Systems and methods for spooling and unspooling linear material

• US 10,556,772 B2
• Filed: 05/26/2017
• Issued: 02/11/2020
• Est. Priority Date: 04/19/2011
• Status: Active Grant

• Current Assignee: Great Stuff, Inc.
• Original Assignee: Great Stuff, Inc.
• Inventors: Tracey, James B. A., Hill, III, Joseph M.
• Primary Examiner(s): Kim, Sang K
• Application Number:
  US15/607,236
• Publication Number:
  US 20170355552A1
• Time in Patent Office: 991 Days
• CPC Class Codes: B65H 75/403 Carriage with wheels
• CPC Class Codes: B65H 75/4436 Arrangements for yieldably braking the reel or the material for moderating speed of winding or unwinding
• CPC Class Codes: B65H 75/4471 Housing enclosing the reel
• 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

Apparatus and methods are disclosed related to spooling and unspooling linear material. Such apparatus and methods can assist the user in deploying and/or retracting linear material.

Claims

1. A reel apparatus with strain relief, the reel apparatus comprising:

a rotatable spool member configured to unwind a linear material as the rotatable spool member rotates in an unspooling direction;

a motor configured to rotate the rotatable spool member in the unspooling direction; and

a controller configured to;

detect that an amount of the linear material unwound from the rotatable spool member satisfies a threshold; and

in response to detecting that the amount of the linear material unwound from the rotatable spool member satisfies the threshold, cause rotation of the rotatable spool member to stop so as to ensure that a proximal end portion of the linear material is wound around the rotatable spool member.

2. The reel apparatus of claim 1, wherein the controller is configured to control the motor so as to stop rotation of the rotatable spool member to thereby ensure that the proximal end portion of the linear material is would around the rotatable spool member.

3. The reel apparatus of claim 1, further comprising a sensor configured to generate an indication of rotation of the rotatable spool member, wherein the controller is configured to detect that the amount of the linear material unwound from the rotatable spool member satisfies the threshold based on the indication of rotation of the rotatable spool member.

4. The reel apparatus of claim 3, wherein the sensor comprises a Hall Effect sensor.

5. The reel apparatus of claim 1, further comprising:

a sensing element on a rotating component, the sensing element being an optical element or a magnetic element, and the rotating component comprising at least one of the rotatable spool member, an output shaft of the motor, or a gear operatively coupled with respect to the motor and the rotatable spool member; and

a sensor configured to monitor rotation of the rotating component by detecting instances of the sensing element passing in proximity to the sensor during rotation of the rotating component, the sensor being an optical sensor or a magnetic sensor;

wherein the controller is configured to detect the amount of the linear material unwound from the rotatable spool member based on a signal from the sensor.

6. The reel apparatus of claim 1, wherein the controller is configured to gradually increase a duty cycle of a breaking mechanism in response to detecting that the amount of the linear material unwound from the rotatable spool member satisfies the threshold.

7. A reel apparatus comprising:

a rotatable spool member configured to unwind a linear material as the rotatable spool member rotates in an unspooling direction;

a motor configured to rotate the rotatable spool member in the unspooling direction;

one or more sensors configured generate an indicator of rotation of the rotatable spool member, and a controller configured to;

obtain a motor signal indicative of a torque that is exerted upon the rotatable spool member and not produced by the motor;

cause the one or more sensors to activate in response to sensing that the motor signal satisfies a motor signal threshold;

detect that an amount of the linear material unwound from the rotatable spool member satisfies a threshold; and

in response to detecting that the amount of the linear material unwound from the rotatable spool member satisfies the threshold, cause a rate at which the linear material is unwound from the rotatable spool member to be reduced.

8. The reel apparatus of claim 7, wherein the controller is further configured to detect the amount of the linear material unwound from the rotatable spool member based on a signal from the one or more sensors.

9. The reel apparatus of claim 7, wherein the one or more sensors are configured to monitor rotation of an optical sensing element on a rotating component, and wherein the rotating component comprises at least one of the rotatable spool member, an output shaft of the motor, or a gear operatively coupled with respect to the motor and the rotatable spool member.

10. The reel apparatus of claim 7, wherein the one or more sensors are configured to monitor rotation of a magnetic sensing element on a rotating component, and wherein the rotating component comprises at least one of the rotatable spool member, an output shaft of the motor, or a gear operatively coupled with respect to the motor and the rotatable spool member.

12. The method of claim 8, wherein the stopping rotation comprises gradually increasing a duty cycle of a breaking mechanism.

11. A method comprising:

controlling a motor to rotate a rotatable spool member so as to cause a linear material to unwind from around the rotatable spool member;

detecting that an amount of the linear material unwound from the rotatable spool member satisfies a threshold while the linear material is being unwound from around the rotatable spool member; and

in response to said detecting that the amount of the linear material unwound from the rotatable spool member satisfies the threshold, stopping rotation of the rotatable spool member so as to ensure that a proximal end portion of the linear material is wound around the rotatable spool member.

13. A reel apparatus comprising:

a spool member configured to rotate bidirectionally to spool and unspool the linear material with respect to the spool member;

a motor configured to rotate the spool member;

one or more sensors configured to generate an indicator of rotation of the spool member; and

a controller configured to;

obtain a motor signal indicative of a tension of the linear material, wherein the motor signal is indicative of a torque that is exerted upon the spool member, and wherein the torque is not produced by the motor; and

cause the one or more sensors to activate in response to detecting that the motor signal satisfies a threshold.

14. The reel apparatus of claim 13, wherein the motor signal is indicative of a reverse electromotive force (EMF) associated with the motor.

15. The reel apparatus of claim 13, wherein the controller is configured to bring the one or more sensors out of a sleep mode of operation in response to detecting that the motor signal satisfies the threshold.

16. The reel apparatus of claim 13, wherein the one or more sensors comprise a Hall Effect sensor.

17. The reel apparatus of claim 16, wherein the one or more sensors are configured to provide a signal indicative of a number of revolutions of an output shaft of the motor to the controller.

18. The reel apparatus of claim 13, wherein the controller is configured to generate an indication of an amount of the linear material unspooled from the spool member based on the indicator of rotation of the spool member.

19. The reel apparatus of claim 13, wherein the threshold is indicative of a user pulling the linear material.

20. The reel apparatus of claim 13, wherein the controller is further configured to cause the motor to unspool the linear material in response to the motor signal satisfying the threshold.