Modular Reel Material Tracking System
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Solution Overview
Problem
Existing material tracking systems for materials stored on reels are prone to inaccuracies due to manual tracking methods, are costly, and lack efficient monitoring and inventory management capabilities, especially when dealing with multiple reels.
Innovation Solution
A modular material tracking system that includes a sensor module and plate module with a detection component to accurately track the length of material on a reel, using a sensor to count rotations and communicate data via radio frequency, enabling efficient monitoring and centralized information management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tracking methods are used to monitor material usage from reels, then the system is simple and low-cost, but accuracy is poor and time-consuming
Solution Approach 1:
The patent replaces manual mechanical tracking with an automated sensor-based system. A detection component (optical or magnetic sensor) mounted on the reel hub automatically detects material passage and generates signals processed by a controller to calculate and display remaining material length, eliminating manual measurement errors and time-consuming tracking.
Solution Approach 2:
The system enables the reel to self-monitor its own material inventory. The detection component mounted on the reel hub detects material characteristics directly as it passes, and the integrated controller automatically calculates and displays remaining length without external intervention, making the tracking self-sufficient.
2Measurement precision
If automated sensor systems are implemented to track material on reels, then tracking accuracy improves, but system cost and complexity increase
Solution Approach 1:
The patent designs a universal tracking system where the controller and detection component can monitor multiple reels simultaneously. The system can track different material types (wire, cable, tubing, yarn, rope) using the same basic architecture, reducing per-unit cost and simplifying manufacturing through standardized components.
Solution Approach 2:
The system uses optical or magnetic sensors that detect material characteristics by reading signals from the material itself or its container. This non-contact detection method avoids complex mechanical measurement devices and reduces calibration requirements, lowering manufacturing costs while maintaining accuracy.
3Measurement precision
If complex roller-based measurement systems are used to track material, then measurement capability is provided, but the system becomes expensive and error-prone
Solution Approach 1:
The patent eliminates complex mechanical roller systems by using non-contact optical or magnetic sensors. The detection component reads material characteristics directly without physical contact, removing mechanical wear, misalignment, and calibration issues that cause errors in roller-based systems.
Solution Approach 2:
The patent uses an intermediary detection component (optical or magnetic sensor) that indirectly measures material passage by detecting characteristics of the material or its container. This intermediary approach provides accurate measurement without the direct mechanical contact and complexity of roller-based systems.
4Productivity
If manual tracking is used for inventory management, then the system is simple to implement, but significant time and expense are required
Solution Approach 1:
The patent implements continuous automated monitoring where the detection component constantly tracks material passage and the controller continuously calculates remaining length. This continuous automatic tracking eliminates periodic manual checks, significantly improving inventory management efficiency and eliminating time loss associated with manual tracking.
Solution Approach 2:
The system automatically monitors and reports material inventory levels without human intervention. The controller displays remaining length in real-time and can trigger alerts when material is low, enabling inventory management to serve itself and eliminating the time employees would spend on manual tracking.
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 system provides accurate and efficient tracking of material usage, reducing waste and project costs by automating the monitoring process and allowing for centralized management of multiple reels.
Implementation Method 1
The sensor may include an accelerometer. The rotations of the reel may be determined using a change in the angular orientation sensed by the sensor.
Data Source
AI summary
A modular material tracking system is provided for tracking material stored on and drawn from a reel using a modular system. The modular material tracking system may include a detection element, digital logic components, location receiver, enclosure, analytic components, interface component, sensor module, and plate module. One or more sensors relative to the reel may detect a position indicative of forward or reverse reel rotation. A processor may analyze signals to count rotations of the reel, which is savable in memory. A battery may provide power. The system may also record the time and location associated with rotations. A method for tracking material stored on and drawn from a reel using a modular material tracking system is also provided.