Coiled Material Length Measurement Device
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Solution Overview
Problem
Construction and manufacturing professionals lack an accurate method to calculate the remaining length of coiled products like rope, steel, or carpet on a spool, leading to inaccurate inventory management, affecting productivity and cost control.
Innovation Solution
A device comprising a housing with a measure wheel, tensioner assembly, and a computing system connected to a printer, which calculates and displays the remaining length of coiled material, generating labels with barcodes or text that include material properties, ensuring accurate tracking and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If no measurement device is used, then the device complexity is low, but the measurement precision of remaining material length is zero
Solution Approach 1:
The patent replaces manual estimation and simple mechanical counters with an integrated system combining electronic sensors, microprocessors, and digital displays. The measurement system uses electronic components to detect and calculate remaining material length, providing precise digital readings instead of rough mechanical estimates.
Solution Approach 2:
The measurement device is designed to handle multiple types of coiled materials (rope, steel, wire, chain, carpet) with a single universal system. The device incorporates multiple functional components including sensors, computing assemblies, displays, and optional printing capabilities within one integrated unit, making it versatile for different material types and measurement needs.
2Loss of information
If manual inventory tracking is used, then the ease of operation is high, but the loss of information regarding material quantity is significant
Solution Approach 1:
The system continuously monitors material consumption and provides real-time feedback through digital displays showing remaining length. The computing assembly processes sensor data and updates the display dynamically, allowing operators to see current inventory status without manual intervention. This closed-loop feedback system eliminates information loss by automatically tracking and displaying material quantity.
Solution Approach 2:
The measurement device automatically performs inventory tracking without requiring manual data entry or calculation. The system self-monitors material usage through sensors, computes remaining length using integrated algorithms, and maintains digital records autonomously, freeing operators from manual tracking tasks while preserving accurate information.
3Reliability
If a simple counter is used, then the device complexity is low, but the reliability of inventory data is insufficient
Solution Approach 1:
The patent replaces unreliable simple mechanical counters with an electronic computing system that uses sensors, microprocessors, and digital algorithms to calculate remaining material length. This electronic system provides more reliable and accurate measurements by using precise sensor data and computational methods rather than simple mechanical counting.
Solution Approach 2:
The system performs preliminary calculations and data processing using the computing assembly to determine remaining length before display or printing. The microprocessor pre-computes measurements based on sensor inputs and material characteristics, ensuring accurate and reliable inventory data is prepared in advance for output, rather than relying on simple real-time counting.
4Productivity
If real-time measurement is implemented, then the productivity is improved, but the use of energy by the device increases
Solution Approach 1:
The system uses periodic measurement and update cycles rather than continuous operation. The sensors and computing assembly periodically sample material consumption and update the display at appropriate intervals, providing real-time measurement capability while allowing the system to enter low-power states between measurement cycles, thus reducing overall energy consumption.
Solution Approach 2:
The measurement system automatically operates without requiring continuous human intervention or power-intensive manual processes. The integrated sensors and computing assembly autonomously perform measurements, calculations, and display updates, optimizing energy usage by only activating components when needed for measurement cycles rather than running continuously at full power.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides real-time measurement and labeling of coiled material, enhancing inventory accuracy, productivity, and material management by enabling precise tracking and recording of material characteristics.
Implementation Method 1
a mechanical to digital sensor
Implementation Method 2
a tensioner assembly which includes a pulley wheel rotatably secured to the housing and operatively connected to the measure wheel and a tensioning arm rotatably secured to the housing
Data Source
AI summary
An inventory management device wherein the user inputs a material of known characteristics such as weight, thickness, and width, or length into a computer via user interface. The device calculates the length of the material and displays the remaining coiled length on a display screen. When the user is ready to feed the material, the material is rolled over a feed wheel, which turns a measure wheel. The measure wheel communicates with a computer control chip to deduct the quantity fed off the coil. The actual remaining length is shown on the display screen in real time or near real time. When the user is finished working with the material, the user can select to print a label with a barcode to affix to the material. The barcode contains characteristics of the material so the material can be inventoried and/or reused on the feeder.