Systems and methods for spooling and unspooling linear material

• US 9,663,322 B2
• Filed: 06/06/2014
• Issued: 05/30/2017
• Est. Priority Date: 04/19/2011
• Status: Active Grant

• Current Assignee: Great Stuff, Inc.
• Original Assignee: Great Stuff, Inc.
• Inventors: Hill, III, Joseph M., Tracey, James B. A., Rosenau, Mark
• Primary Examiner(s): Kim, Sang
• Application Number:
  US14/298,464
• Publication Number:
  US 20150021424A1
• Time in Patent Office: 1,089 Days
• Field of Search: 242390, 2423908, 2423909, 242412, 2424121, 2424122, 242413, 2424131, 2424133, 2424134, 2424135, 242420, 2424205, 2424206
• 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 comprising:

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

a brake configured to oppose rotation of the spool member in the unspooling direction when the brake is engaged; and

a controller configured to vary a duty cycle of engagement of the brake from a first non-zero duty cycle to a second non-zero duty cycle while the rotatable member is deploying the linear material based on detecting a change in a pulling force applied to the linear material.

2. The apparatus of claim 1, further comprising a motor configured to rotate the spool member to deploy the linear material, wherein the controller is configured to vary the duty cycle based on a comparison involving a rotational velocity of the motor.

3. The apparatus of claim 1, wherein the controller is configured to vary the duty cycle using pulse width modulation.

4. The apparatus of claim 3, wherein the controller is configured to vary a magnitude of the brake'"'"'s engagement to oppose the rotation of the spool member.

5. The apparatus of claim 1, wherein the brake is implemented by a motor that is configured to cause the spool member to rotate in the unspooling direction.

6. The apparatus of claim 1, wherein the controller is configured to cause the brake to prevent unspooling of the linear material due to gravity.

7. The apparatus of claim 6, further comprising one or more sensors configured to detect a pull on the linear material, and wherein the controller is configured to cause the brake to cease preventing unspooling of the linear material due to gravity responsive to the one or more sensors detecting the pull on the linear material.

8. The apparatus of claim 6, wherein the apparatus is configured for ceiling mounting.

9. The apparatus of claim 6, wherein the apparatus is mounted to a ceiling.

10. The apparatus of claim 6, wherein the brake is implemented by a motor, and wherein the motor is also configured to cause the spool member to rotate in the unspooling direction.

11. The apparatus of claim 10, wherein the motor is configured to function as a generator when preventing unspooling of the linear material due to gravity.

12. The apparatus of claim 10, wherein the controller is configured to apply a common mode voltage to the motor to thereby prevent the linear material from unspooling due to gravity.

13. A reel apparatus comprising:

a spool member configured to deploy a linear material as the spool member rotates in an unspooling direction; and

a motor configured to selectively rotate the spool member in the unspooling direction, and to operate at a motor duty cycle which depends on a rate of increase in a rotational velocity of the motor while the spool member is rotating in the unspooling direction, such that when the rotational velocity of the motor has a first non-zero rate of increase the motor operates at a first non-zero motor duty cycle and when the rotational velocity of the motor has a second non-zero rate of increase higher than the first rate of increase the motor operates at a second non-zero motor duty cycle that is greater than the first motor duty cycle,

wherein the rotational velocity of the motor depends on a tension applied to the linear material.

14. A reel apparatus comprising:

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

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

a controller configured to control the motor while the motor is causing the spool member to deploy the linear material, so as to vary a rotational velocity of the motor in the unspooling direction from a first non-zero rate to a second non-zero rate based on an indication of the rotational velocity of the motor.

15. The apparatus of claim 14, wherein second non-zero rate has a greater magnitude than the first non-zero rate.

16. The apparatus of claim 14, wherein the controller is configured to control the motor to increase the rotational velocity of the motor from the first non-zero rate to the second non-zero rate based on detecting that the force on the linear material has been increased.

17. The apparatus of claim 14, wherein the indication of the rotational velocity of the motor is indicative of a force on the linear material applied by a user pulling on the linear material.

18. The apparatus of claim 14, wherein the controller is configured cause the motor to cease rotating responsive to detecting that the rotational velocity exceeds a preconfigured threshold value.

19. The apparatus of claim 14, wherein the controller is configured to vary a duty cycle of a signal provided to the motor based on detecting a change in the indication of the rotational velocity of the motor.

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

21. The apparatus of claim 14, wherein the controller is configured to vary a magnitude of the signal provided to the motor.

22. The apparatus of claim 14, wherein the controller is configured to apply a common mode voltage to the motor to cease causing the motor to rotate the spool member in the unspooling direction.

23. The apparatus of claim 14, further comprising a brake configured to selectively oppose rotation of the spool member in the unspooling direction.

24. The apparatus of claim 23, wherein the controller is configured to engage the brake responsive to detecting that the motor is rotating below a certain threshold.

25. The apparatus of claim 14, wherein the controller is configured to detect an increase in the rotational velocity of the motor while the motor is causing the spool member to deploy the linear material and to control the motor based on a rate of the increase.

26. The apparatus of claim 14, further comprising one or more Hall effect sensors configured to generate the indication of the rotational velocity of the motor.

27. The apparatus of claim 26, wherein the controller is configured to detect an increase in the rotational velocity of the motor while the motor is causing the spool member to deploy the linear material based on an output from the one or more sensors and to control the rotational velocity of the motor based on an amount of the increase.

28. The apparatus of claim 26, wherein the controller is 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 Hall effect sensors to activate in response to sensing that the motor signal satisfies a threshold.

29. A reel apparatus comprising:

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

a brake configured to resist rotation of the spool member in the unspooling direction when the brake is engaged; and

a controller comprising a braking circuit configured to cause the brake to be engaged, the braking circuit configured to apply dynamic braking to cause the brake to prevent the linear material from unspooling due to gravity when a distal end of the linear material is unwound from the spool member and hanging above a surface below the spool member,

wherein the apparatus is configured for mounting to a ceiling.

30. The apparatus of claim 29, further comprising one or more sensors configured to detect a pull on the linear material, and wherein the controller is configured to cause the brake to cease preventing the linear material from unspooling due to gravity responsive to the one or more sensors detecting the pull on the linear material.

31. The apparatus of claim 29, wherein the apparatus is mounted to the ceiling.

32. The apparatus of claim 29, wherein the brake is implemented by a motor, and wherein the motor is also configured to cause the spool member to rotate in the unspooling direction.

33. The apparatus of claim 32, wherein the motor is configured to function as a generator when preventing the linear material from unspooling due to gravity.

34. The apparatus of claim 32, wherein the breaking circuit is configured to short leads of the motor to each other to create an electrical load on the motor.

35. The apparatus of claim 29, wherein the controller further comprises circuitry configured to selectively cause the spool member to rotate in the unspooling direction and to cease causing the spool member to rotate in the unspooling direction.