US20260167453A1
2026-06-18
19/417,084
2025-12-11
Smart Summary: A cable spool measurement system helps keep track of how much cable is left on a spool. It has a base with a spool arm and a spindle that holds the spool in place. An optical sensor watches the cable as it is taken off the spool. A processor connected to the sensor calculates how much cable has been used. By subtracting the used amount from the total, it figures out how much cable is still on the spool. 🚀 TL;DR
A cable spool measurement system can include a cable feed device having a base, a spool arm extending from the base, and a spindle extending perpendicularly away from the spool arm to receive and rotatably support a cable spool. The measurement system can further include an optical sensor arranged to view cable dispensed from the cable spool and a processor in communication with the optical sensor. The processor can calculate an amount of cable removed from the cable spool and subtract the amount of cable removed from the cable spool from an original amount of cable on the cable spool to determine an amount of cable remaining on the cable spool.
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B65H75/182 » CPC main
Storing webs, tapes, or filamentary material, e.g. on reels; Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks; Constructional details Identification means
B65H49/32 » CPC further
Unwinding or paying-out filamentary material; Supporting, storing or transporting packages from which filamentary material is to be withdrawn or paid-out; Methods or apparatus in which packages rotate; Package-supporting devices Stands or frameworks
B65H75/18 IPC
Storing webs, tapes, or filamentary material, e.g. on reels; Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks Constructional details
This application claims the benefit of U.S. Provisional Application No. 63/734,333, filed Dec. 16, 2024, which is hereby incorporated by reference in its entirety.
In construction applications, an operator may need to know the amount of metal clad (MC) or armor clad (AC) cable remaining on a cable spool. For example, to determine if enough cable remains on the spool to complete a job. Thus, an operator may need to measure the amount of cable already used and subtract that value from the total cable on a spool in order to determine how much cable is remaining on the cable spool. As should be appreciated, this process may be time-consuming and undesirable to an operator.
According to one aspect of the present disclosure, a cable spool measurement system can include a cable feed device. The cable feed device can include a base, a spool arm extending from the base, and a spindle extending perpendicularly away from the spool arm. The spindle can receive and rotatably support a cable spool. The cable spool measurement system can further include an optical sensor arranged to view cable dispensed from the cable spool and a processor in communication with the optical sensor. The processor can calculate an amount of cable removed from the cable spool and subtract the amount of cable removed from the cable spool from an original amount of cable on the cable spool to determine an amount of cable remaining on the cable spool.
In some examples, the optical sensor can utilize motion detection to track cable movement as the cable is dispensed from the cable spool.
In some examples, the optical sensor can perform dimensional analysis to measure cable diameter or length as the cable passes through a field of view of the optical sensor.
In some examples, the optical sensor can monitor changes in spool diameter as cable is dispensed, and the processor can calculate the amount of cable removed based on the changes in spool diameter.
In some examples, the processor can store calibration data specific to different cable types and utilize the calibration data to accurately calculate the amount of cable removed and remaining.
In some examples, the processor can continuously update the calculations in real-time and provide ongoing feedback to an operator through a display interface.
In some examples, the cable spool measurement system can further include a motor that automatically dispenses cable from the cable spool, wherein the processor can correlate motor rotational data with optical sensor feedback to determine the amount of cable removed from the cable spool.
According to another aspect of the present disclosure, a cable spool measurement system can include a cable feed device. The cable feed device can include a base, a spool arm extending from the base, and a spindle extending perpendicularly away from the spool arm. The spindle can receive and rotatably support a cable spool. The cable spool measurement system can further include a weight sensor arranged within the spindle to determine a weight of the cable spool and a processor in communication with the weight sensor. The processor can determine a weight change of the cable spool during use and calculate an amount of cable remaining on the cable spool based on the weight change of the cable spool.
In some examples, the processor can record an initial weight of the cable spool when positioned on the spindle and continuously monitor weight changes to determine the amount of cable removed.
In some examples, the processor can store weight-per-unit-length data for different cable types and calculate the amount of cable remaining by dividing the measured weight change by the stored weight-per-unit-length data.
In some examples, the processor can include compensation algorithms to adjust weight measurements for environmental factors including temperature variations and vibrations.
In some examples, the processor can access a database of cable specifications to automatically determine cable weight per unit length based on cable type identification.
In some examples, the processor can implement filtering algorithms to smooth out temporary weight fluctuations caused by cable movement and vibrations during dispensing operations.
According to yet another aspect of the present disclosure, a cable spool measurement system can include a cable feed device. The cable feed device can include a base, a spool arm extending from the base, and a spindle extending perpendicularly away from the spool arm. The spindle can receive and rotatably support a cable spool. The cable spool measurement system can further include a line counter arranged around a portion of a cable extending from the cable spool to determine an amount of cable removed from the cable spool and a processor in communication with the line counter. The processor can subtract the amount of cable removed from the cable spool from an original amount of cable on the cable spool to determine an amount of cable remaining on the cable spool.
In some examples, the line counter can include a measurement wheel that rotates as the cable passes through the line counter, and each rotation of the measurement wheel can correspond to a specific length of cable passage.
In some examples, the line counter can incorporate optical encoders that track wheel rotation through light interruption patterns to detect and measure cable movement.
In some examples, the line counter can include tension adjustment mechanisms to ensure proper contact pressure between the cable and a measurement element while preventing cable damage.
In some examples, the processor can receive real-time data from the line counter and continuously update cable quantity calculations using algorithms that account for measurement accuracy and calibration factors.
In some examples, the original amount of cable on the cable spool can be determined through manual entry by a user, barcode scanning, or RFID tag reading, and the processor can store this initial cable amount information in non-volatile memory.
In some examples, the processor can store historical measurement data including timestamps and cable types, and provide predictive analytics to estimate when cable replacement will be needed based on usage patterns and remaining quantities.
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of embodiments of the invention:
FIG. 1 is a diagrammatic view of one example of a cable spool measurement system for use with a cable spool according to aspects of the present disclosure.
FIG. 2 is a diagrammatic view of another example of a cable spool measurement system for use with the cable spool according to aspects of the present disclosure.
FIG. 3 is a diagrammatic view of yet another example of a cable spool measurement system for use with the cable spool according to aspects of the present disclosure.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Given the benefit of this disclosure, various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.
As generally noted above, determining if enough cable to complete a job remains on a cable spool may be a labor-intensive process that requires a user to manually take linear measurements and calculate the amount of cable remaining on a cable spool. As should be appreciated, this process may be time-consuming and error-prone, which is undesirable in many construction application.
To mitigate these issues, the operator may utilize a cable spool measurement system, which may automatically record the amount of cable removed from a cable spool and calculate the amount of cable remaining on the cable spool. For example, the cable spool measurement system may include an optical sensor to visualize cable removed from or added to the spool. The optical sensor may interface with a controller to calculate the amount of cable removed from or remaining on the cable spool.
In another example, the cable spool measurement system may include a weight sensor, which may monitor a change in weight of the cable spool in order to determine the amount of cable removed from or remaining on the cable spool. In yet another example, the cable spool measurement system may include a line counter, which may monitor the amount (e.g., length) of cable removed from the cable spool. In some examples, these values may be communicated to the controller, which may subtract the amount of cable removed from the cable spool from the original amount of cable on the cable spool in order to calculate the amount of cable remaining on the cable spool.
FIG. 1 shows an example of a cable spool measurement system 100. The cable spool measurement system 100 may be used with a cable spool 115 to determine an amount (e.g., length, weight, etc.) of cable that remains on the cable spool 115. In other examples, the cable spool measurement system 100 may be used to determine the amount of cable (e.g., cable 130) that has been removed from the cable spool 115. In some examples, the cable 130 may be in the form of armor clad (AC) or metal clad (MC) cable. However, in other examples, other types of cable are envisioned (e.g., ethernet, wire, non-metallic sheathed (NM), data, underground feeder (UF), audio & video, or any other known type of cable).
In some examples, the cable spool measurement system 100 may include the cable spool 115, which may be secured to a cable feed device 140. The cable feed device 140 may include a base 105 and a spool arm 110. In some examples, the base 105 of the cable feed device 140 may include one or more wheels to permit an operator to transport the cable feed device 140 (and cable spool 115) between worksites. Further, the spool arm 110 may extend from the base 105 and be configured to rotatably support the cable spool 115. For example, the cable spool 115 may be placed on a spindle 120 extending perpendicularly from the spool arm 110.
In some examples, the cable spool 115 may define a central opening, which may extend through a center of the cable spool 115 to permit an operator to mount the cable spool 115 with the spindle 120 extending through the central opening of the cable spool 115. Thus, the cable spool 115 may rotate as shown by arrows 125 about the spindle 120 (e.g., to dispense or retract cable 130 from the cable spool 115). Further, in some examples, the cable feed device 140 may be a manual device, where an operator dispenses or retracts cable 130 from the cable spool 115 manually. However, in other examples, the cable feed device 140 may be an automated or partially-automated device, where the cable 130 is dispensed or retracted from the cable spool under power from a motor, battery, or any other known power source.
In some examples, in order to track the amount of cable 130 remaining on the cable spool 115, the cable spool measurement system 100 may include an optical sensor 135. The optical sensor 135 may be configured to watch (e.g., sense, visualize) the cable 130 as the cable 130 is removed from the cable spool 115. In some examples, the optical sensor 135 may include a camera, a laser sensor, an infrared sensor, a photoelectric sensor, or any other suitable optical detection device capable of monitoring cable movement. The optical sensor 135 may be positioned at various locations relative to the cable spool 115, such as adjacent to the cable exit point, along the cable path, or directed toward the cable spool itself to monitor changes in spool diameter as cable is dispensed. The optical sensor 135 may utilize various detection methods, including motion detection to track cable movement, dimensional analysis to measure cable diameter or length, or pattern recognition to identify specific cable characteristics. Thus, the optical sensor 135 may communicate with a controller 145 (e.g., including a processor and a memory) to determine an amount of cable 130 removed from the cable spool 115.
In some examples, the controller 145 may process the optical data using algorithms that convert visual information into quantitative measurements, such as calculating linear distance based on detected cable movement or determining cable volume based on changes in spool appearance. The controller 145 may also store calibration data specific to different cable types, allowing for accurate measurements across various cable diameters, materials, and configurations.
As a result, the controller 145 may determine the amount of cable 130 remaining on the cable spool 115. For example, by subtracting the measured amount of cable 130 removed from the cable spool 115 from the total amount of cable 130 on the cable spool 115 prior to the cable removal. In some implementations, the controller 145 may continuously update these calculations in real-time, providing ongoing feedback to an operator through a display interface, audible alerts, or wireless communication to external devices.
In some examples, to facilitate this tracking method, the cable feed device 140 may include a motor that automatically dispenses cable 130 from the cable spool 115. The motor may be an electric motor, hydraulic motor, pneumatic motor, or any other suitable power source capable of providing controlled rotation to the cable spool 115 or associated dispensing mechanisms. The motor may be equipped with speed control capabilities, allowing for variable dispensing rates based on operator requirements or automated programming. In some implementations, the motor may include feedback mechanisms such as encoders, tachometers, or other rotational sensors that provide precise information about motor speed, direction, and total rotations. Thus, based on the speed of the motor, in combination with visual information from the optical sensor 135 (e.g., indicating that cable is being removed from the spool), the controller 145 may determine the amount of cable 130 remaining on or removed from the cable spool 115.
In some examples, the controller 145 may correlate motor rotational data with optical sensor feedback to provide redundant measurement systems, improving accuracy and reliability of cable quantity calculations. In some examples, the controller 145 may detect discrepancies between motor-based calculations and optical sensor measurements, which could indicate issues such as cable binding, motor slippage, or sensor malfunction. The automated dispensing system may also include safety features such as emergency stops, overload protection, and automatic shut-off when predetermined cable limits are reached. Additionally, the motor-driven system may be programmable to dispense specific lengths of cable automatically, with the optical sensor providing verification that the correct amount has been dispensed.
FIG. 2 illustrates another example of a cable spool measurement system 200 that can be used with the cable spool 115 of FIG. 1 (e.g., as an alternative configuration of the cable spool measurement system 100). As will be recognized, the cable spool measurement system 200 shares a number of components in common with and operates in a similar fashion to the examples illustrated and described previously. For the sake of brevity, these common features will not be again described below in detail. Rather, previous discussion of similarly named or numbered features, unless otherwise indicated, also applies to example configurations of the cable spool measurement system 200.
In some examples, a cable spool measurement system 200 may include a weight sensor 205 (e.g., a load cell, a strain gauge, a force sensor, a pressure sensor, a piezoelectric sensor, or any other suitable weight measurement device) to determine the amount of cable 130 remaining on or removed from the cable spool 115. The weight sensor 205 may be configured to provide high-precision measurements with accuracy sufficient to detect small changes in cable weight as individual lengths are dispensed. For example, the weight sensor 205 may be positioned within the spindle 120, integrated into the base 105, or mounted at any suitable location where the weight of the cable spool 115 can be accurately measured. In some implementations, the weight sensor 205 may be positioned within a hollow portion of the spindle 120, allowing the sensor to directly support the cable spool 115 while maintaining the rotational capabilities of the spindle. Alternatively, the weight sensor 205 may be positioned beneath or adjacent to the spindle 120, with mechanical coupling elements that transfer the weight load to the sensor while isolating it from rotational forces.
When the cable spool 115 is positioned on the spindle 120, the weight of the cable spool 115 and its contents may be communicated from the weight sensor 205 to the controller 145 through wired or wireless communication protocols. The weight sensor 205 may include signal conditioning circuitry to amplify, filter, and digitize the weight measurements before transmission to the controller 145. In some examples, the weight sensor 205 may be calibrated to account for environmental factors such as temperature variations, vibrations, or electromagnetic interference that could affect measurement accuracy. The controller 145 may also include compensation algorithms to adjust for these factors and provide consistent measurements across different operating conditions.
When an operator initially positions a cable spool 115 on the spindle 120, the controller 145 records the initial weight of the cable spool 115 in its memory, establishing a baseline measurement for subsequent calculations. This initial weight measurement may include the weight of both the cable 130 and the spool structure itself. The controller 145 may prompt the operator to input additional information such as the cable type, cable specifications, or the original length of cable on the spool to enhance measurement accuracy. In some implementations, the controller 145 may access a database of cable specifications to automatically determine cable weight per unit length based on cable type identification, which may be inputted manually by the operator or detected automatically through barcode scanning, RFID tags, or other identification methods.
As the operator removes cable 130 from the cable spool 115 during use, the controller 145 continuously monitors the weight change of the cable spool 115 in real-time or at predetermined intervals. The weight sensor 205 may provide continuous analog output or digital readings at specified sampling rates, allowing the controller 145 to track even small incremental changes in spool weight. The controller 145 may implement filtering algorithms to smooth out temporary weight fluctuations caused by cable movement, vibrations, or brief contact with the spool during dispensing operations. Based on the measured change in weight of the cable spool 115, the controller 145 may determine the amount of cable remaining on or removed from the cable spool 115 using mathematical calculations that correlate weight loss to cable length dispensed.
In some examples, in order to accurately determine the amount of cable remaining on or removed from the cable spool 115, the weight of the cable 130 per unit length (such as per foot, meter, yard, or any other standard or custom dimension) may be pre-stored within the memory of the controller 145. This weight-per-unit-length data may be organized in a comprehensive database that includes specifications for various cable types, sizes, and manufacturers. The database may include information for different cable categories such as armor clad (AC), metal clad (MC), non-metallic sheathed (NM), underground feeder (UF), ethernet, coaxial, fiber optic, and other specialized cable types. For each cable type, the database may store additional parameters such as conductor size, insulation type, sheathing material, and any armor or protective coverings that affect the overall weight per unit length.
Using the stored weight-per-unit-length data and the measured weight change, the controller 145 may calculate the precise number of feet, meters, or other units of cable 130 remaining on or removed from the cable spool 115. The controller 145 may perform these calculations using algorithms that account for measurement tolerances, rounding errors, and cumulative measurement drift over time. In some implementations, the controller 145 may provide multiple calculation methods or cross-reference calculations to verify accuracy and detect potential measurement errors. The calculated results may be displayed to the operator through various output methods, including digital displays, LED indicators, audible alerts, or wireless transmission to external devices such as smartphones, tablets, or computer systems. The controller 145 may also store historical usage data, allowing operators to track cable consumption patterns, estimate future needs, and maintain inventory records for multiple cable spools and projects.
FIG. 3 illustrates another example of a cable spool measurement system 300 that can be used with the cable spool 115 of FIG. 1 (e.g., as an alternative configuration of the cable spool measurement systems 100, 200). As will be recognized, the cable spool measurement system 300 shares a number of components in common with and operates in a similar fashion to the examples illustrated and described previously. For the sake of brevity, these common features will not be again described below in detail. Rather, previous discussion of similarly named or numbered features, unless otherwise indicated, also applies to example configurations of the cable spool measurement system 300.
In some examples, a cable spool measurement system 300 may include a line counter 305 (e.g., a rotary encoder, etc.) to determine the amount of cable 130 remaining on or removed from the cable spool 115. The line counter 305 may be a mechanical, electronic, or electromechanical device specifically designed to measure linear movement of cable as it passes through the device. For example, the line counter 305 may be positioned around a portion of the cable 130 (e.g., adjacent the cable spool 115), so that the cable 130 passes through the line counter 305 as cable is dispensed from the cable spool 115. The line counter 305 may include a housing with an opening or channel through which the cable 130 passes, ensuring consistent contact between the cable and the measurement mechanism. Thus, as the cable 130 is dispensed from the cable spool 115, the cable 130 may rotate a wheel, roller, or other measurement element within the line counter 305, which may correspond to an indication of the amount (e.g., linear distance) of cable 130 removed from the cable spool 115. The measurement wheel or roller may be calibrated to provide precise measurements, with each rotation or partial rotation corresponding to a specific length of cable passage. In some implementations, the line counter 305 may include multiple measurement wheels of different sizes to provide redundant measurements or to accommodate different cable diameters and types.
In some examples, the line counter 305 may incorporate various sensing technologies to detect and measure cable movement. These may include optical encoders that track wheel rotation through light interruption patterns, magnetic sensors that detect rotation through magnetic field changes, or mechanical counters that provide direct numerical readouts. The line counter 305 may also include tension adjustment mechanisms to ensure proper contact pressure between the cable 130 and the measurement wheel, preventing slippage that could lead to inaccurate measurements while avoiding excessive pressure that might damage the cable or impede its movement.
In some examples, the line counter 305 may be designed with quick-release mechanisms or adjustable openings to facilitate easy cable insertion and removal without requiring threading the cable through the device. The values from the line counter 305 may be communicated to the controller 145 through various communication methods, including wired connections such as serial, USB, or analog signal transmission, or wireless protocols such as Bluetooth, Wi-Fi, or radio frequency transmission. The controller 145 may receive real-time data from the line counter 305, allowing for continuous monitoring and updates to cable quantity calculations. The controller 145 can calculate the amount of cable remaining on or removed from the cable spool 115 using algorithms that account for measurement accuracy, calibration factors, and potential sources of error such as cable stretch, temperature effects, or mechanical tolerances.
For example, the controller 145 may subtract the measured amount (e.g., as measured by the line counter 305) of cable 130 removed from the cable spool 115 from the total amount of cable 130 on the cable spool 115 prior to the cable removal. The total amount of cable 130 initially on the cable spool 115 may be determined through various methods, including manual entry by a user through a user interface, automatic detection through barcode scanning or RFID tag reading, retrieval from a manufacturer's database based on cable spool identification, or calculation based on the initial weight measurement and known cable specifications. The user interface may include a touchscreen display, physical keypad, voice input system, or mobile application that allows operators to input cable specifications such as total length, cable type, manufacturer part number, or spool identification codes. In some implementations, the controller 145 may prompt the user to verify the initial cable amount through multiple input methods to ensure accuracy, such as requiring confirmation of automatically detected values or cross-referencing manual entries with stored cable specifications. The controller 145 may also store this initial cable amount information in non-volatile memory to maintain data integrity across power cycles and enable historical tracking of cable usage patterns for inventory management and project planning purposes.
The controller 145 may also store historical measurement data in a comprehensive database that includes timestamps, cable types, project identifiers, and environmental conditions during cable dispensing operations. This historical data storage capability allows the controller 145 to track cumulative cable usage across multiple projects, enabling operators to analyze consumption patterns, identify trends in cable usage efficiency, and optimize inventory management strategies. The controller 145 may provide predictive analytics functionality that utilizes machine learning algorithms or statistical models to estimate when cable replacement or resupply will be needed based on historical usage patterns, current project requirements, and remaining quantities on active spools.
These predictive capabilities may include automated alerts when cable levels reach predetermined thresholds, integration with supply chain management systems to trigger automatic reordering processes, and generation of detailed reports that assist project managers in planning future cable requirements. The controller 145 may also correlate usage data with project timelines, crew productivity metrics, and installation specifications to provide insights that improve project planning accuracy and reduce material waste. Additionally, the system may include data export capabilities that allow integration with enterprise resource planning systems, cost accounting software, and project management platforms, enabling seamless data flow across organizational systems and supporting comprehensive project documentation and analysis.
In some implementations, devices or systems disclosed herein can be utilized, manufactured, or installed using methods embodying aspects of the invention. Correspondingly, any description herein of particular features, capabilities, or intended purposes of a device or system is generally intended to include disclosure of a method of using such devices for the intended purposes, a method of otherwise implementing such capabilities, a method of manufacturing relevant components of such a device or system (or the device or system as a whole), and a method of installing disclosed (or otherwise known) components to support such purposes or capabilities. Similarly, unless otherwise indicated or limited, discussion herein of any method of manufacturing or using for a particular device or system, including installing the device or system, is intended to inherently include disclosure, as embodiments of the invention, of the utilized features and implemented capabilities of such device or system.
Also as used herein, unless otherwise limited or defined, “or” indicates a non-exclusive list of components or operations that can be present in any variety of combinations, rather than an exclusive list of components that can be present only as alternatives to each other. For example, a list of “A, B, or C” indicates options of: A; B; C; A and B; A and C; B and C; and A, B, and C. Correspondingly, the term “or” as used herein is intended to indicate exclusive alternatives only when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” For example, a list of “one of A, B, or C” indicates options of: A, but not B and C; B, but not
A and C; and C, but not A and B. A list preceded by “one or more” (and variations thereon) and including “or” to separate listed elements indicates options of one or more of any or all of the listed elements. For example, the phrases “one or more of A, B, or C” and “at least one of A, B, or C” indicate options of: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more of A, one or more of B, and one or more of C. Similarly, a list preceded by “a plurality of” (and variations thereon) and including “or” to separate listed elements indicates options of multiple instances of any or all of the listed elements. For example, the phrases “a plurality of A, B, or C” and “two or more of A, B, or C” indicate options of: A and B; B and C; A and C; and A, B, and C.
As used herein, unless otherwise defined or limited, directional terms are used for convenience of reference for discussion of particular figures or examples. For example, references to downward (or other) directions or top (or other) positions may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientation or geometry in all installations or configurations.
Also as used herein, unless otherwise limited or defined, “substantially parallel” indicates a direction that is within ±12 degrees of a reference direction (e.g., within ±6 degrees), inclusive.
Also as used herein, unless otherwise limited or defined, “substantially perpendicular” indicates a direction that is within ±12 degrees of perpendicular a reference direction (e.g., within ±6 degrees), inclusive.
Also as used herein, unless otherwise limited or defined, “integral” and derivatives thereof (e.g., “integrally”) describe elements that are manufactured as a single piece without fasteners, adhesive, or the like to secure separate components together. For example, an element stamped, cast, or otherwise molded as a single-piece component from a single piece of sheet metal or using a single mold, without rivets, screws, or adhesive to hold separately formed pieces together is an integral (and integrally formed) element. In contrast, an element formed from multiple pieces that are separately formed initially then later connected together, is not an integral (or integrally formed) element.
Additionally, unless otherwise specified or limited, the terms “about” and “approximately,” as used herein with respect to a reference value, refer to variations from the reference value of ±15% or less, inclusive of the endpoints of the range. Similarly, the term “substantially equal” (and the like) as used herein with respect to a reference value refers to variations from the reference value of less than ±10%, inclusive. Where specified, “substantially” can indicate in particular a variation in one numerical direction relative to a reference value. For example, “substantially less” than a reference value (and the like) indicates a value that is reduced from the reference value by 10% or more, and “substantially more” than a reference value (and the like) indicates a value that is increased from the reference value by 10% or more.
Also as used herein, unless otherwise limited or specified, “substantially identical” refers to two or more components or systems that are manufactured or used according to the same process and specification, with variation between the components or systems that are within the limitations of acceptable tolerances for the relevant process and specification. For example, two components can be considered to be substantially identical if the components are manufactured according to the same standardized manufacturing steps, with the same materials, and within the same acceptable dimensional tolerances (e.g., as specified for a particular process or product).
Unless otherwise specifically indicated, ordinal numbers are used herein for convenience of reference, based generally on the order in which particular components are presented in the relevant part of the disclosure. In this regard, for example, designations such as “first,” “second,” etc., generally indicate only the order in which a thus-labeled component is introduced for discussion and generally do not indicate or require a particular spatial, functional, temporal, or structural primacy or order.
The above detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the above description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Given the benefit of this disclosure, various modifications to these embodiments will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
1. A cable spool measurement system, comprising:
a cable feed device, including:
a base;
a spool arm extending from the base; and
a spindle extending perpendicularly away from the spool arm, the spindle to receive and rotatably support a cable spool;
an optical sensor, the optical sensor arranged to view cable dispensed from the cable spool; and
a processor in communication with the optical sensor, the processor to calculate an amount of cable removed from the cable spool and subtract the amount of cable removed from the cable spool from an original amount of cable on the cable spool to determine an amount of cable remaining on the cable spool.
2. The cable spool measurement system of claim 1, wherein the optical sensor utilizes motion detection to track cable movement as the cable is dispensed from the cable spool.
3. The cable spool measurement system of claim 1, wherein the optical sensor performs dimensional analysis to measure cable diameter or length as the cable passes through a field of view of the optical sensor.
4. The cable spool measurement system of claim 1, wherein the optical sensor monitors changes in spool diameter as cable is dispensed, and the processor calculates the amount of cable removed based on the changes in spool diameter.
5. The cable spool measurement system of claim 1, wherein the processor stores calibration data specific to different cable types and utilizes the calibration data to accurately calculate the amount of cable removed and remaining.
6. The cable spool measurement system of claim 1, wherein the processor continuously updates the calculations in real-time and provides ongoing feedback to an operator through a display interface.
7. The cable spool measurement system of claim 1, further comprising a motor that automatically dispenses cable from the cable spool, wherein the processor correlates motor rotational data with optical sensor feedback to determine the amount of cable removed from the cable spool.
8. A cable spool measurement system, comprising:
a cable feed device, including:
a base;
a spool arm extending from the base; and
a spindle extending perpendicularly away from the spool arm, the spindle to receive and rotatably support a cable spool;
a weight sensor, the weight sensor arranged within the spindle to determine a weight of the cable spool; and
a processor in communication with the weight sensor, the processor to determine a weight change of the cable spool during use and calculate an amount of cable remaining on the cable spool based on the weight change of the cable spool.
9. The cable spool measurement system of claim 8, wherein the processor records an initial weight of the cable spool when positioned on the spindle and continuously monitors weight changes to determine the amount of cable removed.
10. The cable spool measurement system of claim 8, wherein the processor stores weight-per-unit-length data for different cable types and calculates the amount of cable remaining by dividing the measured weight change by the stored weight-per-unit-length data.
11. The cable spool measurement system of claim 8, wherein the processor includes compensation algorithms to adjust weight measurements for environmental factors including temperature variations and vibrations.
12. The cable spool measurement system of claim 8, wherein the processor accesses a database of cable specifications to automatically determine cable weight per unit length based on cable type identification.
13. The cable spool measurement system of claim 8, wherein the processor implements filtering algorithms to smooth out temporary weight fluctuations caused by cable movement and vibrations during dispensing operations.
14. A cable spool measurement system, comprising:
a cable feed device, including:
a base;
a spool arm extending from the base; and
a spindle extending perpendicularly away from the spool arm, the spindle to receive and rotatably support a cable spool;
a line counter, the line counter arranged around a portion of a cable extending from the cable spool to determine an amount of cable removed from the cable spool; and
a processor in communication with the line counter, the processor to subtract the amount of cable removed from the cable spool from an original amount of cable on the cable spool to determine an amount of cable remaining on the cable spool.
15. The cable spool measurement system of claim 14, wherein the line counter includes a measurement wheel that rotates as the cable passes through the line counter, and each rotation of the measurement wheel corresponds to a specific length of cable passage.
16. The cable spool measurement system of claim 14, wherein the line counter incorporates optical encoders that track wheel rotation through light interruption patterns to detect and measure cable movement.
17. The cable spool measurement system of claim 14, wherein the line counter includes tension adjustment mechanisms to ensure proper contact pressure between the cable and a measurement element while preventing cable damage.
18. The cable spool measurement system of claim 14, wherein the processor receives real-time data from the line counter and continuously updates cable quantity calculations using algorithms that account for measurement accuracy and calibration factors.
19. The cable spool measurement system of claim 14, wherein the original amount of cable on the cable spool is determined through manual entry by a user, barcode scanning, or RFID tag reading, and the processor stores this initial cable amount information in non-volatile memory.
20. The cable spool measurement system of claim 14, wherein the processor stores historical measurement data including timestamps and cable types, and provides predictive analytics to estimate when cable replacement will be needed based on usage patterns and remaining quantities.