Fishing reel motor brake

Abstract

A fishing reel includes a housing, a shaft supported in the housing and configured to rotate relative to the housing about a shaft axis extending in a longitudinal direction of the shaft, and a line cup fixed with the shaft to rotate with the shaft about the shaft axis for winding and unwinding fishing line. The fishing reel further includes a stator fixed with the housing, wherein the line cup is configured to rotate with the shaft relative to the stator and the housing, a stator magnet that is an electromagnet fixed with the stator, a rotor including a first rotor plate fixed with the shaft to rotate with the shaft about the shaft axis, and a first rotor magnet fixed with the first rotor plate. The stator magnet is configured to receive electrical current and generate a magnetic field from the stator to the first rotor magnet.

Description

Background Technology

[0001] Fishing reels have a drawback called backlash, which occurs when the spool goes beyond the lead line. This backlash causes the lead line to get stuck in the rotating spool and pull back, resulting in tangles, commonly known as "bird's nests." Fishing reels can include braking devices to stop the reel before a backlash occurs, thus reducing the likelihood of tangles.

[0002] Known braking devices rely on a first permanent magnet selectively positioned near a second permanent magnet or a magnetic feature that attracts the first permanent magnet in some way. Relative movement between the first and second permanent magnets or the magnetic feature generates braking force on the shaft without direct mechanical contact. However, such magnetic braking devices require the permanent magnets and magnetic features to be sized and have corresponding magnetic field strengths suitable for generating sufficient braking force on the shaft. Furthermore, such magnetic braking devices require space to repeatedly move one of the first and second permanent magnets or magnetic features an effective distance to selectively generate and remove braking force on the shaft. Therefore, such magnetic braking devices are often bulky and impractical in terms of weight and volume when stopping fishing reels. Thus, a relatively compact braking mechanism is needed that does not suffer excessive wear when generating braking force on the shaft. Summary of the Invention

[0003] A fishing reel includes: a housing; a shaft supported within the housing and configured to rotate relative to the housing about an axis extending in a longitudinal direction of the shaft; and a spool fixed to the shaft to rotate together with the shaft about the axis for winding and unwinding fishing line. The reel also includes: a stator fixed to the housing, wherein the spool is configured to rotate together with the shaft relative to the stator and the housing; a stator magnet, which is an electromagnet fixed to the stator; a rotor including a first rotor plate fixed to the shaft to rotate together with the shaft about the axis; and a first rotor magnet fixed to the first rotor plate, wherein the stator magnet is configured to receive current and generate a magnetic field from the stator to the first rotor magnet. Attached Figure Description

[0004] Figure 1 This is a perspective view of a fishing reel.

[0005] Figure 2 This is an exploded perspective view of a fishing reel.

[0006] Figure 3 This is a perspective view of a fishing reel, with part of the casing removed.

[0007] Figure 4 This is a first side perspective view of a partially disassembled fishing reel.

[0008] Figure 5 This is a second side perspective view of a partially disassembled fishing reel.

[0009] Figure 6 This is a front view of a partially disassembled fishing reel.

[0010] Figure 7 This is a rear perspective view of a partially disassembled fishing reel.

[0011] Figure 8 A flowchart for actuating the fishing reel during active and passive braking.

[0012] Figure 9 This is a perspective view of the exploded front of a fishing reel, based on another aspect.

[0013] Figure 10 for Figure 9 An exploded perspective view of a fishing reel.

[0014] Figure 11 for Figure 9 Front view of a fishing reel.

[0015] Figure 12 for Figure 9 A schematic side view of a fishing reel. Detailed Implementation

[0016] The description and accompanying drawings are merely illustrative, and various modifications and alterations can be made to the disclosed structures without departing from this disclosure. Referring now to the accompanying drawings, in which the same numbers denote the same parts in all the views, Figure 1 A fishing reel 100 is depicted, comprising a housing 102, a shaft 104, and a spool 110. The shaft 104 is supported within the housing 102 and configured to rotate relative to the housing 102 about an axis 112 extending in the longitudinal direction of the shaft 104 along the width direction of the reel 100. The spool 110 is fixed to the shaft 104 and rotates together with the shaft about the axis 112 to wind and unwind fishing line (not shown) relative to the reel 100. The reel 100 includes a handle 114 for manually rotating the shaft 104 and extending it to the spool 110 for winding and unwinding fishing line relative to the reel 100.

[0017] like Figure 2As shown, the fishing reel 100 includes a motor brake 120, which is fixed to a housing 102 and a shaft 104. The motor brake 120 includes a stator 122 and a rotor 124, which may be formed by a first rotor plate 130 and a second rotor plate 132. When the shaft 104 rotates relative to the housing 102 about an axis 112, the stator 122 is fixed to the housing 102 to remain stationary together with the housing 102. The first rotor plate 130 is fixed to the shaft 104 to rotate relative to the housing 102 together with the shaft 104. The second rotor plate 132 is fixed to the shaft 104 to rotate relative to the housing 102 together with the shaft 104. With this configuration, the rotor 124, including the first rotor plate 130 and the second rotor plate 132, is configured to rotate relative to the housing 102 and the stator 122 together with the shaft 104 and the spool 110 when the fishing line is wound and unwound relative to the fishing reel 100.

[0018] The fishing reel 100 includes a stator magnet 142, which is an electromagnet fixed to a stator 122 to remain stationary with the housing 102 as the shaft 104, spool 110, and rotor 124 rotate relative to the housing 102. The stator magnet 142 is formed by a stator winding 144 (shown schematically), which is a coil winding configured to receive current and generate a magnetic field and configured to generate current when exposed to a changing magnetic field.

[0019] Rotor 124 includes a plurality of first rotor magnets 150, which are permanent magnets, fixed to a first rotor plate 130 for rotation relative to housing 102 and stator 122 (including stator magnets 142) together with shaft 104. Rotor 124 also includes a plurality of second rotor magnets 152, which are permanent magnets, fixed to a second rotor plate 132 for rotation relative to housing 102 and stator 122 (including stator magnets 142) together with shaft 104. While each of the plurality of first rotor magnets 150 and the plurality of second rotor magnets 152 includes, schematically depicted, eight magnets, each of the plurality of first rotor magnets 150 and the plurality of second rotor magnets 152 may include more or fewer magnets without departing from the scope of this disclosure.

[0020] The fishing reel 100 includes a line status sensor 154, which is fixed to the housing 102 to remain stationary with the housing 102 as the shaft 104, spool 110, and rotor 124 rotate relative to the housing 102. The line status sensor 154 is configured to detect a section of fishing line unwound from the spool 110 to generate line status information indicating whether a loop has formed in the unwound line.

[0021] The fishing reel 100 includes a rotation sensor 160, which is fixed to the housing 102 to remain stationary with the housing 102 as the shaft 104, spool 110, and rotor 124 rotate relative to the housing 102. The rotation sensor 160 includes multiple flux sensors, such as Hall effect sensors 162, disposed on a flexible circuit 164. The flexible circuit 164 is supported on a mounting 170 fixed to the stator 122. The rotation sensor 160 is configured to detect a magnetic field from the rotor 124 using the multiple Hall effect sensors 162. Based on the magnetic field detected from the rotor 124, the rotation sensor 160 is configured to generate rotational position information of the shaft 104, spool 110, and rotor 124 relative to the housing 102.

[0022] Figure 3 A fishing reel 100 is depicted, in which a portion of the housing 102 has been removed. (See image below.) Figure 3 As shown, the fishing reel 100 includes a battery 172 disposed in a housing 102 and connected to a stator 122 via a circuit 174. Magnetic fields from the first rotor magnet 150 and the second rotor magnet 152 extend to the stator magnet 142, causing a current to be induced in the stator magnet 142 by the rotor 124 rotating relative to the stator 122. In this way, as the rotor 124 rotates relative to the stator 122, the stator 122 generates a current in the circuit 174 and charges the battery 172.

[0023] The fishing reel 100 includes a controller 180 and a memory 182, which are connected to and configured to control the current flowing from the battery 172 through the circuit 174 to the stator 122. The controller 180, memory 182, and battery 172 are mounted on a support 184, which is a printed circuit board fixed to the housing 102. In this way, the controller 180 and memory 182 are fixed to the housing 102 and configured to actuate the stator 122 to initiate reverse current braking, such that the stator 122 applies braking force on the shaft 104 via the rotor 124.

[0024] As shown, although the controller 180 and the memory are connected to the battery 172, the fishing line status sensor 154 and the rotation sensor 160 via the circuit 174, the controller 180 and the battery 172 may additionally or alternatively drive the stator 122 via a wireless connection with the circuit 174, the battery 172, the fishing line status sensor 154 and the rotation sensor 160, thereby actuating the stator 122 without departing from the scope of this disclosure.

[0025] Controller 180 is a computing device that processes signals and performs general calculations and arithmetic functions. The signals processed by controller 180 may include digital signals that can be received, transmitted, and / or detected, computer instructions, processor instructions, messages, bits, and bit streams. Controller 180 can be a variety of different processors, including multiple single-core and multi-core processors and coprocessors, as well as other single-core and multi-core processor and coprocessor architectures. Controller 180 may include logic circuitry that executes actions, instructions, and / or algorithms stored in memory 182.

[0026] Memory 182 may include volatile memory and / or non-volatile memory. Non-volatile memory may include, for example, ROM (Read-Only Memory), PROM (Programmable Read-Only Memory), EPROM (Erasable PROM), and EEPROM (Electrically Erasable PROM). Volatile memory may include, for example, RAM (Random Access Memory), Synchronous RAM (SRAM), Dynamic RAM (DRAM), Synchronous DRAM (SDRAM), Double Data Rate SDRAM (DDRSDRAM), and Direct RAM Bus RAM (DRRAM). Memory 182 may store the operating system that controls or allocates the resources of controller 180.

[0027] Figure 4 Depicting fishing reel 100, in which the following has been removed. Figure 3 The battery 172, controller 180, and support 184 are shown, with the housing 102 depicted in dashed lines. Figure 4 As shown, the spool 110 and rotor 124 are configured to rotate together with shaft 104 relative to stator 122, fishing line status sensor 154, rotation sensor 160 and housing 102.

[0028] Multiple Hall effect sensors 162 are supported on the mounting bracket 170 and fixed relative to the housing 102. The multiple Hall effect sensors 162 are arranged along the outer periphery 190 of the first rotor plate 130 and the first rotor magnet 150 in the circumferential direction.

[0029] Multiple Hall effect sensors 162 are each configured to detect the amplitude of the magnetic field of the first rotor plate 130 and cooperate to generate rotational position information of the rotor 124, shaft 104, and spool 110. The rotational position information generated by the rotation sensor 160 indicates the rotational position of the rotor 124, shaft 104, and spool 110 relative to the housing 102 about axis 112. Using this configuration, the rotation sensor 160 is configured to detect the magnetic field from the first rotor plate 130 via the multiple Hall effect sensors 162 to detect the rotational position of the rotor 124, shaft 104, and spool 110 relative to the housing 102 about axis 112.

[0030] Rotation sensor 160 is configured to transmit rotational position information to controller 180 via circuit 174. Flexible circuit 164 is connected to circuit 174 to transmit power and information between rotation sensor 160, battery 172, and controller 180. Controller 180 is configured to receive the rotational position information transmitted by rotation sensor 160 to determine the rotational speeds of rotor 124, shaft 104, and spool 110.

[0031] Continue to refer to Figure 4 The fishing line status sensor 154 includes a light source 192 and an optical sensor 194 fixed to the housing 102. The optical sensor 194 is configured to detect light 200 emitted from the light source 192 passing through a section (not shown) of the fishing line unwound from the spool 110. In this way, the fishing line status sensor 154 is configured to generate fishing line status information based on the light 200 passing through the fishing line detected by the optical sensor 194.

[0032] The spool 110 includes a first flange 202, a second flange 204, and a spool shaft 210. The spool shaft 210 is located between and separates the first flange 202 and the second flange 204 in the longitudinal direction of the shaft 104. Therefore, the spool 110 is configured to hold the fishing line wound on the spool shaft 210 in the longitudinal direction of the shaft 104. Figure 4 and Figure 5 As shown, the light source 192 includes a beam emitter 212 and an optics device 214 fixed in the housing 102 by a stator 122. The beam emitter 212 and the optics device 214 are supported in the housing 102 on the side of the first flange 202 opposite to the spool shaft 210 in the longitudinal direction of the axis 104. The beam emitter 212 is configured to generate light in the light source 192. The optics device 214 is configured to collimate the light from the beam emitter 212, such that the light source emits a first beam 220 and a second beam 222 from behind the first flange 202 toward the optical sensor 194 in the longitudinal direction of the axis 104.

[0033] The optical sensor 194 includes a first receiver 224 and a second receiver 230, which are fixed within the housing 102 on the side of the second flange 204 opposite to the spool shaft 210 in the longitudinal direction of the shaft 104. The first receiver 224 and the second receiver 230 are used to receive and detect a first beam 220 and a second beam 222 from the light source 192, respectively. The optical sensor 194 is configured to transmit line status information to the controller 180 using a wired or wireless connection.

[0034] like Figure 6As shown, in the longitudinal direction of shaft 104, stator 122 is positioned between and separates a first rotor plate 130 having a first rotor magnet 150 and a second rotor plate 132 having a second rotor magnet 152. With this configuration, the first rotor magnet 150 is positioned on shaft 104 in the longitudinal direction of shaft 104 on the side of stator 122 opposite to the second rotor magnet 152. The first rotor magnet 150 and the second rotor magnet 152 are spaced apart from stator 122 such that when controller 180 actuates stator 122, stator magnet 142 generates a magnetic field from stator 122 to the first rotor magnet 150 and the second rotor magnet 152.

[0035] The stator 122 is formed of a printed circuit board that defines a first stator surface 232 and a second stator surface 234, the second stator surface 234 being opposite to the first stator surface 232 in the longitudinal direction of the shaft 104. For example, the stator 122 may be formed of a multilayer circuit board, such as 12 or more layers. The first stator surface 232 and the second stator surface 234 are planar and extend along the first rotor plate 130 and the second rotor plate 132, respectively, in the radial direction of the shaft 104 perpendicular to the longitudinal direction of the shaft 104.

[0036] The stator magnet 142 comprises a plurality of stator windings 240, which are coil windings that can be disposed on a first stator surface 232, a second stator surface 234, and an intermediate layer, and the stator magnet 142 is configured to receive current from the circuit 174 and generate a magnetic field. The stator windings 240 are disposed along the first rotor plate 130 and the second rotor plate 132 to define a space between the first rotor plate 130 and the second rotor plate 132 in the longitudinal direction of the shaft 104.

[0037] Continue to refer to Figure 6 A first rotor plate 130 defines a flat first rotor surface 242 extending radially along a first stator surface 232 on a shaft 104. A first rotor magnet 150 is disposed on the first rotor surface 242 to define a first space 244 between the first rotor magnet 150 and the stator 122 in the longitudinal direction of the shaft 104. The first rotor magnet 150 is arranged circumferentially on the first rotor plate 130 for balanced rotation about an axis 112. In such an embodiment, stator windings 240 on the first stator surface 232 are spaced apart from the first rotor magnet 150 such that when the controller 180 actuates the stator 122, the stator windings 240 generate a magnetic field from the stator through the first space 244 to the first rotor magnet 150.

[0038] The second rotor plate 132 defines a flat second rotor surface 250 extending radially along the second stator surface 234 in the direction of the shaft 104. A second rotor magnet 152 is disposed on the second rotor surface 250 to define a second space 252 between the second rotor magnet 152 and the stator 122 in the longitudinal direction of the shaft 104. The first rotor magnet 150 is arranged circumferentially on the second rotor plate 132 for balanced rotation about the axis 112. With this configuration, the stator windings 240 on the second stator surface 234 are spaced apart from the second rotor magnets 152, such that when the controller 180 actuates the stator 122, the stator windings 240 generate a magnetic field from the stator 122 through the second space 252 to the second rotor magnets 152.

[0039] Continuing the example above, the first rotor magnet 150 and the second rotor magnet 152 are positioned along the shaft 104, spaced apart from the stator 122, such that the first rotor magnet 150 and the second rotor magnet 152 are configured to rotate together with the shaft 104 about the axis 112 without directly contacting the stator 122. In this way, the motor brake 120 forms a brushless motor, which is configured to brake and / or drive the spool 110 via the rotor 124 and the shaft 104, and the motor brake 120 does not undergo excessive wear when braking and / or driving the spool 110.

[0040] The first rotor magnet 150 and the second rotor magnet 152 are positioned close to the stator 122 to minimize the first space 244 and the second space 252 in the longitudinal direction of the shaft 104. The stator magnet 142 is sufficiently close to the stator 122 to generate a magnetic field through the first rotor magnet 150 and the second rotor magnet 152, effectively applying braking force and / or driving force from the stator 122 to the rotor 124. The first rotor plate 130, the first rotor magnet 150, the second rotor plate 132, the second rotor magnet 152, and the stator 122 are each formed into a plate shape with minimal thickness in the longitudinal direction of the shaft 104 to reduce the total thickness of the motor brake 120 in the longitudinal direction of the shaft 104. With this configuration, the motor brake 120 has a relatively compact structure, wherein the size of the housing 102 required to assemble the stator 122 and the rotor 124 is reduced.

[0041] like Figure 7As shown, the rotation sensor 160 is mounted to the stator 122 such that the rotation sensor 160 is fixed to the housing 102 via the stator 122. In the illustrated embodiment, the mounting member 170 may extend from the stator 122 to position the Hall effect sensor 162 along the first rotor magnet 150. In another embodiment, the mounting member 170 may additionally or alternatively extend from the stator 122 to position the Hall effect sensor 162 along the second rotor magnet 152 for generating rotational position information based on the detected magnetic field from the second rotor magnet 152.

[0042] The fishing line status sensor 154 is configured to transmit fishing line status information to the controller 180, for example, during a casting operation where the fishing line is unwound from the spool 110. The rotation sensor 160 is configured to transmit rotational position information to the controller 180, including during a casting operation where the fishing line is unwound from the spool 110.

[0043] refer to Figure 3 and Figure 7 During the throwing operation, shaft 104 rotates relative to housing 102 about axis 112 in a first rotational direction. Controller 180 is configured to direct current through stator magnet 142 to perform reverse current braking using rotor 124, such that shaft 104 encounters braking force from stator 122 via rotor 124 in a second rotational direction opposite to the first rotational direction. Controller 180 is also configured to direct current through stator magnet 142, such that stator 122 and rotor 124 form a three-phase motor configured to apply braking force to shaft 104 from housing 102.

[0044] The controller 180 can be configured to initiate reverse current braking based on the rotational speed of one or more of the rotor 124, shaft 104, and spool 110. For example, when the rotational speed of the rotor 124, shaft 104, and / or spool 110 is below a predetermined threshold, the controller 180 can be configured to perform reverse current braking by guiding current through the stator winding 240. In this way, the stator magnet 142 generates an active braking magnetic field on the rotor 124 via the first rotor magnet 150. The active braking magnetic field generated by the stator 122 causes the rotor 124 to rotate in a second rotational direction of the shaft 104, which is opposite to the first rotational direction of the shaft 104.

[0045] As another example, when the rotational speed of rotor 124, shaft 104, and / or spool 110 exceeds a predetermined threshold, controller 180 is configured to perform reverse current braking using passive braking force. For example, controller 180 may direct current through stator winding 240 while short-circuiting one or more of the stator windings 240 during passive braking. In this way, stator magnet 142 generates a passive braking magnetic field on rotor 124 via first rotor magnet 150. The passive braking magnetic field generated by stator 122 causes rotor 124 to rotate in the same direction as the active braking magnetic field, but with a relatively smaller amplitude. Controller 180 may also be configured to control the duration of the applied braking force in such a way that the passive braking magnetic field is applied for a shorter duration compared to the active braking magnetic field. For example, during active braking, pulse width modulation (PWM) or another control signaling method may be used to direct current through stator winding 240 for a longer duration compared to passive braking, but the amplitude of the generated magnetic field may be relatively the same.

[0046] Figure 8 A flowchart detailing a method 300 for operating a fishing reel 100 during casting is provided. In this manner, method 300 provides monitoring the line condition of the fishing line at block 302 and the rotational speeds of the rotor 124, shaft 104, and spool 110 at block 304, wherein the controller 180 bases its information on the line condition from the line condition sensor 154 and the rotational position information from the rotation sensor 160. The rotational position information received by the controller 180 over time during casting is processed by the controller 180 to determine the rotational speeds of the rotor 124, shaft 104, and spool 110. Information from the rotation sensor 160 is also used for timing (commutation) of the drive current sent to the stator 122 during active braking. The rotation sensor 160 can also be used to notify electronic operations to turn the power generation function for charging the battery 172 on and off, and to control the magnitude of the resistance setting corresponding to the amount of electricity collected during charging.

[0047] In block 306 of method 300, controller 180 determines whether a loop has formed in the fishing line unwound from spool 110 based on fishing line status information from fishing line status sensor 154. If no loop has formed, the fishing line status and the rotational speeds of rotor 124, shaft 104, and spool 110 continue to be monitored. When controller 180 determines that a loop is forming in the fishing line, the method proceeds to block 310 of method 300. In block 310, controller 180 compares the rotational speeds of rotor 124, shaft 104, and spool 110 with predetermined thresholds based on rotational position information from rotation sensor 160.

[0048] In block 310 of the method, controller 180 determines whether the rotational speed is below a predetermined threshold. The predetermined threshold may be a value corresponding to a predetermined rotational speed. To determine whether the rotational speed determined in block 304 is at or below the predetermined threshold, controller 180 may compare the rotational speed with the predetermined threshold. If the rotational speed is below the predetermined threshold, method 300 continues to block 312, and if the rotational speed is above the predetermined threshold, method 300 continues to block 314.

[0049] At blocks 312 and 314 of method 300, controller 180 drives stator 122 by current flowing through stator magnet 142, causing stator magnet 142 to generate a magnetic field from stator 122 to first rotor magnet 150 and second rotor magnet 152. Thus, stator 122 applies braking force on shaft 104 via rotor 124. In this way, controller 180 is configured to actuate motor brake 120 via stator 122 when controller 180 determines that a loop is forming in the fishing line, regardless of whether the compared rotational speed is above or below a predetermined threshold.

[0050] Continue to refer to Figure 8 When, in block 310, controller 180 determines that the compared rotational speed of one or more of the rotor 124, shaft 104, and spool 110 is below a predetermined threshold, method 300 proceeds to block 312. At block 312, controller 180 directs current through stator winding 240, causing stator magnet 142 to generate an active braking magnetic field on rotor 124 via first rotor magnet 150 and second rotor magnet 152. When unwinding the fishing line, the active braking magnetic field generated by stator 122 is opposite to the rotational direction of spool 110. Therefore, in response to controller 180 determining at block 306 that a loop is formed in the fishing line unwound from spool 110 during casting and that the rotational speed at block 310 is at or below the predetermined threshold, controller 180 causes stator 122 to influence the active braking magnetic field on rotor 124. Other thresholds can be determined to adjust the level of applied active braking, and controlled via pulse width modulation (PWM) or similar control signals, wherein the braking is applied with an on / off duty cycle at a frequency much higher than the rotational frequency of rotor 124, shaft 104, and spool 110. Controller 180 can also predetermine the timing of applying braking force based on the sensed rotational speed.

[0051] When the controller 180 determines in block 310 that the compared rotational speed is equal to or exceeds a predetermined threshold, method 300 proceeds to block 314. At block 314, the controller 180 directs current through the stator winding 240, causing the stator magnet 142 to generate a passive braking magnetic field on the rotor 124 via the first rotor magnet 150 and the second rotor magnet 152. As described above, the passive braking magnetic field generated by the stator 122 is in the same direction as the active braking magnetic field and opposite to the rotational direction of the spool 110, but is relatively smaller in amplitude or duration than the active braking magnetic field. Therefore, in response to the controller 180 determining in block 306 that a loop has formed in the fishing line unwound from the spool 110 during the casting operation and that the rotational speed exceeds the predetermined threshold at block 310, the controller 180 causes the stator 122 to influence the passive braking magnetic field on the rotor 124. In this way, the controller 180 actuates dynamic reverse current braking based on the rotational speed of one or more of the rotor 124, shaft 104 and spool 110.

[0052] Figures 9 to 12 A fishing reel motor brake 400 according to another aspect of this disclosure is shown. Unless otherwise stated, refer to Figures 9 to 12 The described motor brake 400 for fishing reels includes references Figure 1-8 The fishing reel 100 described has similar features and functions.

[0053] like Figure 9 As shown, the motor brake 400 includes a spool 402 fixed to a shaft 404 for rotation together with the shaft 404 about an axis 410 extending in the longitudinal direction of the shaft 404. A first rotor 412 is attached to the spool 402 such that the first rotor 412 is fixed to the shaft 404 via the spool 402 and configured to rotate together with the spool 402 and the shaft 404 about the axis 410. In the illustrated embodiment, the first rotor 412 is a right-handed rotor plate having opposing flat surfaces perpendicular to the axis 410, and may be a circular plate with a radial direction perpendicular to the axis 410. The first rotor 412 defines a first aperture 414 extending along the axis 410, through which the shaft 404 extends along the axis 410, and the first rotor 412 is centered on the shaft 404 at the axis 410. The first rotor 412 is attached to the first (right) flange 420 of the spool 402 and can be accommodated in the recess 422 provided in the first flange 420.

[0054] The first rotor 412 includes a plurality of first magnets fixed to it. The first magnets are arranged in a circumferential direction perpendicular to axis 410 and extend in a radial direction (i.e., the radial direction of axis 404). Each of the plurality of first magnets 424 is a permanent magnet and extends in the radial direction of the first rotor 412 between an inner edge 430 defining a first aperture 414 and an outer edge 432 defining an outer periphery of the first rotor 412 in the radial direction. Each of the plurality of first magnets 424 is disposed on an outer surface 434 relative to a spool 402 of the first rotor 412. The inner surface (not visible) of the first rotor 412 abuts a first flange 420.

[0055] The motor brake 400 includes a second rotor 440 fixed to a shaft 404 for rotation about an axis 410 together with the spool 402, the shaft 404, and the first rotor 412. In the illustrated embodiment, the second rotor 440 is a left-handed rotor plate with opposing planar surfaces and is a circular plate with its radial direction perpendicular to the axis 410. The second rotor 440 defines a second aperture 442 extending along the axis 410, through which the shaft 404 extends along the axis 410, and the second rotor 440 is centered on the shaft 404 at the axis 410.

[0056] like Figure 10 As shown, the second rotor 440 includes a plurality of second magnets 444 fixed together with the second rotor 440, arranged in a circumferential direction perpendicular to the axis 410 of the second rotor 440, and extending in the radial direction of the second rotor 440 (i.e., the radial direction of the axis 404). Each of the plurality of second magnets 444 is a permanent magnet, extending in the radial direction of the second rotor 440 between an inner edge 450 defining a second aperture 442 and an outer edge 452 defining an outer periphery of the second rotor 440 in the radial direction. Each of the plurality of second magnets 444 is disposed on the inner surface 454 of the second rotor 440 relative to the spool 402.

[0057] The motor brake 400 includes a stator 460 configured to remain stationary relative to the spool 402, shaft 404, first rotor 412, and second rotor 440 as the spool 402, shaft 104, first rotor 412, and second rotor 440 rotate about axis 410. In an exemplary embodiment, the stator 460 is a substantially circular plate with its radial direction perpendicular to axis 410 and defines a third aperture 462 extending along axis 410, through which shaft 404 extends along axis 410 and through third aperture 462, with stator 460 centered on shaft 404.

[0058] The stator 460 includes a plurality of third magnets 464 fixed to the stator 460, arranged circumferentially to the stator 460 perpendicular to axis 410, and extending radially in the stator 460 (i.e., radially in the direction of axis 404). Each of the plurality of third magnets 464 is an electromagnet that extends radially in the stator 460 between an inner edge 470 defining a third aperture 462 and an outer edge 472 defining an outer periphery of the stator 460 in the radial direction. Each of the plurality of third magnets 464 is configured to selectively receive current supplied through conductor 474 and generate a magnetic field from the stator 460.

[0059] The second rotor 440 includes a key 480, and the key 480 is connected to... Figure 10 The keyway 482 shown is interlocked, and the keyway is formed by a notch defined on the spool 402. For example... Figure 9 and Figure 10 As shown, key 480 is configured to extend through third aperture 462 in the direction of axis 410, facing and entering keyway 482. As key 480 extends into keyway 482, key 480 and keyway 482 interlock the second rotor 440 and spool 402 relative to the rotational direction of spool 402 about axis 410. Although, as illustrated, spool 402 and second rotor 440 are interlocked by key 480 and keyway 482 in the rotational direction of spool 402 about axis 410, second rotor 440 and spool 402 may additionally or alternatively be secured together with additional complementary key and keyway pairs having a similar construction to key 480 and keyway 482, and other interlocking portions are joined by third aperture 462, adhesive, welding, or other means to secure spool 402 to second rotor 440 without departing from the scope of this disclosure.

[0060] like Figure 9As shown, shaft 404 includes a shoulder 484, which has a circular profile when viewed perpendicular to axis 410. The diameter of the outer surface 490 of shoulder 484 is complementary to the diameter of the inner edge 450 of second rotor 440, such that second rotor 440 is located on shaft 404 at shoulder 484, and shoulder 484 supports second rotor 440 on shaft 404 in a direction perpendicular to axis 410. The inner diameter of third aperture 462 defined by inner edge 470 of stator 460 at shoulder 484 is larger than the diameter of outer edge 472 of stator 460, such that stator 460 is spaced apart from shaft 404 and second rotor 440 including key 480. In this way, when the second rotor 440 and shaft 404 rotate about axis 410, stator 460 does not directly contact shaft 404 or second rotor 440, and is configured to remain stationary relative to second rotor 440 and shaft 404 when second rotor 440 and shaft 404 rotate about axis 410.

[0061] Figure 11 An axial view of a motor brake 400 is shown. The motor brake 400 includes a spool 402 assembled with a shaft 404, a stator 460, and a second rotor 440. Figure 12 A partially exploded side view of a motor brake 400 is shown, which includes a housing 492 and a battery 494, depicted schematically. Figure 12 As shown, housing 492 includes a first housing portion 500 and a second housing portion 502, which are configured to engage with each other about the motor brake 400 and the spool 402 in the radial direction of shaft 404. The first housing portion 500 includes a first bearing 504, shown in dashed lines, configured to receive the proximal end 510 of shaft 404, such that the proximal end 510 of shaft 404 is supported in the first housing portion 500 in a direction perpendicular to axis 410, and the proximal end 510 of shaft 404 is configured to rotate relative to the first housing portion 500 about axis 410. The second housing portion 502 includes a second bearing 512, shown in dashed lines, configured to receive the distal end 514 of shaft 404, such that the distal end 514 of shaft 404 is supported in the second housing portion 502 in a direction perpendicular to axis 410, and the distal end 514 of shaft 404 is configured to rotate relative to the second housing portion 502 about axis 410. In this manner, housing 492 supports shaft 404 in a direction perpendicular to axis 410, and shaft 404 is configured to rotate about axis 410 relative to housing 492. Distal end 514 can be engaged with a hand crank (not shown) via a clutch mechanism (not shown) to rotate spool 402 in a conventional manner.

[0062] The stator 460 is fixed to the housing 492, wherein the fastener 520 is inserted into the housing 492 through the opening 522 defined on the housing 492, and inserted into... Figure 9 In the hole 524 defined in the stator 460 shown. For example... Figure 9 As shown, the stator 460 includes a flange 530 defining a hole 524 in the stator 460, the hole 524 being configured to receive a fastener 520, wherein the flange 530 is positioned along the outer edge 472 of the stator 460 in the circumferential direction. Although the fastener 520 shown is a screw, the fastener 520 may alternatively include bolts, pins, or similar types of fasteners without departing from the scope of this disclosure. Although the depicted motor brake 400 includes fasteners 520 to secure the stator 460 to the housing 492, the motor brake 400 may additionally or alternatively feature adhesives, welding, or other joining methods to secure the stator 460 to the housing 492 without departing from the scope of this disclosure. With the stator 460 supported and secured in the housing 492, the spool 402, shaft 404, first rotor 412, and second rotor 440 are configured to rotate together with respect to the stator 460 and the housing 492.

[0063] like Figure 12 As shown, the stator 460 is positioned along the shaft 404 in the direction of the axis 410 between and separates the first rotor 412 and the second rotor 440, wherein the first rotor 412 and the second rotor 440 are positioned along the shaft 404 and spaced apart from the stator 460, such that the first rotor 412 and the second rotor 440 rotate together with the shaft 404 without directly contacting the stator 460, and when the first rotor 412 and the second rotor 440 rotate with the shaft 404 about the axis 410 relative to the housing 492, the stator 460 remains stationary relative to the first rotor 412 and the second rotor 440. The first rotor 412 and the second rotor 440 are positioned together with the stator 460 along the shaft 104 such that when the plurality of third magnets 464 receive current and generate a magnetic field, the magnetic field extends through the plurality of first magnets 424 in the first rotor 412 and the plurality of second magnets 444 in the second rotor 440, and the shaft 104 is subjected to a braking force from the stator 460 through the first rotors 412 and the second rotor 440 to slow down and stop the rotation of the spool 402 and the shaft 404 relative to the stator 460 and the housing 492 about the axis 410 as the first rotors 412 and the second rotor 440 rotate relative to the stator 460. When the plurality of third magnets 464 do not receive current, the plurality of third magnets do not generate a magnetic field or apply a braking force to the first rotors 412 and the second rotor 440.

[0064] The battery 494 is disposed inside the housing 492 together with the first rotor 412, the second rotor 440, and the stator 460. The battery 494 is mounted to the inner surface 532 of the housing 492, which defines the interior of the housing 492. With the battery 494 mounted to the inner surface 532 of the housing 492, the battery 494 remains stationary relative to the housing 492 and the stator 460 when the spool 402, shaft 404, first rotor 412, and second rotor 440 rotate relative to the housing 492 about axis 410. Battery 494 is configured to supply current to a plurality of third magnets 464 via wires 474, such that the plurality of third magnets 464 generate a magnetic field extending through a plurality of first magnets 424 in first rotor 412 and a plurality of second magnets 444 in second rotor 440, the magnetic field being strong enough to subject the first rotor 412 and second rotor 440 to braking forces relative to stator 460, wherein the braking forces are sufficient to slow and / or stop spool 402 from rotating about axis 410 relative to stator 460 and housing 492. In this way, when spool 402 is used to cast fishing line (not shown) causing shaft 404, first rotor 412 and second rotor 440 to rotate about axis 410 relative to housing 492, motor brake 400 is configured to apply braking force on shaft 404 at the end of casting via first rotor 412, second rotor 440 and stator 460 to slow and stop spool 402 relative to housing 492 and prevent backlash. In embodiments where the motor brake 400 is configured to drive the spool 402 to wind fishing line onto the spool 402, or to assist in unwinding the fishing line to increase casting distance, the battery 494 supplies current to a plurality of third magnets 464 to generate a magnetic field configured to drive a first rotor 412 via a plurality of first magnets 424 and a second rotor 440 around an axis 410 via a plurality of second magnets 444, which in turn drive a shaft 404 around the axis 410 and thus drive the spool 402.

[0065] Battery 494 is rechargeable, and housing 492 may include a power inlet (not shown) configured to receive electrical energy from an external power source to recharge battery 494. In an alternative embodiment, motor brake 400 does not include a battery and is configured to supply current directly from an external power source to a plurality of third magnets 464.

[0066] In an embodiment, when the first rotor 412 and the second rotor 440 rotate relative to the stator 460 about the axis 410, for example during throwing, the motor brake 400 is configured to generate current and recharge the battery 494. For this purpose, when the first rotor 412 and the second rotor 440 rotate relative to the stator 460 about the axis 410, a plurality of first magnets 424 and a plurality of second magnets 444 rotate relative to a plurality of third magnets 464 and wires 474 about the axis 410, wherein the magnetic flux experienced by the plurality of third magnets 464 and wires 474 induces current in the plurality of third magnets 464 and wires 474 to recharge the battery 494.

[0067] Continue to refer to Figure 12 The motor brake 400 includes a controller 534 configured to actuate a battery 494 to supply current to a third set of magnets 464. The controller 534 is housed within a housing 492 and mounted to the inner surface 532 of the housing 492 along with the battery 494. When the spool 402 is used to cast fishing line, the controller 534 is configured to determine or predict the occurrence of a "backlash" event in response to a signal received from a sensor 540 supported on the housing 492, and is configured to actuate the battery 494 such that the motor brake 400 applies a braking force to the spool 404, thereby slowing and stopping the spool 402 in a manner similar to that described in U.S. Provisional Patent Application No. 63 / 128895 regarding the controller 24, sensor 20, and braking mechanism 26. In an alternative embodiment, the motor brake 400 includes a controller configured to actuate the battery 494 to supply current to a plurality of third magnets 464, wherein the controller is located externally to the housing 492. The motor brake 400 is also configured to receive input from the user to the controller 534 via a user interface 542 to actuate the battery 494. The controller 534 can control the charging of the battery 494, for example by controlling the circuit connection between the battery 494 and a power source (not shown), to selectively prevent and allow current to flow from the power source to the battery 494.

[0068] Although the illustrated motor brake 400 includes a stator 460 located between a first rotor 412 and a second rotor 440 along a shaft 404, the motor brake 400 may include more than one stator with a similar structure to the stator 460, wherein each stator is located between a pair of rotors along a shaft 404, and each rotor is constructed similarly to the first rotor 412 and the second rotor 440.

[0069] While the motor brake 400 is configured to control the rotation of fishing reel portions (such as spool 402 and shaft 404) relative to housing 492, the motor brake 400 may be configured to otherwise control the rotation of portions of the device (including shafts and elements fixed to the shafts) relative to housing or other fixed structures without departing from the scope of this disclosure.

[0070] Continue to refer to Figure 12 The first rotor 412 and the second rotor 440 are positioned along the shaft 404 and spaced apart from the stator 460, such that the first rotor 412 and the second rotor 440 rotate together with the shaft 404 about the axis 410 without directly contacting the stator 460, and the stator 460 applies braking and / or driving forces on the shaft 404 through the first rotor 412 and the second rotor 440. In this way, the motor brake 400 forms a brushless motor configured to brake and / or drive the spool 402, and the motor brake 400 does not undergo excessive wear when braking and / or driving the spool 402.

[0071] The stator 460 is positioned between the first rotor 412 and the second rotor 440 along axis 404 in the direction of axis 410, separating them such that the first rotor 412 and the second rotor 440 sandwich the stator 460 in the middle and are positioned close to the stator 460 to minimize the distance between the inner surface of the first rotor 412 and the outer surface 544 of the second rotor 440 along axis 404 in the direction of axis 410. A plurality of third magnets 464 are sufficiently close to the stator 460 to generate a magnetic field passing through the plurality of first magnets 424 and the plurality of second magnets 444, which effectively applies braking and / or driving forces from the stator 460 to the first rotor 412 and the second rotor 440. With this configuration, the motor brake 400 has a relatively compact construction, wherein the size of the housing 492 required to assemble the first rotor 412, the second rotor 440, and the stator 460 in the direction of axis 410 is reduced.

[0072] The spool 402 includes a second flange 550 located on the side of the spool 402 opposite to the first flange 420 relative to the axis 410. The first rotor 412 is received within a recess 422 provided in the first flange 420. Compared to a configuration where the first rotor 412 is not received in the first flange 420, the recess 422, the first rotor 412, the second rotor 440, and the stator 460, which are part of the motor brake 400, are retracted into the first flange 420 and positioned closer to the second flange 550 relative to the axis 410, thereby reducing the distance between the outer surface 544 of the second rotor 440 and the second flange 550 in the direction of the axis 410. With this configuration, the motor brake 400 has a relatively compact construction, wherein the size of the housing 492 required to assemble the spool 402, the first rotor 412, the second rotor 440, and the stator 460 inside the housing 492 in the direction of the axis 410 is reduced.

[0073] The first rotor 412, the second rotor 440, and the stator 460 are each formed of a plate having a thickness extending in the direction of axis 410, and the respective thicknesses of the first rotor 412, the second rotor 440, and the stator 460 are minimized to further reduce the distance between the inner surface of the first rotor 412 and the outer surface 544 of the second rotor 440. With this configuration, the motor brake 400 has a relatively compact construction, wherein the size of the housing 492 required to assemble the first rotor 412, the second rotor 440, and the stator 460 inside the housing 492 in the direction of axis 410 is reduced.

[0074] It should be understood that the various features and functions of the disclosed embodiments above, as well as other features and functions, or their alternatives or variations, can be suitably incorporated into many other different systems or applications. Various substitutions, modifications, variations, or improvements that are not currently foreseen or anticipated can then be made thereto by those skilled in the art, which are also intended to be included in the following claims.

Claims

1. A fishing reel, comprising: case; A shaft, which is supported in the housing and configured to rotate relative to the housing about an axis extending in the longitudinal direction of the shaft; A spool, which is fixed to the shaft to rotate together with the shaft about the axis, for winding and unwinding fishing line; A stator, the stator being fixed to the housing, wherein the spool is configured to rotate relative to the stator and the housing together with the shaft; A stator magnet, wherein the stator magnet is an electromagnet fixed to the stator; and The rotor includes a first rotor plate fixed to the shaft for rotating together with the shaft about the axis, and a first rotor magnet fixed to the first rotor plate. The stator magnet is configured to receive current and generate a magnetic field from the stator to the first rotor magnet. The rotor further includes: A second rotor plate, fixed to the shaft to rotate together with the shaft about the axis, and positioned on the shaft on the side of the stator opposite to the first rotor plate, such that the stator is positioned between the first rotor plate and the second rotor plate in the longitudinal direction of the shaft and separates the first rotor plate and the second rotor plate; and The second rotor magnet is fixed together with the second rotor plate. The stator magnet is configured to receive current and generate a magnetic field from the stator to the second rotor magnet.

2. The fishing reel as described in claim 1, wherein, The first rotor magnet is included in a plurality of first rotor magnets, which are permanent magnets fixed to the first rotor plate and arranged in a circumferential direction perpendicular to the axis of the first rotor plate. The second rotor magnet is included in a plurality of second rotor magnets, which are permanent magnets fixed together with the second rotor plate and arranged in a circumferential direction perpendicular to the axis of the second rotor plate.

3. The fishing reel as described in claim 2, wherein, The stator defines a flat first stator surface and a flat second stator surface on the side of the stator opposite to the first stator surface in the longitudinal direction of the shaft, wherein the first stator surface and the second stator surface extend along the first rotor plate and the second rotor plate, perpendicular to the longitudinal direction of the shaft, and The stator magnet is a coil winding disposed on at least one of the first stator surface and the second stator surface, and is configured to receive current and generate a magnetic field.

4. The fishing reel as described in claim 3, wherein, The first rotor plate defines a flat first rotor surface, and the first rotor magnet is disposed on the first rotor surface to define a space between the first rotor magnet and the stator in the longitudinal direction of the shaft. The second rotor plate defines a flat second rotor surface, and the second rotor magnet is disposed on the second rotor surface to define a space between the second rotor magnet and the stator in the longitudinal direction of the shaft.

5. The fishing reel as described in claim 1, wherein, The stator defines a flat first stator surface that extends along the first rotor plate in a radial direction of the axis, perpendicular to the longitudinal direction of the axis. The stator magnet is a coil winding disposed along the first rotor plate on the surface of the first stator to define a space between the stator magnet and the first rotor plate in the longitudinal direction of the shaft. The coil winding is configured to receive current and generate a magnetic field.

6. The fishing reel as described in claim 1, wherein, The stator is a printed circuit board, and the stator magnet is disposed on a flat first stator surface defined by the printed circuit board.

7. The fishing reel as described in claim 6, wherein, The first rotor plate defines a flat first rotor surface, and the first rotor magnet is disposed on the first rotor surface to define a space between the first rotor magnet and the stator in the longitudinal direction of the shaft.

8. The fishing reel as claimed in claim 1, further comprising: A battery is disposed in the housing and connected to the stator via a circuit, wherein the rotor, which rotates relative to the stator, induces a current in the stator magnet, causing the stator to generate a current in the circuit and charge the battery.

9. The fishing reel as described in claim 1, wherein, Further includes: A controller configured to control the current flowing to the stator; and A rotation sensor, fixed to the housing, is configured to generate rotational position information of at least one of the shaft, the spool, and the rotor relative to the housing during a throwing operation, and is configured to transmit the rotational position information to the controller. The controller is configured as follows: Based on the rotational position information received from the rotation sensor, the rotational speed of at least one of the shaft, the rotor, and the spool is determined during the throwing operation. The determined rotational speed is compared with a predetermined threshold. When the determined rotational speed is lower than the predetermined threshold, a guiding current flows through the stator winding, causing the stator magnet to generate an active braking magnetic field on the rotor via the first rotor magnet. This active braking magnetic field is opposite to the direction of rotation of the spool when the fishing line is unwound. When the determined rotational speed exceeds the predetermined threshold, the guiding current passes through the stator winding, causing the stator magnet to generate a passive braking magnetic field on the rotor through the first rotor magnet. The passive braking magnetic field is in the same direction as the active braking magnetic field, but its amplitude or duration is relatively small.

10. The fishing reel as described in claim 9, wherein, The rotation sensor is mounted on the stator, so that the rotation sensor is fixed to the housing through the stator.

11. The fishing reel as described in claim 9, wherein, The rotation sensor includes a Hall effect sensor, which is fixed relative to the housing and configured to detect the amplitude of the magnetic field to generate rotational position information of the rotor, wherein the controller receives the rotational position information of the rotor to determine the rotational speed of the rotor.

12. The fishing reel as described in claim 11, wherein, The rotation sensor includes multiple Hall effect sensors configured to detect the magnetic field of the first rotor plate and cooperate with each other to generate the rotational position information.

13. The fishing reel as claimed in claim 1, further comprising: A controller, fixed to the housing and configured to actuate the stator such that the shaft is subjected to braking force from the stator via the rotor; as well as A fishing line status sensor, fixed to the housing, is configured to detect a section of fishing line unwound from the spool to generate fishing line status information, and to transmit the fishing line status information to the controller. Wherein, the controller: Determine whether the fishing line status information indicates that a loop is forming in the fishing line being unwound from the spool during casting, and The stator is actuated by a current guided through the stator magnet, causing the stator magnet to generate a magnetic field from the stator to the first rotor magnet, and the shaft is subjected to braking force from the stator through the rotor when the controller determines that a loop is forming in the fishing line unwound from the spool during the casting operation.

14. The fishing reel as claimed in claim 13, further comprising: A rotation sensor, fixed to the housing, is configured to generate rotational position information of at least one of the shaft, the spool, and the rotor relative to the housing during a throwing operation, and is configured to transmit the rotational position information to the controller. The controller is configured as follows: Based on the rotational position information received from the rotation sensor, the rotational speed of at least one of the shaft, the rotor, and the spool is determined during the throwing operation. When the controller determines that a loop is forming in the fishing line being unwound from the spool, it compares the determined rotational speed with a predetermined threshold. When the determined rotational speed is lower than the predetermined threshold, a guiding current flows through the stator winding, causing the stator magnet to generate an active braking magnetic field on the rotor via the first rotor magnet. This active braking magnetic field is opposite to the direction of rotation of the spool when the fishing line is unwound. When the determined rotational speed exceeds the predetermined threshold, the guiding current passes through the stator winding, causing the stator magnet to generate a passive braking magnetic field on the rotor through the first rotor magnet. The passive braking magnetic field is in the same direction as the active braking magnetic field, but its amplitude or duration is relatively small.

15. The fishing reel as described in claim 13, wherein, The fishing line status sensor includes a light source and an optical sensor fixed to the housing. The optical sensor is configured to detect light emitted from the light source that passes through the section of fishing line unwound from the spool to generate fishing line status information and is configured to transmit the fishing line status information to the controller.

16. The fishing reel as claimed in claim 1, further comprising: A controller configured to actuate the stator such that the shaft experiences a braking force from the stator through the rotor. During a throwing operation in which the shaft rotates relative to the housing in a first rotational direction about the axis, the controller is configured to direct current through the stator magnet to perform reverse current braking using the rotor, such that the shaft is subjected to braking force from the stator by the rotor in a second rotational direction opposite to the first rotational direction.

17. The fishing reel as described in claim 16, wherein, When the rotational speed of the shaft is lower than a predetermined threshold, the controller is configured to perform the reverse current braking by guiding current through the stator winding, so that the stator magnet generates an active braking magnetic field on the rotor through the first rotor magnet, the active braking magnetic field being opposite to the first rotation direction.

18. The fishing reel as described in claim 17, wherein, When the rotational speed of the shaft exceeds the predetermined threshold, the controller is configured to perform the reverse current braking by guiding current through the stator winding, so that the stator magnet generates a passive braking magnetic field on the rotor through the first rotor magnet. The passive braking magnetic field is in the same direction as the active braking magnetic field, but its amplitude or duration is relatively small.

19. The fishing reel as claimed in claim 1, further comprising: A controller, fixed to the housing and configured to actuate the stator, such that the shaft experiences a braking force from the stator via the rotor. The controller is configured to guide current through the stator magnet, such that the stator and the rotor form a three-phase motor, the three-phase motor is configured to apply braking force from the stator to the shaft, and the controller is further configured to control the duration of the braking force based on the sensed rotational speed of the shaft via pulse width modulation or signal control.

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