation of the spool member;

a controller configured to control operation of the electric motor, the controller configured to;

monitor a length of the linear material unwound from the spool member based at least in part on the one or more signals indicative of rotation of the spool member generated by the one or more sensors and communicated to the controller;

control the electric motor to wind the linear material around the spool member upon detection of a pulling force on the linear material;

control the electric motor to wind the linear material around the spool member upon detection of the pulling force on the linear material over a pull distance within a predetermined range;

control the electric motor to not wind the linear material around the spool member upon detection that the pulling distance is greater than the predetermined range; and

control the electric motor to stop upon detection of a holding force on the linear material that holds the linear material in place.

16. The automatic reel apparatus of claim 15, wherein the controller is further configured to detect the holding force by sensing a first spike in electric current draw of the electric motor corresponding to the spool member not rotating at a first length of the linear material unwound from the spool member, and wherein the controller is further configured to set a home position corresponding to the first length of the linear material unwound from the spool member.

17. The automatic reel apparatus of claim 15, wherein the controller is further configured to control the electric motor to not wind the linear material around the spool member upon detecting the pulling distance within the predetermined range when the pulling force is applied on the linear material within a predetermined time period of detecting the holding force on the linear material.

18. The automatic reel apparatus of claim 15, wherein the controller is further configured to stop unwinding of the linear material from the spool member at a maximum deployable length of the linear material to provide a strain relief portion of the linear material allowing to pull the linear material to initiate winding of the linear material around the spool member.

19. The automatic reel apparatus of claim 18, further comprising a brake configured to inhibit rotation of the spool member, wherein the controller is further configured to engage the brake to stop unwinding of the linear material from the spool member at the maximum deployable length of the linear material.

20. The automatic reel apparatus of claim 15, wherein the controller is further configured to control the electric motor to stop when electric current draw of the motor is greater than a current spike limit or a maximum current limit corresponding to when the linear material is obstructed from being wound onto the spool member.

21. The automatic reel apparatus of claim 15, wherein the one or more sensors are mounted on the output shaft of the motor on an opposite side of the motor from the spool member on which the linear material is wound to help accurately measure rotation of the spool member.

22. The automatic reel apparatus of claim 15, wherein the one or more sensors comprise one or more Hall Effect sensors configured to measure one or more counts indicative of one or more revolutions of the spool member, each of said one or more counts corresponding to an amount of linear material spooled or unspooled on the spool member.

23. The automatic reel apparatus of claim 22, wherein the controller is further configured to control a power output of the motor based at least in part on said one or more counts to maintain winding speed of the linear material generally constant.

24. The automatic reel apparatus of claim 22, wherein the controller is further configured to adjust power to the motor such that a time period between said one or more counts is generally constant.

25. The automatic reel apparatus of claim 15, wherein the controller is further configured to:

determine when the linear material passes a docking point location at which the linear material loses contact with a ground surface based at least in part on a sensed change in winding speed of the linear material; and

adjust power to the electric motor to maintain winding speed of an end of the linear material through the docking point location generally constant.