Abstract:
An apparatus that accurately measures rope, wire, tubing and other materials is herein disclosed. A variety of different-sized models would possess different sized openings. One model with a one-inch opening would be used to measure small wire and cable. Another model with approximately a 3-inch opening would be used for larger electrical cables, rope, tubing and the like. An even large model would be available for measuring ductwork, hoses, and other large diameter material. As the material is pulled through the opening, an optical sensor, similar to that used on an optical computer mouse, accurately measures the material to the fraction of an inch. A mechanical sensor, utilizing a guide wheel is also envisioned. The length is displayed on a digital readout on the perimeter of the invention that is provided with a power button, reset button and the like. It is envisioned that various attachments such as a belt loop, a spool attachment and other items to increase the versatility of the invention would also be provided.

Description:
RELATED APPLICATIONS 
     The present invention was first described in and claims the benefit of U.S. Provisional Application No. 60/774,042, filed Feb. 17, 2006, the entire disclosures of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a system and method incorporating an apparatus to accurately measures rope, wire, tubing and other non-rigid material and, more particularly, to the measuring means being both mechanical and optical reader. 
     BACKGROUND OF THE INVENTION 
     One of the most common tools found in toolboxes of contractors and do-it-yourselfers is the tape measure. It is used in all stages of a project from the beginning planning stages, through detailed design, construction and final inspection. It provides extremely accurate measurements at a minimal cost. However, while a tape measure works great with rigid materials and fixed distances, it does not do so well with non-rigid materials such as rope, wire, cable, tubing and the like. Typically, the user must lay the material down and lay the tape measure along side it. This can be a source of inaccuracy. Also, on many jobsites, there is not enough room to lay such material out. All of these difficulties can lead to costly mistakes if material is cut to a wrong dimension. 
     Several attempts have been made in the past to develop a device for accurately measuring the length of rope, cord, chain, or other elongate device with a portable device. U.S. Pat. No. 6,129,796, in the name of Steinberg et al., discloses an apparatus and method for dispensing and labeling cord, wherein the apparatus has at leas tone spool of cord where one can measure a length of cord, and a label is applied to the cord. The Steinberg et al. apparatus is not an electronic counting apparatus that displays the amount of cord played out as in the present invention. 
     U.S. Pat. No. 5,430,665, in the name of Jin et al., teaches a length measuring apparatus for accurately measuring the length of communication cable in a moving state, combining a marking and encoding system, and a detection system. The Jin et al. device, unfortunately, is not designed for portability and cannot be held by hand. Additionally, the Jin et al. device marks the object during the length measuring process. 
     U.S. Pat. No. 5,065,527, in the name of Shaw, describes a length measuring and positive drive apparatus including two rotatable members that surround the product with an encoder, display device, and means to cut or mark pre-set lengths. The Shaw device is not easily portable and is not designed to be conveniently and comfortably held by hand. Also, the Shaw device does not also incorporate an optical sensing mechanism. 
     U.S. Pat. No. 5,245,760, in the name of Smart et al., discloses an apparatus for the lineal measurement of continuous or stranded materials, such as cloth, comprising a gravity-operated contact wheel which generated incremental distance pulses when rotated, an electric eye, a support base, and a display means. In addition to the aforementioned prior art, the Smart et al. design is not suitable for hand-held portability and also does not include an optical sensing mechanism. 
     U.S. Pat. No. 4,798,003, in the name of Haglöf, teaches a thread meter comprising a holder for a thread reel, a counter with a rotary measuring wheel, and guides for the thread. In addition to the aforementioned prior art, the Haglöf design is not suitable for hand-held portability and also does not include an optical sensing mechanism. 
     U.S. Pat. No. 4,570,348, in the name of Amsler et al., describes an apparatus for measuring length of elongate cable, with a pair of rotating rollers, a magnetically-activated switch, a pulse-transmitting device, and a receiver for counting and displaying the number of pulses. The Amsler et al. device does not have a logic function to calculate the measured length of elongate material that passes therethrough. The Amsler et al. apparatus also utilizes a magnetically-activated switch and does not comprise an optical sensing mechanism and therefore does not fall under the scope of the present invention. 
     U.S. Pat. No. 4,400,882, in the name of Thornton, discloses a system for marking cables employing optical devices for measuring the distance impressions. 
     None of the prior art particularly describes a portable device that utilizes mechanical and optical readers to accurately measure the length of an elongate substrate, such as rope, cord, chain, etc. Accordingly, there exists a need for a means by which measurement of non-rigid material can be accurately made without the disadvantages as described above. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is need for an apparatus to accurately measure the length of an elongate material, such as wire, cord, rope, chain, or the like. 
     A further observation is that such an apparatus is needed to measure either a desired or entire length of such an elongate material with a portable and electronic device. 
     An object of the present invention is to provide such an apparatus in the design of a circular, disc-shaped housing with a central orifice comprising a sensor mechanism and a digital display module. 
     A further object of the present invention is to provide such a housing fabricated out of injection-molded plastic and said central orifice is preferably in the range between and including one and three inches in diameter. 
     A further object of the present invention provides for such an apparatus further comprising a circuit board with integral power distribution, sensor input processing, logic processing, and output data processing, and a power supply comprising batteries. 
     Another object of the present invention provides for said logic processing including means to process said sensor input into a measured length output display. 
     Still another object of the present invention is to provide a mechanical sensor mechanical sensor further comprising a stationary roller providing an idler means as said elongate material is fed through said central portal opening; a compliant roller oriented opposite from said stationary roller; a rotary encoder attached to said compliant roller, providing a continuous pulsing signal for calculation of said measured length; a roller bracket comprising an attachment means to said compliant roller with a pair of compression springs, thereby providing a spring force to said compliant roller; and, an adjustor assembly, comprising a threaded member with a knob, wherein said adjustment of said adjustor assembly applies and releases said spring force, thereby enabling said compliant roller to provide a spring-loaded contact with said elongate material as it is fed through said central portal opening. 
     Still another object of the present invention is to provide an optical sensor that emits an optical beam comprising a suitable resolution, thereby providing said input signal to said circuit board for calculation of said measured length. 
     Still another object of the present invention provides a digital display module, further comprising a user interface display for display of said measured length of said elongate material upon receipt of said output signal of said circuit board; and, a reset button located adjacent to said user interface display and in electrical communication with said circuit board for providing a reset signal, thereby returning the user interface display to zero. 
     Still another object of the present invention provides for said user interface display comprising a light emitting diode display (LED) or a liquid crystal diode display (LCD) in both English and metric units. 
     Yet another object of the present invention provides for said housing to further comprise various attachment means including at least one of the following list: hooks, clamps, or belt adapters. 
     Yet another object of the present invention provides for said housing to further comprise integrated material cutting attachments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which: 
         FIG. 1  is a front perspective view of the automatic cord length measuring device  10 , according to a preferred embodiment of the present invention; 
         FIG. 2  is a rear perspective view of the invention  10 , according to a preferred description of the present invention; 
         FIG. 3  is an internal break-away view of the automatic cord length measuring device  10 , according to a preferred embodiment of the present invention; 
         FIG. 4  is an electrical block diagram of the automatic cord length measuring device  10 , according to a preferred embodiment of the present invention; 
         FIG. 5   a  is a rear perspective view of the invention  10 , according to an alternate description of the present invention; 
         FIG. 5   b  is a rear perspective view of the invention  10 , according to another alternate description of the present invention; and, 
         FIG. 5   c  is a rear perspective view of the invention  10 , according to yet another alternate description of the present invention. 
     
    
    
     DESCRIPTIVE KEY 
     
       
         
               
               
             
           
               
                   
               
             
             
               
                 10 
                 automatic cord length measuring device 
               
               
                 20 
                 housing 
               
               
                 21 
                 portal opening 
               
               
                 22 
                 on/off switch 
               
               
                 23 
                 selector switch 
               
               
                 24 
                 battery compartment 
               
               
                 30 
                 display module 
               
               
                 31 
                 digital display 
               
               
                 32 
                 reset button 
               
               
                 33 
                 optical beam 
               
               
                 34 
                 optical sensor 
               
               
                 35 
                 rotary encoder 
               
               
                 36 
                 circuit board 
               
               
                 41 
                 stationary roller 
               
               
                 42 
                 compliant roller 
               
               
                 43 
                 spring 
               
               
                 44 
                 adjuster 
               
               
                 45 
                 knob 
               
               
                 46 
                 roller bracket 
               
               
                 50 
                 hook 
               
               
                 51 
                 clamp 
               
               
                 52 
                 belt adapter 
               
               
                 60 
                 cutting attachment 
               
               
                 61 
                 cutting attachment housing 
               
               
                 70 
                 material 
               
               
                   
               
             
          
         
       
     
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within  FIGS. 1 through 4 . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope. 
     The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. 
     The present invention describes an apparatus and method for an automatic cord length measuring device (herein described as the “apparatus”)  10 , which provides a means for accurately measuring the length of various materials  70  such as rope, wire, tubing, and the like. The apparatus  10  takes the form of a circular disk shaped housing  20 , with a central portal opening  21 . Various sized models are envisioned to provide different sized portal openings  21  for measuring a variety of materials  70  therein. As material  70  is pulled through the portal opening  21 , a selection of two (2) measurement techniques is provided being an optical sensor  34  method or a mechanical sensor  35  based upon the type of material  70  to be measured. The length of said material  70  is then displayed on a digital display  31  located at the perimeter of the apparatus  10 . 
     Referring now to  FIG. 1 , a front perspective view of the apparatus  10 , according to the preferred embodiment of the present invention, is disclosed. The apparatus  10  comprises a housing  20 , a portal opening  21 , an optical beam  33 , a stationary roller  41 , a compliant roller  42 , a digital display  31 , and a reset button  32 . The housing  20  comprises a circular disk shape plastic molding providing a convenient hand-held profile. The housing  20  is envisioned to be made using an injection molding process being common in the art. The portal opening  31  is centrally located and is envisioned to be provided in a variety of diameter ranges of approximately one (1″) inch to three (3″) inches thereby corresponding to particular material sizes  70  to be measured. The portal opening  21  provides two (2) means of measurement being an optical  34  and a mechanical measuring  41 ,  42  means. The optical beam  33  is emitted from an optical sensor  34  (not shown) thereby providing a non-contact means of measuring the material  70  (see  FIG. 3  description). The rollers  41 ,  42  provide an alternate mechanical means of measurement. The stationary roller  41  provides an idler means as the material  70  is pulled through the portal opening  21 . The compliant roller  42  provides a spring force against said material  70  securely holding it between the two (2) rollers  41 ,  42  during the measurement procedure. The contact rollers  41 ,  42  further provide an encoder signal  35  (not shown) thereby producing an accurate measurement of said material  70  (see  FIGS. 3 and 4 ). The digital display  31  and accompanying reset button  32  are located at the perimeter of the apparatus  10  and provide a user interface display of the measured length of the material  70 . The digital display  31  is envisioned using common electronic technology such as a light emitting diode display (LED), a liquid crystal diode display (LCD), or the like. The digital display  31  is envisioned to provide a display of both English and metric units. The reset button  32  provides a reset signal thereby returning the digital display  31  to zero (see  FIGS. 3 and 4 ). 
     Referring now to  FIG. 2 , a rear perspective view of the apparatus  10 , according to the preferred embodiment of the present invention, is disclosed. The apparatus  10  comprises a housing  20 , a portal opening  21 , an optical beam  33 , a stationary roller  41 , a compliant roller  42 , an on/off switch  22 , a selector switch  23 , and a battery compartment  24 . The on/off switch  22  provides a means for switching the direct current (DC) power source contained therein the battery compartment  24 , to the electronics of the apparatus  10 . The selector switch  23  provides a switching means between the optical measurement method and the mechanical measurement method. The on/off switch  22  and the selector switch  23  are envisioned to be standard sliding panel mounted single-pole, single throw switches common in the industry. The battery compartment  24  comprises a latching enclosure for a plurality of preferably AA-size batteries; however, may utilize various voltages and quantities of battery combinations. 
     Referring now to  FIG. 3 , an internal breakaway view of the apparatus  10 , according to the preferred embodiment of the present invention, is disclosed. The apparatus  10  comprises a housing  20 , a portal opening  21 , an on/off switch  22 , a selector switch  23 , a battery compartment  24 , a display module  30 , a digital display  31 , a reset button  32 , an optical beam  33 , an optical sensor  34 , a rotary encoder  35 , a circuit board  36 , a stationary roller  41 , a compliant roller  42 , a pair of springs  43 , an adjuster  44 , a knob  45 , and a roller bracket  46 . 
     The roller bracket  46  provides an attachment means to the compliant roller  42 , the pair of springs  43  and the adjustor  44  thereby allowing the compliant pulley  42  to make spring-loaded contact with the material  70  in a floating and compliant manner thereby conforming to the contour of said material  70 . The springs  43  are envisioned to be standard compression springs common in the industry. The adjustor  44  provides a spring release means for the compliant roller  42  and is envisioned to be a threaded shaft type device being thereby affixed to the housing  20 . The adjusting knob  45  being attached to the end of the adjustor  44  thereby providing a manual adjusting means to apply and release the spring force  43  being applied to the material  70 . 
     The apparatus  10  as illustrated here depicts interconnecting wiring  37  between the major electronic components and the circuit board  36 . The circuit board  36  provides control electronics and software to operate the apparatus  10 . The optical beam  33  is emitted via an optical sensor  34  being connected thereto the circuit board  36 . The optical sensor  34  comprises a sensor similar to that used on an optical computer mouse common in the industry; however, other commercially available measuring devices may be provided such as various optical measuring devices, as well as laser diode type devices and as such, should not be interpreted as a limiting factor of the present invention  10 . The optical sensor  34  comprises a suitable resolution thereby providing an accurate measurement the material  70 . The rotary encoder  35  is attached to the compliant roller  42  and provides a continuous pulsing signal to the circuit board  36  for calculation of the measured length. The rotary encoder  35  is envisioned to be a miniature shaft mount type encoder common in the industry. 
     Referring now to  FIG. 4 , an electrical block diagram of the electronic portion of the apparatus  10 , according to the preferred embodiment of the present invention, is disclosed. The apparatus  10  is illustrated here depicting a circuit of interconnecting wiring  37  between various electronic components and a circuit board  36 . The said electrical components include an on/off switch  22 , a selector switch  23 , a battery compartment  24 , a display module  30 , an optical sensor  34 , and a rotary encoder  35 . The circuit board  36  receives direct current (DC) power when a single pole-single throw switch  22  is manually activated thereby enabling DC power to flow from a plurality of batteries  24 . The circuit board  36  comprises custom circuits and components common in the electronics industry and thereby performs functions such as power distribution, data input/output, and logic processing. The circuit board  36  further comprises embedded software to process data using technologies such as read-only-memory (ROM), or the like. The circuit board  36  processes pulse and optical type input data and thereby calculates the length of the material  70  via said software. Said input data is provided to the circuit board  36  via an optical sensor  34  or a rotary encoder  35  based upon the selected measuring mode  23 . The circuit board  36  then provides output data to a digital display module  30 . The digital display module  30  further comprises particular user interface components being a numeric digital display  31  and a reset button  32 . The numeric digital display  31  provides visible measurement information in feet and inches or meters. The reset button  32  provides a means to return the numeric digital display  31  to zero. It is also envisioned that selection of the desired measurement units may be obtained by pressing and holding the reset button. 
       FIGS. 5   a  through  5   c  represent rear perspective views of various alternate embodiments of the present invention  10 . More particularly,  FIG. 5   a  illustrates the present invention  10  comprising a hook  50  attachment thereon the housing  20 .  FIG. 5   b  depicts a clamp  51  and belt adapter  52  thereon the housing  20 . Both  FIGS. 5   a  and  5   b  depict alternate attachment means therefor the present invention  10  thereon a user.  FIG. 5   c  illustrates a cutting attachment  60  stored within a cutting attachment housing integrated thereon the housing  20  for providing a user a material cutting means. 
     It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope. The preferred embodiment of the present invention can be utilized by the common user, who has little or no training, in a simple and effortless manner with. After initial purchase or acquisition of the apparatus  10 , it would be utilized as indicated in  FIGS. 1 and 2 . 
     The method of utilizing the apparatus  10  may be achieved by performing the following steps: selecting the appropriate model of the apparatus  10  based upon the physical size of the material  70  to be measured; activating the apparatus  10  by moving the on/off switch  22  to the ON position; resetting the numeric digital display  31  to zero by pressing the reset button  32  and verifying that the digital display  31  reads zero; feeding the material  70  through the portal opening  21  until obtaining the desired length or feeding all the available material  70  through the portal opening  21  to calculate the total length of the material  70 ; and, making a note of the digital display reading  31 , pressing the reset button  32 , and repeating the measurement procedure as many times as required. 
     An alternative embodiment of the present invention  10  comprises various attachment means such as hooks  50 , clamps  51 , belt adapters  52 , or the like to secure the apparatus  10  to personnel, cable spools, various equipment, and the like based upon the intended application. 
     Another alternative embodiment of the present invention  10  comprises a graduated series of models of the apparatus  10  with varying portal opening sizes  21  of up to approximately twelve (12″) inches thereby measuring large commercial and construction materials  70  such as, but not limited to, large piping, hose, or the like. 
     Another alternative embodiment of the present invention  10  comprises a more economical model thereby providing only an optical sensor  34  type measurement means. 
     Yet another alternative embodiment of the present invention  10  comprises a second more economical model thereby providing only a mechanical type measurement means using the aforementioned contact rollers  41 ,  42 . 
     Yet another alternative embodiment of the present invention  10  comprises integrated material cutting attachments  60  residing therein a cutting attachment housing  61 , which could be applied to specific families of materials  70  such as hose, plastic piping, and the like. 
     The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.