Systems and methods for spooling and unspooling linear material

• US 8,746,605 B2
• Filed: 04/17/2012
• Issued: 06/10/2014
• Est. Priority Date: 04/19/2011
• Status: Active Grant

• Current Assignee: Great Stuff, Inc.
• Original Assignee: Great Stuff, Inc.
• Inventors: Tracey, James B. A., Rosenau, Mark, Hill, Joseph M. III
• Primary Examiner(s): Marcelo, Emmanuel M
• Assistant Examiner(s): Stefanon, Justin
• Application Number:
  US13/449,123
• Publication Number:
  US 20130015284A1
• Time in Patent Office: 784 Days
• Field of Search: 242/390, 242/390.8, 242/390.9, 242/412, 242/412.1, 242/412.2, 242/413, 242/413.1, 242/413.3, 242/413.4, 242/413.5, 242/420, 242/420.5, 242/420.6
• US Class Current: 242/390.9
• 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. An apparatus for spooling a linear material, the 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; and

a controller configured to;

monitor a length of the linear material unspooled from the spool member based on an indicator of movement of the spool member generated by one or more sensors;

cause the motor to spool the linear material around the spool member at a first rate of spooling;

reduce the first rate of spooling to a second rate of spooling in response to detecting that the length of linear material unspooled from the spool member becomes less than a first threshold length;

wherein the second rate of spooling is at a non-zero speed; and

adjust the second rate of spooling to a third rate of spooling in response to detecting that the length of linear material unspooled from the spool member becomes less than a second threshold length, wherein the second threshold length is less than the first threshold length, and wherein the third rate of spooling is at a non-zero speed.

2. The apparatus of claim 1, further comprising a housing containing the spool member, the housing having a mounting element attached thereto, the mounting element configured to mount the housing with respect to a surface, wherein the linear material is a water hose.

3. The apparatus of claim 1, wherein the third rate of spooling is greater than the second rate of spooling.

4. The apparatus of claim 3, wherein the third rate of spooling is less than the first rate of spooling.

5. The apparatus of claim 1, wherein the controller is configured to program the second threshold length at the direction of a user.

6. The apparatus of claim 5, wherein the controller is configured to receive a command from the user to indicate a ground contact length between the spool member and a lower surface that can support the linear material, the controller further configured to determine the second threshold length based on the ground contact length.

7. The apparatus of claim 1, wherein the one or more sensors comprise at least one Hall Effect sensor configured to detect rotation of the spool member.

8. The apparatus of claim 1, further comprising at least two magnetic elements coupled to the spool member, and wherein the indicator of movement of the spool member comprises or is based on detection of instances of the at least two magnetic elements passing in proximity to individual sensors of the one or more sensors as the spool member rotates.

9. The apparatus of claim 1, further comprising at least two magnetic elements coupled to a rotating component configured to rotate when the spool member rotates, and wherein the indicator of movement of the spool member comprises or is based on detection of instances of the at least two magnetic elements passing in proximity to individual sensors of the one or more sensors as the rotating component rotates.

10. The apparatus of claim 1, wherein the controller is further configured to:

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

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

11. The apparatus of claim 1, wherein the controller is further configured to cause the motor to cease spooling the linear material in response to the one or more sensors detecting that the spool member is not rotating in the spooling direction.

12. The apparatus of claim 1, wherein the controller is further configured to control the motor so as to vary a rotational velocity of the spool member in an unspooling direction based on detecting a change in a pulling force applied to the linear material.

13. The apparatus of claim 12, wherein the controller is configured to vary a duty cycle of a signal provided to the motor based on the changes in the pulling force.

14. The apparatus of claim 12, wherein the controller is configured to vary the duty cycle using pulse width modulation.

15. The apparatus of claim 1, wherein the controller is further configured to control engagement of a brake to vary a degree to which the brake opposes the rotation of the spool member based on detecting a change in a pulling force applied to the linear material.

16. The apparatus of claim 15, wherein the controller varies a duty cycle of the engagement of the brake based on the changes in the pulling force.

17. The apparatus of claim 16, wherein the controller varies the duty cycle using pulse width modulation.

18. The apparatus of claim 1, wherein the controller is further configured to control the motor so as to stop rotation of the spool member or decrease rotational velocity of the spool member in the unspooling direction while unwinding a proximal end portion of the linear material.

19. The apparatus of claim 1, wherein the linear material comprises a water hose.

20. The apparatus of claim 19, wherein the third rate of spooling is greater than the second rate of spooling.

21. The apparatus of claim 19, wherein the one or more sensors comprise at least one Hall Effect sensor configured to detect rotation of the spool member.

22. The apparatus of claim 19, further comprising at least two magnetic elements coupled to the spool member, and wherein the indicator of movement of the spool member comprises or is based on detection of instances of the at least two magnetic elements passing in proximity to individual sensors of the one or more sensors as the spool member rotates.

23. The apparatus of claim 19, further comprising at least two magnetic elements coupled to a rotating component configured to rotate when the spool member rotates, and wherein the indicator of movement of the spool member comprises or is based on detection of instances of the at least two magnetic elements passing in proximity to individual sensors of the one or more sensors as the rotating component rotates.

24. The apparatus of claim 19, wherein the controller is further configured to:

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

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

25. The apparatus of claim 19, wherein the controller is further configured to cause the motor to cease spooling the water hose in response to the one or more sensors detecting that the spool member is not rotating in the spooling direction.

26. The apparatus of claim 19, wherein the controller is further configured to control the motor so as to vary a rotational velocity of the spool member in the unspooling direction based on detecting a change in a pulling force applied to the water hose.

27. The apparatus of claim 19, wherein the controller is further configured to control engagement of a brake to vary a degree to which the brake opposes the rotation of the spool member based on detecting a change in a pulling force applied to the water hose.

28. The apparatus of claim 19, wherein the controller is further configured to control the motor so as to stop rotation of the spool member or decrease rotational velocity of the spool member in the unspooling direction while unwinding a proximal end portion of the water hose.

29. The apparatus of claim 1, wherein the controller is further configured to automatically cause the motor to spool the linear material around the spool member at the first rate of spooling, reduce the first rate of spooling to second rate of spooling, and adjust the second rate of spooling to the third rate of spooling.

30. The apparatus of claim 1, wherein the controller is further configured to cause substantially all of the momentum of the linear material to be lost by causing the motor to spool the linear material at the second rate of spooling.