Wireless Encoder for Cable Length Measurement and Data Storage
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Solution Overview
Problem
Current methods for measuring wire and cable length are inadequate as they fail to store data for business analysis, require labor-intensive visual tracking, and are prone to human error, lacking wireless communication and automated inventory updates.
Innovation Solution
A wireless encoder system comprising an encoder disc, shaft, encoder module, microprocessor, and communication component that converts physical wire payout into digital data, transmitting it wirelessly for real-time display and cloud database updates, eliminating the need for physical markings and reducing human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If incremental encoder with display screen is used to measure wire length, then measurement accuracy is improved, but data storage for business analysis is lost
Solution Approach 1:
The patent introduces a microprocessor and communication component as intermediaries between the encoder and the external environment. The microprocessor collects measurement data from the encoder and transmits it via RF communication to a remote database or cloud system, enabling both accurate local measurement and centralized data storage for business analysis without requiring physical markings on the wire.
2Ease of operation
If visual tracking with markings on wire is used, then wire length tracking is achieved, but labor intensity increases
Solution Approach 1:
The patent replaces the mechanical/visual tracking system (markings on wire and manual visual inspection) with an electronic sensing system. The incremental encoder electronically detects wire payout through shaft rotation, and the microprocessor automatically processes and transmits this data, eliminating the need for physical markings and manual visual tracking while significantly reducing labor requirements.
3Reliability
If manual inventory recording is used, then inventory tracking is achieved, but human error increases
Solution Approach 1:
The system enables self-service inventory tracking where the encoder-microprocessor-communication component assembly automatically performs data collection, processing, and transmission to the database. The system serves itself by eliminating the need for manual reading and writing of inventory data, thereby removing human error sources while maintaining ease of operation through automated processes.
4Extent of automation
If RF communication component is added to encoder, then wireless data transmission is achieved, but device complexity increases
Solution Approach 1:
The patent merges the RF communication component with the existing encoder assembly, integrating multiple functions (encoding, processing, and wireless transmission) into a single unified device. The microprocessor serves as a common platform that handles both encoder signal processing and RF data transmission, reducing overall system complexity compared to separate standalone components.
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, real-time measurement and tracking of wire and cable length, enhancing productivity and inventory management by automating data collection and analysis, and reducing manual errors.
Implementation Method 1
The encoder module may include an emitting portion to emit light, and a sensing portion to sense the light
Data Source
AI summary
An apparatus for measuring wire and cable length is provided for using a wireless encoder for wire and cable processing. The apparatus for measuring wire and cable length may include a housing, battery, communication component, microcontroller, printed circuit board, encoder module, encoder disc, shaft, wire counter and spool.