Automatic reel devices and method of operating the same

• US 9,067,759 B2
• Filed: 03/13/2013
• Issued: 06/30/2015
• Est. Priority Date: 04/17/2012
• Status: Active Grant

• Current Assignee: Great Stuff, Inc.
• Original Assignee: Great Stuff, Inc.
• Inventors: Tracey, James B. A., Hill, Joseph M. III, Tracey, Johnathan R.
• Primary Examiner(s): KIM, SANG K
• Application Number:
  US13/802,398
• Publication Number:
  US 20140021283A1
• Time in Patent Office: 839 Days
• Field of Search: 242/390.1, 242/390.6, 242/390.8, 242/390.9
• US Class Current: 1/1
• 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 motor to wind the linear material at a drag speed when the linear material is on a ground, at a crawl speed lower than the drag speed when the length of linear material on the ground is shorter than a first threshold amount and through a second predetermined amount once the linear material lifts off the ground to inhibit swing of the linear material as it comes off the ground, and at a docking speed greater than the crawl speed when the unwound linear material is shorter than the second threshold amount.

Claims

1. A method for spooling linear material on an automatic device supported above a ground surface, the method comprising:

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

winding the linear material around the spool member at a first speed when a length of linear material unwound from the spool member is greater than a first predetermined amount, at least a portion of the linear material disposed on the ground surface;

winding the linear material around the spool member at a second speed lower than the first speed when the length of linear material unwound from the spool member decreases below the first predetermined amount but is greater than a docking point location at which the linear material loses contact with the ground surface;

winding the linear material around the spool member at a third speed lower than the first speed when the length of linear material unwound from the spool member decreases below the docking point location but is greater than a third predetermined amount, said linear material length being disposed above the ground surface such that the linear material is not in contact with the ground surface; and

winding the linear material around the spool member at a fourth speed greater than the third speed when the length of linear material unwound from the spool member decreases below the third predetermined amount,

wherein winding the linear material comprises automatically winding the linear material via a controller that controls rotation of an electric motor of the automatic device, and

wherein winding at said second and third speeds is configured to dissipate kinetic energy from the winding of the linear material so as to maintain swing of an end of the linear material below a predetermined limit amount in a direction transverse to a vertical axis when the linear material passes the docking point location.

2. The method of claim 1, wherein the rotatable spool member is mounted on a ceiling.

3. The method of claim 1, wherein the third speed is generally equal to the second speed.

4. 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 spool member, each of said counts corresponding to an amount of linear material unspooled from the spool member.

5. The method of claim 4, further comprising controlling with the controller a power output of the electric motor, wherein the electric motor is coupled to the spool member based at least in part on said measured counts, and wherein the electric motor rotates the spool member such that the third speed is generally constant and substantially equal to the second speed irrespective of ambient temperature changes or a mounting height of the automatic device.

6. The method of claim 5, wherein the controller is further configured to adjust power to the electric motor such that a time period between said counts is generally constant.

7. The method of claim 4, wherein a number of counts over a total unspooled length of the linear material is at least 1000 to facilitate adjusting winding speeds to be generally constant.

8. The method of claim 4, further comprising controlling with the controller power to the electric motor, wherein the electric motor is coupled to the spool member, and wherein the controller is configured to stop power to the electric motor when a time period between measured counts is greater than a maximum count timeout corresponding to when the linear material is obstructed from being wound onto the spool member.

9. The method of claim 8, wherein the maximum count timeout is 75 milliseconds.

10. The method of claim 1, further comprising unwinding the linear material from the spool member with the electric motor, wherein the electric motor is coupled to spool member and controlling with the controller power to the electric motor, wherein the controller is configured to detect a change in unwinding speed of the linear material with the one or more sensors and stop power to the electric motor when the change in unwinding speed is less than a minimum unwinding acceleration of the linear material.

11. The method of claim 1, further comprising engaging a power relay between a power source and the electric motor when a user pulls the linear material a predetermined pull amount.

12. The method of claim 1, further comprising disengaging a power relay between a power source and the electric motor after winding the linear material around the spool member at the fourth speed to a predetermined docking amount of the linear material.

13. The method of claim 1, wherein said predetermined limit amount is less than one foot to mitigate striking a nearby object with the end of the linear material.

14. The method of claim 1, wherein the linear material is an electrical cord.

15. The method of claim 1, further comprising winding the linear material around the spool member at a fifth speed lower than the fourth speed when the length of linear material unwound from the spool member decreases below a fourth predetermined amount, wherein winding at the fifth speed when the length of linear material unwound from the spool member decreases below the fourth predetermined amount is configured to inhibit slamming the end of the linear material into the automatic device.

16. A method for spooling linear material on an automatic device mounted on a wall, ceiling, or bench above a ground surface, the method comprising:

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

winding the linear material around the spool member at a drag speed when a length of linear material unwound from the spool member is greater than a first predetermined amount;

winding the linear material around the spool member at a crawl speed slower than the drag speed when the length of linear material unwound from the spool member decreases below the first predetermined amount but is greater than a second predetermined amount, wherein between the first and second predetermined amounts is a docking point location at which linear material loses contact with the ground surface, and wherein a distance between the docking point location and the first predetermined amount defines a first length; and

winding the linear material around the spool member at a docking speed greater than the crawl speed when the length of linear material unwound from the spool member decreases below the second predetermined amount shorter than the docking point location by a second length,

wherein said crawl speed is generally constant and winding the linear material at the crawl speed through the first and second lengths dissipates kinetic energy from the winding of the linear material so as to maintain swing of an end of the linear material below a predetermined limit amount in a direction transverse to a vertical axis when the linear material passes the docking point location and lifts off the ground surface,

wherein winding the linear material comprises automatically winding the linear material via a controller that controls rotation of an electric motor of the automatic device.

17. The method of claim 16, further comprising measuring with the one or more sensors one or more counts indicative of one or more revolutions of the spool member, each of said counts corresponding to an amount of linear material spooled or unspooled from the spool member, the one or more sensors comprising one or more Hall Effect sensors configured to measure the one or more counts, and further comprising controlling with the controller a power output of the electric motor, wherein the electric motor is coupled to the spool member based at least in part on said measured counts, wherein the electric motor is rotates the spool member such that the crawl speed is generally constant irrespective of ambient temperature changes or a mounting height of the automatic device, the controller adjusting power to the electric motor such that a time period between said counts is generally constant.

18. The method of claim 17, wherein said time period is about 100 milliseconds.

19. The method of claim 16, wherein said predetermined limit amount is one foot.

20. The method of claim 16, further comprising:

winding the linear material around the spool member at a first speed greater than the drag speed when the length of linear material unwound from the spool member is greater than a third predetermined amount that is greater than the first predetermined amount; and

initiating a winding operation of the linear material around the spool member at a start-up speed slower than the first speed over a fourth predetermined amount of linear material upon receipt of a command to begin winding the linear material to help prevent at least one of tipping of the automatic device or yanking the linear material from a hand of a user.

21. The method of claim 16, wherein the ratio of the first length to the second length is at least 2 to 1.

22. The method of claim 16, further comprising engaging a power relay between a power source and the electric motor when a user pulls the linear material a predetermined pull amount.

23. The method of claim 16, further comprising disengaging a power relay between a power source and the electric motor after winding the linear material around the spool member at the docking speed to a predetermined docking amount of the linear material.

24. The method of claim 16, further comprising disengaging a power relay between a power source and the electric motor when electric current draw of the electric motor from the power source is greater than at least one of a current spike limit or a maximum current limit corresponding to when the linear material is obstructed from being wound onto the spool member.

25. An apparatus for spooling a 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 configured to rotate the spool member; and

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

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

control the motor to wind the linear material around the spool member at a start-up speed over a first predetermined length,

control the motor to wind the linear material around the spool member at a second speed faster than the start-up speed when the amount of linear material unwound from the spool member is greater than a second predetermined amount,

control the motor to wind the linear material around the spool member at a drag speed slower than the second speed when the amount of linear material unwound from the spool member decreases below the second predetermined amount but is greater than a third predetermined amount,

control the motor to wind the linear material around the spool member at a crawl speed slower than the drag speed when the amount of linear material unwound from the spool member decreases below the third predetermined amount, and

control the motor to wind the linear material around the spool member at a docking speed faster than the crawl speed when the amount of linear material unwound from the spool member decreases below a fourth predetermined amount,

wherein winding the linear material at at least one of the drag or crawl speeds is configured to dissipate kinetic energy from the winding of the linear material so as to inhibit swinging of an end of the linear material when the linear material loses contact with a ground surface.

26. The apparatus of claim 25, further comprising a housing configured to house the spool member, the housing having a mounting element configured to mount the housing to a surface.

27. The apparatus of claim 26, wherein the mounting element is configured to mount the housing to a ceiling.

28. The apparatus of claim 25, wherein the controller is further configured to cause the motor to wind a predetermined length of the linear material around the spool member such that a grasping length of the linear material remains unspooled to facilitate grasping of the linear material.

29. The apparatus of claim 25, 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 allowing the user pull the linear material a predetermined pull amount to initiate winding of the linear material around the spool member.

30. The apparatus of claim 29, 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.

31. The apparatus of claim 29, wherein the maximum deployable length is less than a total unspooled length of the linear material, and wherein the controller is further configured to determine the total unspooled length of the linear material by detecting a change in rotation direction of the spool member when a user extracts the total unspooled length of the linear material.

32. The apparatus of claim 25, 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 counts corresponding to an amount of linear material spooled or unspooled on the spool member, the controller is further configured to control a power output of the motor based at least in part on said measured counts, to maintain winding speed of the linear material generally constant, and the controller is further configured to adjust power to the motor such that a time period between said counts is generally constant.

33. The apparatus of claim 32, further comprising an interface configured to visually display a reference number based on said counts indicative of the one or more revolutions of the spool member to provide a user with an indication of the amount of linear material that is unwound.

34. The apparatus of claim 25, wherein the linear material is an electrical cord.

35. The apparatus of claim 25, wherein the controller is further configured to determine a docking point location at which the linear material loses contact with the ground based at least in part on a sensed change in winding speed of the linear material by the one or more sensors, the controller further configured to determine when to control the motor to wind the linear material at said drag, crawl, and docking speeds based at least partly on said determination of the docking point location.

36. The apparatus of claim 25, further comprising a remote control configured to communicate with the controller by sending a wireless signal indicating how to control the operation of the motor.

37. The apparatus of claim 36, wherein the remote control is attached on the end of the linear material.

38. The apparatus of claim 25, wherein the controller is further configured to control the motor to not wind the linear material when electric current draw of the motor from a power source is greater than at least one of a current spike limit or a maximum current limit corresponding to when the linear material is obstructed from being wound onto the spool member.