Reel-Mounted Sensor System for Accurate Material Length Tracking
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Solution Overview
Problem
Current material tracking systems for materials wound on reels are either expensive, prone to errors, or lack advanced features such as inventory management and accurate length tracking, making them inefficient for construction and manufacturing processes.
Innovation Solution
A system comprising a sensor, processor, memory, and transceiver attached to the reel to track rotations and calculate the remaining length of material, with optional features like radio frequency transmission, location tracking, and angular orientation sensing, allowing for centralized management and accurate inventory control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tracking of material usage is used, then no additional equipment is needed, but tracking accuracy deteriorates due to human error and time consumption increases
Solution Approach 1:
The patent replaces manual mechanical tracking with an automated sensor-based system. A detection component (magnetic sensor) mounted on the reel detects rotational position, and a processor automatically calculates material usage based on rotation data, eliminating human error and time consumption associated with manual tracking.
Solution Approach 2:
The system enables self-service tracking where the reel itself, equipped with the detection component, automatically monitors and reports its own material usage. The processor continuously calculates remaining material based on rotational data without requiring external manual intervention.
2Measurement precision
If complex roller-based measuring devices are used, then measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential measurement function from complex roller-based systems. Instead of using entire roller assemblies, it isolates the core capability by mounting a simple magnetic detection component directly on the reel, which detects rotational position without requiring complex external measuring machinery.
Solution Approach 2:
The system replaces expensive, complex roller-based measuring devices with inexpensive magnetic sensors and processing units. The simplified detection component is cost-effective and can be easily replaced or reconfigured for different applications without the burden of complex machinery.
3Measurement precision
If recalibration for different material diameters is implemented, then measurement accuracy is maintained, but ease of operation deteriorates
Solution Approach 1:
The system dynamically adapts to different material diameters through software-based calculations. The processor automatically adjusts measurements based on the specific reel and material configuration, eliminating the need for manual recalibration while maintaining accuracy across varying conditions.
Solution Approach 2:
The system changes operational parameters through software rather than physical recalibration. The processor modifies calculation parameters based on detected rotational data and known material properties, allowing accurate measurement across different material diameters without manual intervention.
4Adaptability or versatility
If inventory management and tracking features are added, then material control capability is improved, but device complexity increases
Solution Approach 1:
The system provides multiple functions including real-time tracking, inventory management, usage analysis, and integration with enterprise systems through a single integrated platform. The processor and detection component serve multiple purposes: measuring rotation, calculating usage, monitoring inventory levels, and providing data for business decisions.
Solution Approach 2:
The system implements continuous feedback loops where the detection component monitors reel rotation, the processor calculates usage in real-time, and the results are fed back to users through various interfaces. This feedback mechanism enables proactive inventory management and automated reordering decisions without adding significant complexity.
Data Source
AI summary
A material tracking system is provided for tracking material stored on and drawn from a reel. The material tracking system may include a reel, detection element, digital logic components, battery and power components, transceiver and communication components, location receiver, enclosure, analytic component and interface component. 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 to operate a tracking material stored on and drawn from a reel using the material tracking system is also provided.