Patent Publication Number: US-2016244293-A1

Title: Motor operated spool

Description:
TECHNICAL FIELD 
     The present invention generally relates to spools for winding cable, hose, rope or some other rope like object, and in particular to a spool operated by an electric motor. 
     RELATED APPLICATION 
     This application claims the benefit of priority from Australian Patent No 2013242793, the contents of which are incorporated in entirety by reference. 
     BACKGROUND 
     Spools, or rewind reels, operated by an electric motor are preferred for winding and storage of hoses and cables. These spools save time and do not require physical effort to wind the cable for storage after use. Another advantage is that they can be adapted to operate via a remote control device to enable the winding of the cable from a position other than at the reel device. 
     Prior art electric spools are produced for this purpose but they are relatively large, heavy or bulky, taking up more space than traditional spools and therefore eliminating their ability to be used on small equipment such as 12 volt weed and pesticide sprayers. These spools also require the use of high current dedicated electrical wiring on vehicles as they are commonly used in mobile applications. 
     Currently known electric motor operated spools all employ a drum or cylinder for storing the coiled cable or hose and an electric motor separate from the spool. The motor rotates the spool through some form of gearing or reduction mechanism so that the hose becomes wrapped around the spool at a rate that is safe. Various methods are employed to transfer the rotating movement from the motor to the spool, all of which have their inherent drawbacks. 
     Some prior art drive methods include: 
     Belt and pulley system—this system poses a potential safety hazard if left uncovered and requires a belt tensioning or adjusting device. The belts will slip if they are not maintained causing failed operation; 
     Chain and sprocket system—if uncovered, this system poses the same problems as the belt and pulley system and it generates more noise; 
     Direct connected open gears—this system is similar to the chain and sprocket system, but is more difficult to cover for safety. The motor must also extend outside the spool width, thereby taking up more space; 
     Direct connected motor/gearbox unit to spindle that supports the spool—this system significantly adds to the overall width of the spool assembly; and 
     Direct gear drive to hub assembly that supports the spool on one side (see for example Australian Patent 2005231518)—this system requires heavy framework, hub bearings and a shaft to support the spool, resulting in a heavy finished product. 
     The reference in this specification to any prier publication for information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. 
     BRIEF SUMMARY 
     The present invention seeks to provide a compact, economical, electric motor operated spool. 
     In accordance with the invention, there is provided a spool with a huh to carry a spooled hose or cable and first and second couplings to attach the spool to a cradle, wherein the first coupling is arranged to be fixed against rotation as the hub rotates and the second coupling is arranged to rotate in unison with the hub and wherein a drive unit is fitted between the first coupling and the hub to drive the hub around the first coupling and thereby wind the hose or cable around the hub. 
     Preferably, the drive unit is an electric motor at least partially recessed in the hub. 
     Preferably, the motor includes a stator component fixed relative to the first coupling and a rotor component keyed for rotation with the hub. 
     Preferably, an outer housing of the motor is fixed to the rotor component. 
     Preferably, the housing includes a flange element fixed to a first side of the spool, to loci the rotor and hub together for rotation in unison. 
     Preferably, the motor is substantially housed within the hub. 
     Preferably, the first coupling is in the form of a shaft with a first end projecting from the first side of the spool, for receipt in a first mount of the cradle. 
     Preferably, the second coupling includes a rotary coupler that has an inlet, an outlet, a gallery that provides fluid communication between the inlet and outlet, and a swivel that allows relative rotation between the inlet and the outlet, wherein the outlet provides a connection for a hose carried by the spool and the inlet provides a connection for a supply line to allow fluid to pass between the supply line and the hose. 
     Preferably, the gallery and outlet are formed in a body of the coupler that is mounted to a second side of the spool, for rotation in unison with the hub. 
     Preferably, the body supports a bearing for a second end of the shaft, that extends through the motor and toward the second side of the spool, the bearing allowing relative rotation between the second coupling and the shaft. 
     Preferably, the second coupling includes an extension piece that is supported in a bearing assembly used to mount the second coupling in a second mount of the cradle. 
     In another aspect, there is provided a spool assembly including a spool, as described above, and a cradle with first and second mounts arranged to support the first and second couplings of the spool. 
     Preferably, the spool assembly further includes a hose or cable wound onto the hub of the spool. 
     Preferably, the cradle includes a hose guide. 
     Preferably, the spool can be remotely operated. 
    
    
     
       BRIEF DESCRIPTION OF FIGS. 
       Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non-limiting embodiment, described in connection with the accompanying drawings, in which: 
         FIG. 1  illustrates an exploded isometric view of a preferred embodiment of the invention showing the motor and first side of the spool; 
         FIG. 2  illustrates an exploded isometric view of a preferred embodiment of the invention showing the second side of the spool; 
         FIG. 3  illustrates a cross section of a preferred embodiment of the invention; 
         FIG. 4  illustrates an isometric view of an assembled spool according to the current invention; 
         FIG. 3  illustrates a cross section of an alternative embodiment of the invention including hose attachments; 
         FIG. 6  illustrates an exploded isometric view of the spool of  FIG. 5 ; 
         FIG. 7  illustrates an isometric view of the spool of  FIG. 6  in an assembled condition; 
         FIG. 8  illustrates an isometric view of an alternative embodiment of a spool, including converging sides and a hose guide; 
         FIG. 9  illustrates a top view of the embodiment from  FIG. 8 ; 
         FIG. 10A  illustrates a front view of the embodiment from  FIG. 8 ; 
         FIG. 10B  illustrates a hose guide; 
         FIG. 11  illustrates a side view of the embodiment from  FIG. 8 ; 
         FIG. 12  illustrates a rear view of the embodiment from  FIG. 8 ; 
         FIG. 13  illustrates a second side view of the embodiment from  FIG. 8 ; 
         FIG. 14  illustrates a second isometric view of the embodiment from  FIG. 8 ; 
         FIG. 15  illustrates a third isometric view of the embodiment from  FIG. 8 ; 
         FIG. 16  illustrates a fourth isometric view of the embodiment from  FIG. 8 ; and 
         FIG. 17  illustrates a fifth isometric view of the embodiment from  FIG. 8 . 
     
    
    
     PREFERRED EMBODIMENTS 
     The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments. 
     In the Figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts. 
     Throughout the specification the term cable is intended to include any type of cable or similar object including, but not limited to, various different types of cable, hose, rope, or any other rope-like object. 
     Referring to  FIG. 1 , a preferred embodiment of a spool  1  is shown that can be used for winding cable. The spool  1  includes a first side  2 , a second side  3  and a central hub  4 . 
     The spool  1  is mounted on a cradle  5  that includes a first mount  6 , a second mount  7  and a base plate  8 . The two side mounts  6 ,  7  may be joined by welding or bolting or any other suitable arrangement to the base plate  8 , forming the support mechanism to suspend the spool  1 . The spool  1  and cradle  5  together form a spool assembly  9 . 
     A motor  10  is arranged to it into a recess  11  formed in the side  2 . The motor  10  includes a cylindrical outer housing  12  with a flange  13  for attaching the motor  10  to the side  2 , via fasteners  14 . The motor  10  also has a shaft  15  with a first end  16  for receipt in a bracket  17  of the first mount  6 . The shaft  15  forms a first coupling  20  of the spool  1 . 
     In a preferred embodiment the motor  10  is a brushless direct current (DC) electric motor. A brushless DC motor has many advantages over conventional brushed DC motors, including, but not limited to, longer life and higher reliability, higher efficiency, no radio frequency interference due to brush commutation, linear torque/current relationship, smooth acceleration or constant torque and low cost to manufacture. 
     The motor  10  operates by providing a torque that rotates the housing  12  and flange  13  relative to the shaft  15 , to thereby rotate the hub  4 . Since the spool  1  has the motor  10  mounted within it, the motor housing  12  becomes an integral part of the spool  1 . When fixed to the spool  1  via the flange  13 , the first end  16  of the shaft  15  projects from the side  2  of the spool  1 , for receipt in the mount  6 . As the motor  10  is an integral part of the spool  1 , the shaft  15  becomes a load carrying element for one side of the rotating spool  1 . 
     The shaft  15  is also designed to be fixed against rotation which means no bearing is needed between the mount  6  and the coupling  20 , In a preferred embodiment a bolt  21  is used to secure the shaft first end  16  to the bracket  17  and to prevent it rotating. 
     Referring now to  FIG. 2 , a second coupling  22  is shown. The coupling  22  includes a generally cylindrical body  23  that is fixed to the second side  3  of the spool  1  such as by bolts  23   a,  to rotate in unison with the hub  4 . The body  23  includes an extension piece  24  that is supported by a bearing assembly  25  and bracket  18  used to mount the second coupling  22  to the second mount  7 . 
     Referring now to  FIG. 3 , the second coupling  22  supports a bearing  27 , internally of the spool  1 , for receipt of a second end  26  of the shaft  15 . The second coupling  22  thereby supports the second side  3  of the spool  1  on the mount  7  while still allowing the spool  1  and hub  4  to rotate freely when the motor  10  operates. More particularly, the first side  2  is supported on the first mount  6  by the fixed shaft  15  of the first coupling  20  and the second coupling  22  supports the second side  3  on the second mount  7  via bearing assembly  25 . This arrangement has a benefit that the side  2  can be of lighter construction as radial loads are distributed through the spool  1  so as not to deflect side  2  or affect the alignment of shaft  15 . Of course, alternative arrangements are possible where, instead of supporting a second end of the shaft  15 , a single ended shaft motor is used, which is connected only to the first coupling. 
       FIG. 3  also shows the cross section of the motor  10 . The motor  10  includes a stator component  28  and a rotor component  29 . The stator component  28  is fixed on the shaft  15  while the rotor component is designed to rotate about the shaft  15  on bearings  30 . The outer housing  12  is fixed to the rotor component  29  such that rotational drive provided by the motor  10  causes the hub  4  to rotate, since the hub  4  and housing  12  are keyed together for rotation in unison by the fasteners  14 . 
     The motor  10  is controlled by a brushless DC motor controller (not shown) to allow it to operate from a vehicle battery of either 12 or 24 volts, or any other suitable power source. The motor  10  may also be configured to be controlled remotely. Although a brushless DC motor is preferred, any other suitable motor or equivalent drive unit can instead be used. For example, a geared motor may be used instead of the brushless motor  10  described above. 
     In any case, it is apparent from  FIGS. 3 and 4  that the motor  10  is at least partially housed within the hub  4  and, preferably, substantially entirely housed inside the spool  1  so that the housing  12  only projects from the side  2 , to a minimal extent. The spool  10  is thereby provided with a neat and compact appearance without any exposed componentry that might otherwise present a danger or hazard. 
     Referring now to  FIG. 5 , a hose  31  is shown wound/spooled around the hub  4 . The second coupling  22  is modified to include a rotary coupler  32 . The coupler  32  includes an outlet  33  for connection to the hose  31 , an inlet  34  for connection to a supply line  35  and an internal gallery  36  to provide fluid communication between the inlet  34  and outlet  33 . The outlet  33  and gallery  36  are formed in the body  23  of the coupling  22 , which rotates in unison with the hub  4 . A swivel  37  allows the inlet to remain stationary and in communication with the gallery  36  when the spool  1  rotates. 
     The supply line  35  may be used to provide water to the hose  31 . Alternatively, the coupler  32  may be used to supply any other form of liquid or gas, as required. 
     Referring to  FIGS. 6 and 7 , the spool assembly  9  is shown respectively in an exploded view and an assembled form where the hose  31  is connected to the outlet  33  of the coupler  32 , through an opening  38  in the side  3  of the spool  1 . As the spool  1  is rotated, to either wind the hose  31  on or off the spool  1 , the outlet  33  and opening  38  will rotate in unison, while the swivel  37  allows the inlet to remain fixed relative to the mount  7 . 
     Referring to  FIG. 8  an alternative example embodiment is shown that includes converging spool sides  2 ,  3  and a hose exit  40  with a hose guide  41 .  FIG. 9  shows a top view of this embodiment, illustrating the narrow opening between the spool sides  2 ,  3  and the alignment with the hose guide  41 . The converging spool sides  2 ,  3  cooperate with the hose guide  41  and protect the stored hose  31  from excessive exposure to the elements. 
     The hose guide  41  enables the operation of the spool assembly  9  via a remote control device. A system to guide the hose  31  onto the spool  1  is required as the operator may be positioned away from the spool assembly  9 . 
     In one embodiment, such as that shown in  FIG. 10A , the hose guide  41  is in the form of a tubular bush with a radiused lead-in. The relationship between the length and diameter of the bore is such that the natural curvature of the hose  31  creates a slight resistance to draw through of the hose  31 . This eliminates the need of a brake on the spool  1  to prevent unintended dc-spooling. When the hose  31  is pulled it is straightened and this resistance is reduced. 
     In another embodiment, the hose guide  41  is as shown in  FIG. 10B . This hose guide  41  includes a body  42  with four concave rollers  43  spaced apart to create an opening  44  through which the hose  31  passes. The rollers  43  are spaced such that the natural curvature of the hose  31  creates a slight resistance to draw through of the hose  31 . Once again this eliminates the need of a brake on the spool  1 . 
     In some example embodiments, the spool assembly  9  provides the ability to recharge the battery during manual de-spooling of the hose  31 . As the hose  31  is pulled out the rotation of the spool  1  is used to generate electricity, preferably using the motor  10 , to charge the batteries that power the rewind. This is of particular benefit when using a standalone rechargeable battery without continual charging capabilities, such as when used with a combustion engine powered pump that is manually started and does not have its own battery, for example. 
     Preferably, the remote control will incorporate variable rewind speed selection. Also preferably, the spool assembly  9  will incorporate an audible and/or visual warning of the pending operation of the spool  1  for safety purposes. 
     Referring to  FIGS. 8 to 17 , the embodiment shown includes a base plate  8  with a number of different faces, as well as an additional bracket  8   a.  This design of the base plate  8  and bracket  8   a  provides the ability to mount the spool assembly  9  onto a horizontal surface, a vertical surface or even overhead. Preferably, the major components of the frame are formed by the assembly of two identical pressed or folded sheet metal components, thereby simplifying production. 
     Referring still to  FIGS. 8 to 17 , this alternative embodiment also includes a recess  45  in the first side  2  (see  FIGS. 14 and 15 ) and a recess  46  in the second side  3  (see  FIG. 17 ). This allows the portion of the spool  1  outside the hub  4  to be as wide as possible within the frame and therefore hold as much hose  31  as possible, yet still allows the motor  10  or other components to protrude from the sides  2 ,  3  if necessary. 
     Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention.