Systems and methods for controlling spooling of linear material

• US 7,350,736 B2
• Filed: 06/30/2005
• Issued: 04/01/2008
• Est. Priority Date: 07/01/2004
• Status: Active Grant

• Current Assignee: Great Stuff, Inc.
• Original Assignee: Great Stuff, Inc.
• Inventors: Tracey, James B. A., Lee, Michael J., Koebler, Martin, Caamano, Ramon Anthony
• Primary Examiner(s): Cuomo; Peter M.
• Assistant Examiner(s): Dondero; William E
• Application Number:
  US11/172,420
• Publication Number:
  US 20060000936A1
• Time in Patent Office: 1,006 Days
• Field of Search: 242/389, 242/390, 242/390.1, 242/390.2, 242/390.9, 242/420, 242/420.5, 242/416, 242/390.8, 318/16, 318/282, 318/430, 318/431, 318/6, 318/7
• US Class Current: 242/390.9
• CPC Class Codes: B65H 2701/33 Hollow or hose-like material
• CPC Class Codes: B65H 2701/34 electric cords or electric power cables
• 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

Preferred embodiments of the invention comprise an automatic reel capable assisting a user when attempting to unspool a linear material, such as a water hose. The automatic reel includes a control system having a motor controller capable of sensing a pulling of, or increased tension of, the linear material and capable of causing a motor to rotate to unspool the linear material. In certain embodiments, the motor controller tracks the length of the unspooled portion of the linear material and/or reduces the spooling speed of the motor when retracting a terminal portion of the linear material.

Claims

1. A reel for automatically spooling a hose, the reel comprising:

means for rotating to spool a hose;

means for interacting with the means for rotating to control a rotational velocity of the means for rotating; and

means for monitoring a motor signal and, based on the motor signal, outputting at least one signal to the means for interacting to decrease the rotational velocity of the means for rotating while winding a terminal portion of the hose.

2. A motorized reel for facilitating the spooling of linear material, the motorized reel comprising:

a rotatable member configured to rotate to wind a linear material around the rotatable member;

a motor configured to interact with the rotatable member in at least a first direction; and

control circuitry configured to monitor rotation of the rotatable member by monitoring at least one motor signal to determine at least when an end of the linear material is approaching the rotatable member.

3. The motorized reel of claim 2, wherein the motor is further configured to interact with the rotatable member in a second direction.

4. The motorized reel of claim 2, wherein the control circuitry is further configured to detect a tension of the linear material by sensing a reverse electromagnetic force (EMF) associated with the motor.

5. The motorized reel of claim 2, wherein the control circuitry is further configured to cease rotation of the rotatable member after detecting a substantial increase in a current supplied to the motor.

6. The motorized reel of claim 2, wherein the control circuitry is further configured to detect when substantially all the linear material is wound around the rotatable member.

7. The motorized reel of claim 2, further comprising a substantially spherical shell.

8. The motorized reel of claim 2, wherein the rotatable member is further configured to spool a hose.

9. The motorized reel of claim 2, wherein the control circuitry is further configured to cause the rotatable member to rotate at a slower speed when the end of the linear material is approaching the rotatable member.

10. A method of providing a motorized reel for spooling linear material, the method comprising:

providing a rotatable member configured to rotate to wind a linear material around the rotatable member;

providing a motor configured to interact with the rotatable member to control a rotational velocity of the rotatable member; and

providing a motor controller configured to monitor a signal associated with the motor and to output, based on the motor signal, at least one control signal to the motor to decrease the rotational velocity of the rotatable member while winding a terminal portion of the linear material.

11. The method of claim 10, wherein the terminal portion is identified by a predetermined length of the linear material.

12. The method of claim 11, wherein the motor controller is further configured to measure the predetermined length.

13. The method of claim 12, wherein said measuring comprises monitoring a number of motor rotations.

14. The method of claim 11, wherein the motor controller is further configured to output a signal to reverse the rotation of the rotatable member in response to detecting a reverse electromagnetic force (EMF) associated with the motor.

15. The method of claim 10, further comprising providing a current sensor configured to measure a current drawn by the motor, wherein the motor controller is further configured to suspend rotation of the rotatable member in response to the current sensor detecting a substantial increase in the current drawn by the motor.

16. The method of claim 15, wherein the motor controller is further configured to suspend rotation of the rotatable member when a duration of the substantial increase in the current exceeds a predetermined period of time.

17. The method of claim 10, further comprising adjusting a length of the terminal portion of the linear material through an interface.

18. An automatic reel for facilitating the spooling of linear material, the automatic reel comprising:

a rotatable member having a spool surface, the rotatable member configured to wind a linear material around the spool surface as the rotatable member rotates in a first direction, the rotatable member further configured to deploy the linear material from around the spool surface as the rotatable member rotates in a second direction;

a motor configured to interact with the rotatable member to selectively rotate the rotatable member in the first direction or in the second direction;

a sensor configured to monitor a motor signal indicative of a tension of the linear material; and

control circuitry in communication with the sensor, the control circuitry configured to output a control signal to cause the motor to rotate the rotatable member in the second direction to deploy the linear material when the motor signal monitored by the sensor indicates that the tension of the linear material exceeds a certain amount.

19. The automatic reel of claim 18, wherein the motor signal comprises a reverse electromagnetic force (EMF) signal associated with the motor.

20. The automatic reel of claim 18, wherein the control circuitry is further configured to monitor a length of a portion of the linear material not wound on the rotatable member.

21. The automatic reel of claim 20, wherein the control circuitry is further configured to cause a rotational velocity of the rotatable member in the first direction to decrease when the length of the unwound linear material is less than a predetermined threshold length.

22. The automatic reel of claim 18, wherein the control circuitry is further configured to cease rotation of the rotatable member in response to detecting a substantial increase in a current supplied to the motor.

23. The automatic reel of claim 18, further comprising a shell substantially surrounding the rotatable member, the sensor, the motor and the control circuitry.

24. The automatic reel of claim 23, wherein the shell comprises an aperture through which linear material is spooled.

25. The automatic reel of claim 18, further comprising a user interface.

26. The automatic reel of claim 25, wherein the user interface is configured to receive at least one signal from a remote control device.

27. The automatic reel of claim 18, wherein the sensor comprises a transistor.