Motorized Cord Reel Control for Safe Unwinding and Thermal Limits
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Solution Overview
Problem
Conventional reel assemblies face challenges in efficiently managing the unwinding and winding of linear elements like electrical cords, leading to excessive heat generation and potential safety issues due to inadequate thermal management and manual operation, which can result in non-compliance with standards and increased maintenance costs.
Innovation Solution
The introduction of a motorized reel assembly with a controller that monitors the rotation of the spool and automatically adjusts the power state of the electrical cord to maintain optimal temperature, utilizing wireless communication and remote control functionality for efficient unwinding and winding, along with redundant thermal monitoring for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation is used to rotate the reel, then device complexity is reduced, but productivity decreases and user fatigue increases
Solution Approach 1:
The patent replaces manual mechanical operation with an automated motorized system. A motor is integrated into the reel assembly to automatically rotate the spool, winding the hose without user intervention. This substitution of mechanical manual effort with an electromechanical system resolves the contradiction by significantly improving productivity while accepting increased device complexity through the addition of the motor and control electronics.
2Volume of moving object
If electrical cord is wound tightly around the spool, then space utilization improves, but heat generation increases due to inadequate thermal management
Solution Approach 1:
The patent implements a feedback control system using temperature sensors to monitor the electrical cord temperature during winding. When the temperature exceeds a predetermined threshold, the controller automatically adjusts the winding process or activates cooling mechanisms. This feedback loop enables the system to maintain optimal spool capacity while preventing excessive heat generation, resolving the contradiction between space utilization and thermal management.
3Ease of operation
If automated motor control is implemented, then ease of operation improves, but device complexity increases due to additional control systems
Solution Approach 1:
The patent implements a self-service control system where the reel assembly automatically monitors its own operational parameters through integrated sensors and adjusts its behavior accordingly. The controller receives input from temperature, rotation, and position sensors, and autonomously makes decisions about motor operation without requiring complex external control systems or user intervention. This self-monitoring and self-adjusting capability improves ease of operation while managing device complexity through intelligent automation rather than mechanical complexity.
4Productivity
If rapid unwinding is performed, then productivity increases, but heat generation increases exceeding safe temperature limits
Solution Approach 1:
The patent implements periodic monitoring and control during the unwinding process. The temperature sensors continuously monitor the electrical cord temperature at regular intervals, and the controller adjusts the unwinding speed dynamically. When safe temperature limits are approached, the system automatically reduces unwinding speed or pauses operation to allow cooling. This periodic monitoring and adaptive speed control enables rapid unwinding when safe while preventing thermal hazards, resolving the contradiction between productivity and safety.
Data Source
AI summary
An electrical cord reel assembly can include a spool configured to wind and unwind an electrical cord therefrom. The electrical cord reel assembly can include a motor configured to rotate the spool to wind and unwind the electrical cord about the spool. The electrical cord reel assembly can include a controller in electrical communication with the motor and the electrical cord. The controller can be configured to, in response to an unwind command, place or maintain the electrical cord in a power off state. The controller can be configured to in response to the unwind command, transmit an unwind signal to the motor to cause the motor to unwind the electrical cord from the spool. The controller can be configured to automatically place the electrical cord in a power on state based at least in part on an amount of rotation of the spool during the unwinding.