Reel Material Tracking System Using Sensor Rotation Detection
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Solution Overview
Problem
Manual tracking of material usage from reels is time-consuming, expensive, and prone to inaccuracies, leading to waste and increased project costs, while existing tracking systems are either too complex, expensive, or lack inventory management capabilities.
Innovation Solution
A system comprising sensors and a processor that track the rotation of a reel's flanges to calculate the remaining length of material, with a transceiver for wireless data transmission and a memory for inventory management, allowing for accurate tracking and minimization of waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tracking of material usage is used, then no additional system cost is incurred, but tracking accuracy deteriorates and time consumption increases
Solution Approach 1:
The patent replaces manual mechanical tracking methods with an automated electronic sensing system. Sensors detect the position of material on the reel and convert it to electrical signals, which are processed to automatically calculate and display material usage, eliminating manual measurement and recording operations.
Solution Approach 2:
The tracking system is designed to automatically monitor and record material usage without requiring human intervention. The system self-calibrates using the known relationship between reel rotation and material length, and continuously updates usage data without manual input or calibration adjustments.
2Measurement precision
If complex roller-based measuring devices are used, then measurement capability is achieved, but system cost increases and reliability deteriorates
Solution Approach 1:
The patent extracts the essential measurement function from complex mechanical roller systems and implements it through simpler electronic sensors. Instead of using physical rollers to measure material passage, the system uses sensors to detect reel rotation position and calculates material usage mathematically, removing unnecessary mechanical complexity that reduces reliability.
Solution Approach 2:
The patent employs inexpensive electronic sensors and a simple processor instead of expensive, complex mechanical measuring devices. The system uses affordable components that can be easily replaced if needed, providing a cost-effective alternative to high-end industrial measurement equipment while maintaining adequate measurement capability.
3Measurement precision
If recalibration for different material diameters is performed, then measurement accuracy is maintained, but operational complexity increases
Solution Approach 1:
The patent performs preliminary calibration by establishing the relationship between reel rotation and material length during system setup or manufacturing. This pre-calibration data is stored in memory, allowing the system to automatically compensate for different material diameters without requiring on-site recalibration, thus simplifying operation while maintaining accuracy.
Solution Approach 2:
The patent uses parameter changes in the calculation algorithm to adapt to different material diameters. Instead of physically recalibrating the system, the processor adjusts calculation parameters based on stored calibration data or user-input material specifications, maintaining measurement accuracy across different material types without complex adjustment procedures.
4Adaptability or versatility
If inventory management capabilities are added, then material control improves, but system complexity increases
Solution Approach 1:
The patent implements multiple functions within a single integrated system. The same sensors and processor used for basic material usage tracking also perform inventory management, billing calculations, and project planning data collection. This multi-functionality is achieved through software programming rather than additional hardware, avoiding increased physical complexity while expanding capabilities.
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 enabling real-time inventory management and minimizing human error, while being cost-effective and adaptable for multiple reels.
Implementation Method 1
two or more sensors physically deployed relative to the reel flange and each other such that each sensor independently produces a detection element present signal when the detection element is near the respective sensor
Data Source
AI summary
A system and method for tracking the remaining length of a material wound on a reel is disclosed. In the system, two sensors deployed relative to the reel (and each other) produce a detection signals when a detection element mounted on the reel is near the respective sensor in an order indicative of forward or reverse reel rotation. The system further includes a processor operably receiving the detection signals to count a total number of forward rotations of the reel, which count is saved in memory. A battery powers the processor, memory, and sensors. The system further includes a transceiver that removably and operably couples between the memory and a calculator that calculates the remaining length of the material wound on the reel based on the total number of forward rotations of the reel. The system may also record the time and location associated with the rotations.