Patent Description:
Line dispensing devices, such as auto-belay devices used for climbing or descender devices for workers or conveyances, can be used to protect against falls by retracting slack when the line is not under load and providing a braking force when the line is loaded, so that the weight (e.g., climber) on the end of the line descends at a safe speed. Line dispensing devices can include various braking systems that generate the braking forces. These braking systems can include friction-based systems, hydraulicbased systems, electromagnetic-based systems, and magnetic-based systems (e.g., an eddy current braking mechanism). Document <CIT> discloses a safety device with fall arrest and descending modes.

This disclosure describes examples of a line dispensing device, such as an auto belay device used for climbing activities or descender devices for workers or conveyances. In the line dispensing device described herein, features are described that increase the performance of the device. For example, increased reactivity of the braking and retraction assemblies so that the device is more responsive to climbers needs. In another example, the life-cycle of the device is increased by increasing its loading capacity. Additionally, features are described that increase manufacturing and assembly efficiencies. For example, the entire device is enabled to be more quickly and accurately assembled and disassembled (e.g., during service and inspection processes). Accordingly, a higher performing and more efficient line dispensing device is provided.

In an aspect, the technology relates to a line dispensing device including: a housing; a rotatable shaft rotatably supported by the housing and defining a rotational axis; a line drum disposed about the rotational axis and configured to extend and retract a line from the housing; a retraction assembly disposed about the rotational axis and configured to generate a retraction force and retract the line from the housing; and a braking assembly disposed about the rotational axis and configured to generate a braking force on the line and during extension of the line from the housing.

In an example, the braking assembly includes a rotor assembly having one or more conductors and a stator assembly having one or more magnets, and the rotor assembly is coupled to the rotatable shaft and rotatable around the rotational axis so as to generate an eddy current braking force. In another example, the stator assembly includes a pair of plates each having a plurality of keys extending therefrom, and the one or more magnets are coupled to the pair of plates and the plurality of keys at least partially define a polarity orientation of the one or more magnets. In yet another example, the line drum is coupled to the rotatable shaft and rotatable around the rotational axis, and the line drum is rotatable around the rotational axis at a different speed than the rotatable shaft. In still another example, a transmission is coupled between the line drum and the rotatable shaft so that rotation of the line drum drives rotation of the rotatable shaft. In an example, the retraction assembly is coupled to the line drum and rotatable around the rotational axis, and the retraction assembly is rotatable around the rotational axis at a different speed than the rotatable shaft.

In another example, one end of the rotatable shaft includes a female spline connector configured to receive another exterior shaft and drive rotation thereof. In yet another example, the braking assembly is an eddy current braking device, a hydraulic braking device, a friction braking device, or an electromagnetic braking device.

In another aspect, the technology relates to a line dispensing device including: a line drum housing a line and configured to rotate about a rotational axis during extension and retraction of the line; a rotatable shaft rotatable around the rotational axis; and a transmission extending between the line drum and the rotatable shaft so that rotation of the line drum drives corresponding rotation of the rotatable shaft.

In an example, the transmission includes: a sun gear coupled to the rotatable shaft; an internal gear co-axial with the sun gear and fixed relative to the rotational axis; and a plurality of planet gears meshed with the sun gear and the internal gear, the plurality of planet gears are supported on the line drum. In another example, the line drum includes: a pair of drum plates; and a hub supported on the rotatable shaft, the line is wrapped around the hub and disposed between the pair of drum plates, and the hub includes a pair of substantially parallel planer surfaces. In yet another example, the hub further includes at least one arcuate projection configured to receive at least a portion of a short webbing for coupling the line to the line drum. In still another example, a housing has a nozzle that the line extends through, the nozzle includes a pair of covers that are pivotably coupled to the housing. In an example, a guide roller is proximate the nozzle, the guide roller is rotatably supported by a pair of shoulders defined by the housing.

In another example, a retraction assembly is coupled to the line drum, the retraction assembly includes: a hub supported on the rotatable shaft; a coil spring coupled to the hub; and a pair of flexible plates sandwiching the coil spring therebetween.

In another aspect, the technology relates to a line dispensing device including: a housing defining an interior cavity and an external cavity; a rotatable shaft rotatably supported by the housing and defining a rotational axis, wherein one end of the rotatable shaft is cantilevered within the external cavity; and a braking assembly at least partially disposed within the external cavity and configured to apply a braking force on the rotatable shaft, wherein the braking assembly includes: a stator assembly coupled to the housing; and a rotor assembly coupled to the rotatable shaft and rotatable around the rotational axis.

In an example, the stator assembly includes a pair of plates that have an outer perimeter with one or more male pins that selectively engage with corresponding female receptors defined within the external cavity. In another example, the rotor assembly includes: a pair of rotor plates having at least one bent tab extending therefrom; one or more conductors pivotably coupled to the pair of rotor plates; and at least one biasing element extending between the at least one bent tab and the one or more conductors. In yet another example, the biasing element includes hooks or loops at each end that directly engage with the at least one bent tab and the one or more conductors. In still another example, the line dispensing device further includes: a line drum supported on the rotatable shaft and configured to rotate around the rotational axis; and a retraction assembly supported on the rotatable shaft and configured to rotate around the rotational axis. In an example, the housing defines at least one mounting aperture, and a bushing is coupled to the at least one mounting aperture.

These and various other features as well as advantages that characterize the line dispensing devices described herein will be apparent from a reading of the following detailed description and a review of the associated drawings. Additional features are set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the technology. The benefits and features of the technology will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

It is to be understood that both the foregoing introduction and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

The following drawing figures, which form a part of this application, are illustrative of described technology and are not meant to limit the scope of the invention as claimed in any manner, which scope shall be based on the claims appended hereto.

This disclosure describes examples of a line dispensing device, such as an auto belay device used for climbing activities. Although, the features of the line dispensing device described herein can also be used in any other line braking system (e.g., industrial or occupational descender devices, such as personnel, equipment, or training, recreational descender devices, such as conveyances, rides, trolleys, ziplining, free-fall devices, and the like) as required or desired. The line dispensing device provides various improvements for an eddy current braking assembly so as to generate a braking force on the line and control descent of a load attached to the line. However, it should be appreciated that improvements to other operational systems (e.g., line drums, retraction assemblies, etc.) can be used in any other type of line dispensing device (e.g., frictional braking, hydraulic braking, electromagnetic braking, etc.).

In the line dispensing device described herein, features are described that increase the performance of the device. For example, increased reactivity of the braking and retraction assemblies so that the device is more responsive to climbers needs. In another example, the life-cycle of the device is increased by increasing its loading capacity. Additionally, features are described that increase manufacturing and assembly efficiencies. For example, the entire device is enabled to be more quickly and accurately assembled and disassembled (e.g., during service and inspection processes). Accordingly, a higher performing and more efficient line dispensing device is provided.

The line dispensing device includes a housing with an interior cavity and an exterior cavity and a rotatable shaft rotatably mounted thereto. A braking assembly is at least partially coupled to the rotatable shaft and disposed in the exterior cavity. A line drum that houses a main line for the device and a retraction assembly are supported on the rotatable shaft and disposed in the interior cavity. By separating the braking assembly from the rest of the device components, heat generated during use is more efficiently dissipated, thereby increasing performance. Additionally, the braking assembly uses a rotor assembly and a stator assembly so as to decrease the number of rotating components in the device. This results in a system that has a decreased mass and a more efficient rotational moment of inertia when extending and retracting the loaded line.

Additional features of the line dispensing device include components that are sized and shaped to be coupled together in only one orientation and direction. This reduces the overall number of components and increases assembly and disassembly efficiencies. A redundant transmission system is utilized to couple the line drum to the rotatable shaft to drive rotation thereof. By creating a redundant system, the torque loads induced across each component are reduced, thereby increasing the life-cycle capabilities of the device. Further improvements include a nozzle that does not completely release from the housing so that line maintenance and replacement is easier and component parts are not lost or dropped. Many other features of the line dispensing device are described further below.

As used herein, the terms "axial" and "longitudinal" refer to directions and orientations, which extend substantially parallel to a centerline of the component or system. Moreover, the terms "radial" and "radially" refer to directions and orientations, which extend substantially perpendicular to the centerline of the component or system. In addition, as used herein, the term "circumferential" and "circumferentially" refer to directions and orientations, which extend arcuately about the centerline of the component or system.

<FIG> is a side view of an exemplary line dispensing device <NUM>. The line dispensing device <NUM> includes a main line <NUM> that is configured to be attached to a user (e.g., climber) via a carabiner (not shown), and can be retracted into a housing <NUM> as the user climbs and be controllably extended when loaded (e.g., when the climber falls). As used herein, the term "line" refers to any cable, rope, string, chain, wire, webbing, strap, or any other length of flexible material. The line dispensing device <NUM> has a nozzle <NUM> disposed at a bottom end of the housing <NUM> that is configured to enable the line <NUM> to extend out of the housing <NUM>. The nozzle <NUM> is described further below in reference to <FIG>. At the top end of the housing <NUM>, a mounting aperture <NUM> is formed. Additionally, a secondary mounting aperture <NUM> and a handle <NUM> are formed to either side of the mounting aperture <NUM>. The mounting apertures <NUM>, <NUM> are configured to couple the line dispensing device <NUM> to a support structure (e.g., a climbing wall).

In some examples, a bushing <NUM> may line the apertures <NUM>, <NUM>. The bushing <NUM> decreases wear on the housing <NUM> from the coupling device(s) (e.g., a carabiner) and are replaceable as required or desired. Additionally, the bushing <NUM> can decrease friction between the housing <NUM> and the coupling device(s) so that the line dispensing device <NUM> can more easily move around during use. Furthermore, the bushing <NUM> can reduce dynamic vibrations (e.g., provide a damper) between the line dispensing device <NUM> and the support structure. These vibrations may generate a resonance condition that is undesirable. One example of the bushing <NUM> is described further below in reference to <FIG>. In the example, one or more covers <NUM> can at least partially cover the housing <NUM>. The cover can be utilized to cover components and/or provide a surface for product identification and/or color. In an aspect, the cover <NUM> is attached with molded tabs that connect with the housing <NUM>. In other aspects, the cover <NUM> can be attached with one or more fasteners (e.g., bolts).

<FIG> is an exploded perspective view of the line dispensing device <NUM>. The main line <NUM> and the cover <NUM> (both shown in <FIG>) are not illustrated for clarity. In the example, the housing <NUM> is a two piece housing <NUM>, <NUM> that is coupled together with a plurality of fasteners <NUM> (e.g., bolts). This coupling allows for the components within the housing <NUM> to be accessed for inspection and maintenance. The line dispensing device <NUM> includes a braking assembly <NUM> that is configured to apply a braking force to the line as it extends, a line drum <NUM> configured to house the line and allow the line to extend and retract therefrom, and a retraction assembly <NUM> that is configured to retract the line when the line is not loaded. The retraction assembly <NUM> includes coil spring (not shown) that provides the retraction force. The line drum <NUM> is described further below in reference to <FIG> and the retraction assembly <NUM> is described further below in reference to <FIG>.

In the example, the housing <NUM> forms an interior cavity <NUM> via the housing sections <NUM>, <NUM>. The line drum <NUM> and the retraction assembly <NUM> are disposed within the interior cavity <NUM>. Additionally, both the line drum <NUM> and the retraction assembly <NUM> are supported on a rotatable shaft <NUM> that is rotatably supported within the housing <NUM> by a pair of bearings <NUM>. In the example, both the line drum <NUM> and the retraction assembly <NUM> are rotatable within the housing <NUM>. The braking assembly <NUM> is disposed outside of the interior cavity <NUM> and within an exterior cavity <NUM> formed on one of the housing sections <NUM>. It should be appreciated that the cover <NUM> may at least partially cover the braking assembly <NUM> so that it is not completely exposed on the line dispensing device <NUM>.

The rotatable shaft <NUM> enables increased safety of the line dispensing device <NUM> (e.g., gear redundancy), increased functionality of the line dispensing device <NUM> (e.g., attachment of one or more accessory mechanisms), and increased ability to more reliably and accurately sense, track, and be responsive to status conditions of components (e.g., velocity, change of directions, amount of line dispensed, etc.) during operation of the line dispensing device <NUM> and as described further herein. In contrast, most, if not all, currently known line dispensing devices have a fixed shaft with components that rotate relative to the fixed shaft.

The braking assembly <NUM> includes a rotor assembly <NUM> and a stator assembly <NUM>. The rotor assembly <NUM> is coupled to the rotatable shaft <NUM> and thus is also rotatable within the line dispensing device <NUM>. In contrast, the stator assembly <NUM> is coupled to the housing section <NUM> and thus is fixed with respect to rotation. In the example, the braking assembly <NUM> is an eddy current braking mechanism with the rotor assembly <NUM> having a plurality of conductors <NUM> and the stator assembly <NUM> having a plurality of magnets <NUM>. In operation, upon rotation of the rotor assembly <NUM> the generated centrifugal forces radially displace the conductors <NUM> in a direction towards the magnets <NUM> so that braking forces are generated. The braking assembly <NUM> is described further below in reference to <FIG>. Additionally, eddy current braking mechanisms similar in function for line dispensing devices are described in <CIT> and <CIT>. As described herein, the braking assembly <NUM> is an eddy current braking device. It should be appreciated, however, that the braking assembly <NUM> could be any other braking device that enables the line dispensing device <NUM> to function as described herein. For example, the braking device could be a hydraulic braking device, a friction braking device (e.g., drum and pads or rotor and pads), an electromagnetic braking device, or the like.

In the example, the rotatable shaft <NUM> is supported on the housing sections <NUM>, <NUM> by the pair of bearings <NUM> and one bearing <NUM> is offset and inwards from one end of the shaft <NUM>. As such, one end of the rotatable shaft <NUM> cantilevers into the exterior cavity <NUM> and supports the rotor assembly <NUM>. In an aspect, the cantilevered end of the rotatable shaft <NUM> is shorter in length than the length of the shaft <NUM> between the bearings <NUM>. In the example, the line drum <NUM> and the retraction assembly <NUM> are each disposed between the bearings <NUM> on the rotatable shaft <NUM>.

By isolating the braking assembly <NUM> from the line drum <NUM> and the retraction assembly <NUM>, thermal control of the braking assembly <NUM> is increased, thereby increasing performance of the line dispensing device <NUM>. During operation of the braking assembly <NUM>, eddy current braking forces can generate heat. The housing section <NUM> can act as a thermal barrier to reduce or prevent heat from adversely affecting the line drum <NUM> and the retraction assembly <NUM>. Furthermore, the exterior cavity <NUM> can be more effectively passively cooled, (e.g., via vents) with only the braking assembly <NUM> disposed therein. Additionally, by reducing the span lengths of the rotatable shaft <NUM> that support the operational systems, bending forces are reduced on the shaft <NUM>, thereby increasing performance and resistance to wear (e.g., from shipping and maintenance).

Furthermore, in this example, the number and size of rotatable components are decreased, thereby also decreasing mass. For example, the magnets <NUM> are stationary and not rotatable. Additionally, all of the rotatable components rotate around a single rotational axis. Thus, the inertia of the rotatable components is reduced so that the braking assembly <NUM> and the retraction assembly <NUM> are faster to respond during operation of the line dispensing device <NUM> since they are at least partially dependent on rotation. This configuration results in increase responsiveness to user's climbing movements and improved performance.

The line dispensing device <NUM> also includes a guide roller <NUM> that is disposed proximate the nozzle <NUM>. When the line <NUM> wraps and unwraps from the line drum <NUM>, the line rolls over the guide roller <NUM> so as to position the line relative to the nozzle <NUM> and exit from the housing <NUM>, as well as inducing a smoother extension and retraction of the line without twisting thereof. In the example, the guide roller <NUM> is rotatable about a fastener <NUM> that is also used to couple the two housing sections <NUM>, <NUM> together. The guide roller <NUM> is also elongated in the axial direction. In an aspect, the axial length of the guide roller <NUM> is twice or more the thickness of the line <NUM>. In another aspect, the axial length of the guide roller <NUM> is greater than the axial distance between two drum plates <NUM>, <NUM> of the line drum <NUM> and which the line is disposed between. The guide roller <NUM> is described further below in reference to <FIG>.

<FIG> is a cross-sectional view of the line dispensing device <NUM>. Certain components are described above, and thus, are not necessarily described further. The rotatable shaft <NUM> defines a rotational axis <NUM> that a number of components rotate about. The rotatable shaft <NUM> is rotatably coupled to and supported by the housing sections <NUM>, <NUM> at the bearings <NUM> so that the shaft <NUM> can rotate around the axis <NUM>. The cantilevered end of the rotatable shaft <NUM> is disposed within the exterior cavity <NUM> of the housing section <NUM>. The cantilevered end is coupled to the rotor assembly <NUM> of the braking assembly <NUM> so that rotation of the rotatable shaft <NUM> directly drives the rotor assembly <NUM> (e.g., during operation the shaft <NUM> and the rotor assembly <NUM> rotate at the same speed). The braking assembly <NUM> also includes the stator assembly <NUM> which the rotor assembly <NUM> and the rotatable shaft <NUM> rotates relative thereto. The stator assembly <NUM> includes an inside plate <NUM> supporting a plurality of magnets <NUM> and an outside plate <NUM> supporting a plurality of magnets <NUM>. Both plates <NUM>, <NUM> are supported by the housing section <NUM> and fixed relative to the rotational axis <NUM>. The magnets <NUM> of each plate <NUM>, <NUM> face each other and a gap <NUM> is formed therebetween. The rotor assembly <NUM> includes a plurality of conductors <NUM> that can be displaced at least partially into the gap <NUM> so as to generate a braking force. The rotor assembly <NUM> is coupled to the rotatable shaft <NUM> by a nut <NUM>.

The rotatable shaft <NUM> is coupled to the line drum <NUM> by a transmission <NUM> so that rotation of the line drum <NUM> can drive rotation of the rotatable shaft <NUM>. In the example, the transmission <NUM> is a planetary gear system with a sun gear <NUM> that is coupled to and extends from the rotatable shaft <NUM>. In an aspect, the sun gear <NUM> is a spur gear. The planetary gear system also includes a plurality of planet gears <NUM> that are rotatably coupled to one of the drum plates <NUM> and an internal gear <NUM> coupled to and fixed to the housing section <NUM>. The planet gears <NUM> are meshed with both the sun gear <NUM> and the internal gear <NUM>, and in an aspect, are spur gears. The line drum <NUM> also includes a hub <NUM> that at least partially surrounds the rotatable shaft <NUM> and between the drum plates <NUM>, <NUM>. In the example, the hub <NUM> is supported on the rotatable shaft <NUM> by one or more bearings <NUM>, and as such, the line drum <NUM> can rotate around the rotational axis <NUM> at a different rotational speed than the rotatable shaft <NUM>.

The retraction assembly <NUM> is directly coupled to the hub <NUM> so that it rotates with the line drum <NUM>. In the example, one or more fasteners <NUM> (e.g., bolts) couple the retraction assembly <NUM> to the hub <NUM> of the line drum <NUM>. In <FIG>, the coil spring that provides retraction forces to the system is not illustrated for clarity. Additionally, the main line <NUM> (shown in <FIG>) that is configured to wrap and unwrap about the hub <NUM> of the line drum <NUM> is not illustrated for clarity.

In operation, the line <NUM> is wrapped at least partially around the hub <NUM> and a free end extends out of the housing <NUM> via the nozzle <NUM>. When the line <NUM> is extended and not loaded (e.g., a climber climbing up a climbing wall), the retraction assembly <NUM> is configured to rotate the line drum <NUM> around the rotational axis <NUM> so as to retract the line <NUM> back into the housing <NUM> and wrap around the hub <NUM>. This rotation of the line drum <NUM>, via the retraction assembly <NUM>, induces a corresponding, but not necessarily equal, rotation in the rotatable shaft <NUM> via the transmission <NUM>. The rotor assembly <NUM> also rotates via the rotatable shaft <NUM>. In the example, the braking assembly <NUM> generates an eddy current braking force during retraction of the line <NUM> via retraction assembly <NUM> so as to decrease wear on the coil spring of the retraction assembly <NUM>. Additionally, by generating a braking force during retraction of the line <NUM>, the retraction of the line is more controlled, for example, during unanticipated line releases.

When the line <NUM> is loaded (e.g., a climber falling from the wall), the line drum <NUM> is configured to rotate in the other direction, which overcomes the retraction force generated by the retraction assembly <NUM>, so that the line <NUM> extends from the housing <NUM> and unwraps from the hub <NUM>. This rotation of the line drum <NUM> induces a corresponding, but not necessarily equal, rotation in the rotatable shaft <NUM> via the transmission <NUM> to drive rotation of the rotor assembly <NUM> and extend the conductors <NUM> into the magnetic field of the magnets <NUM>. This generates an eddy current braking force on the rotatable shaft <NUM> to control the extension of the line from the housing <NUM> and the descent rate of the load attached thereto.

<FIG> is an exploded perspective view of the braking assembly <NUM>. Certain components are described above, and thus, are not necessarily described further. The braking assembly <NUM> is disposed at least partially within the exterior cavity <NUM> of the housing section <NUM>. The housing section <NUM> has a center opening <NUM> that is sized and shaped to support the rotatable shaft <NUM> via the bearing <NUM> (shown in <FIG>). The exterior cavity <NUM> is formed by a side wall <NUM> and a base wall <NUM>. The side wall <NUM> is a radial side wall relative to the rotational axis of the rotatable shaft <NUM>. The base wall <NUM> extends substantially orthogonally to the rotational axis of the rotatable shaft <NUM> and can provide a thermal barrier for the components disposed within housing and with respect to the braking assembly <NUM>. Additionally, the base wall <NUM> can include one or more mounting posts <NUM> that receive fasteners <NUM> so as to secure the inside magnet plate <NUM> to the housing section <NUM>. The side wall <NUM> includes one or more female receptors <NUM> that are sized and shaped to receive corresponding male pins <NUM>, <NUM> on the plates <NUM>, <NUM> in a bayonet type coupling connection. The outside magnet plate <NUM> can further be secured to the housing section <NUM> with one or more fasteners <NUM> (e.g., bolts).

In the example, the female receptors <NUM> within the side wall <NUM> can receive both male pins <NUM>, <NUM> from each plate <NUM>, <NUM>. As such, when the plates <NUM>, <NUM> are mounted to the housing section <NUM>, the male pins <NUM>, <NUM> can be positioned circumferentially offset from one another. By utilizing the structure of the housing section <NUM> as supports and connectors to the stator assembly <NUM>, efficiency and performance of the line dispensing device is increased. For example, assembly efficiencies are increased as the braking assembly <NUM> can only fit together in one configuration and there are less overall components to assemble. Additionally, performance is increased because the number of rotating components are decreased. Furthermore, although a bayonet type coupling connection is shown and described, it is appreciated that the stator assembly <NUM> can be mounted within the exterior cavity <NUM> via any other connection type as required or desired. In other examples, the male pins <NUM> on the inside magnet plate <NUM> need not to be used, and the inside magnet plate <NUM> can be only coupled to the housing section <NUM> via fasteners <NUM>. In still other examples, the male pins on the inside magnet plate <NUM> can be replaced by one or more notches (not shown) that are configured to engage with one or more corresponding protrusions (not shown) disposed within the exterior cavity <NUM> of the housing section <NUM>. In this example, the notches and protrusions are utilized for orienting the inside magnet plate <NUM> with respect to the housing section <NUM>.

<FIG> is an exploded perspective view of the rotor assembly <NUM> of the braking assembly <NUM> (shown in <FIG>). The rotor assembly <NUM> includes a pair of rotor plates <NUM>, <NUM> that are spaced apart by a spacer <NUM>. In the example, the plates <NUM>, <NUM> and the spacer <NUM> each have a square center opening that is configured to couple to the rotatable shaft <NUM> (shown in <FIG>). In other examples, a spline connection can be utilized as required or desired. For example, the spacer can have a center opening shaped for a spline that is on the rotatable shaft <NUM> and the spacer can have a first end that engages with a first plate and a second end that engages with a second plate, and the first end and the second end can be different from one another. The spacer <NUM> has projections <NUM> disposed on each side that are shaped and sized to align with corresponding holes <NUM> on each plate <NUM>, <NUM>. In an aspect, the projections <NUM> are asymmetrically spaced with regards to each other. Accordingly, the plates <NUM>, <NUM> can only be attached in a specific orientation so that the plates <NUM>, <NUM> can align with each other. This configuration increases assembly efficiencies of the rotor assembly <NUM>. In the example, the rotor plates <NUM>, <NUM> are substantially circular. In other examples, the rotor plates <NUM>, <NUM> can be any other shape as required or desired (e.g., triangular, square, etc.).

A plurality of conductors <NUM> are pivotably mounted between the rotor plates <NUM>, <NUM> at fasteners <NUM> (e.g., through bolts) that extend through openings <NUM> in the plates <NUM>, <NUM>. In an aspect, three conductors <NUM> are included in the rotor assembly <NUM> and are formed from a non-ferritic material (e.g., a high grade aluminum for greater conductivity and increased braking performance). The conductors <NUM> include a pin <NUM> that is configured to be slidable received within tabbed openings <NUM> defined within each plate <NUM>, <NUM>. A spring tab <NUM> extends axially from the plates <NUM>, <NUM> and is disposed proximate the tabbed openings <NUM>. Each conductor <NUM> includes one or more biasing elements <NUM> (e.g., tension springs on each plate side) that are connected at one end to the pin <NUM> and at the other end to the tab <NUM>. In operation, centrifugal forces induced on the conductors <NUM> from rotation of the rotor assembly <NUM> cause the conductors <NUM> to radially extend out from between the plates <NUM>, <NUM>. This movement generates braking forces due to interaction with a corresponding magnetic field, and the system is described further in <CIT> and <CIT>.

In this example, the biasing elements <NUM> have loops or hooks at each end so they can directly engage with the pin <NUM> and the tab <NUM> without the need for connection plate elements. Furthermore, the tab <NUM> is integral with the plates <NUM>, <NUM> so as to reduce the number of components and to simplify structural support of the conductors <NUM>. These configurations increase assembly efficiencies of the rotor assembly <NUM>. Additionally, by containing the components of the rotor assembly <NUM> with the plates <NUM>, <NUM> the entire assembly is easier to handle and move in and out of the line dispensing device. In the example, the spring tab <NUM> is adjacent and forms part of the tabbed opening <NUM>. In other examples, the spring tab <NUM> may be positioned outside from the opening <NUM>, but still adjacent thereto.

<FIG> is a plan view of the outside plate <NUM> of the stator assembly <NUM> of the braking assembly <NUM> (shown in <FIG>). <FIG> is a plan view of the inside plate <NUM> of the stator assembly <NUM>. Referring concurrently to <FIG>, both plates <NUM>, <NUM> form the stator assembly and are configured to be coupled to the housing section <NUM> (shown in <FIG>) so that they are fixed about the rotation axis. Magnets <NUM> are selectively coupled to the plates <NUM>, <NUM> so that the stator assembly forms a magnetic field. In the example, the magnets <NUM> are arranged in alternating north-south polarities and are grouped together in three circumferential sections of four magnets apiece for a total of twelve. In another example, the magnets <NUM> may be equidistantly spaced around the circumference of the plates <NUM>, <NUM> and alternating polarities. In this example, any number of magnets <NUM> can be used (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc.). In an aspect, a total number of magnets <NUM> may be <NUM>. When mounted in the stator assembly, the magnets <NUM> of each plate <NUM>, <NUM> face each other with the gap <NUM> (shown in <FIG>) formed therebetween. In an aspect, the illustrated number and layout of the magnets <NUM> increases performance and efficiency of the braking assembly. It should be appreciated that any other numbers and/or layouts of the magnets <NUM> can be used that enables the braking assembly to function as described herein. In the example, the magnets <NUM> can be a rare-earth magnet, such as, neodymium, so that the thickness and weight of the magnets <NUM> are reduced.

The outside plate <NUM> includes an outer ring section <NUM> that the magnets <NUM> are configured to mount to and an inner section <NUM>. The inner section <NUM> restricts access to the rotor assembly <NUM> (shown in <FIG>) when the braking assembly is installed in the line dispensing device and has a plurality of openings <NUM> so as to provide ventilation for the braking assembly. In other examples, the inner section <NUM> may be substantially solid with few or no openings <NUM>. For example, the openings <NUM> may be less than <NUM>%, or less than <NUM>%, of the total surface area of the inner section <NUM>. The outer perimeter of the outer ring section <NUM> includes male pins <NUM> that enable the outside plate <NUM> to be mounted to the housing section <NUM> (shown in <FIG>). The male pins <NUM> extend substantially orthogonally from the outer ring section <NUM>. In the example, the male pins <NUM> are at least partially received by the female receptors <NUM> of the housing section <NUM> (shown in <FIG>) so that the outside plate <NUM> is mounted to the housing and can be offset and spaced from the inside plate <NUM>. Adjacent the male pins <NUM>, the outer perimeter of the outer ring section <NUM> includes a cutout <NUM> that receives a portion of the female receptors <NUM> to further secure the placement of the outside plate <NUM> in the housing. In other examples, the one or more protrusions (not shown) may extend within the cutout <NUM> and are configured to engage with the housing as required or desired. The outer perimeter of the outer ring section <NUM> can also include one or more notches <NUM> that receive at least a portion of the fastener <NUM> (shown in <FIG>) so that the outside plate <NUM> can be fastened to the housing.

The outer ring section <NUM> also includes a plurality of keys <NUM> extending therefrom and a plurality of lugs <NUM> extending therefrom. The keys <NUM> and the lugs <NUM> are configured to correctly place and space the magnets <NUM> attached thereto. The lugs <NUM> are circumferentially arranged so that a magnet <NUM> can be placed between a pair of lugs <NUM>. As such, the correct array of magnets <NUM> are easily achieved when the stator assembly is being assembled. The magnets <NUM> themselves are magnetically coupled to the outside plate <NUM> and adhesive or glue is not necessarily required. The lugs <NUM> also restrict or prevent circumferential movement of the magnets <NUM> on the outer ring section <NUM>. Additionally, because the plate <NUM> is stationary in the line dispensing device, the thickness of the plate <NUM> can be reduced to save weight without attenuating braking power. In the example, the lugs <NUM> are substantially cylindrical in shape. In other examples, the lugs <NUM> can be of any other shape as required or desired.

Each magnet <NUM> includes an aperture <NUM> that is configured to receive the key <NUM>. The aperture <NUM> is offset from a centerline of the magnet <NUM> and the key <NUM> is disposed between the pair of lugs <NUM>, but also offset from a centerline between the pair of lugs <NUM>. This arrangement of the keys <NUM> requires a predetermined placement of the magnets <NUM> so as to ensure the correct north-south polarity at the specific location on the plate <NUM>. That is, the structure of the plate <NUM> (e.g., via the keys <NUM>, the lugs <NUM>, and the apertures <NUM>) forces the magnets <NUM> to be installed in the correct polarity, because if the polarity is reversed, the keys <NUM> do not align with the apertures <NUM>.

The inside plate <NUM> also includes an outer ring section <NUM> that the magnets <NUM> are configured to mount to. In the example, the inner section of the inside plate <NUM> is free from any structure to reduce weight thereof. The outer perimeter of the outer ring section <NUM> includes male pins <NUM> that enable the inside plate <NUM> to be mounted to the housing section <NUM>. In the example, the male pins <NUM> include radially long pins <NUM> and radially short pins <NUM> that both selectively engage with the female receptors <NUM> of the housing section <NUM> so as to ensure proper plate <NUM> placement. Additionally or alternatively, one or more notches (not shown but similar to the notch <NUM> shown in the plate <NUM>) may be defined on the outer perimeter of the outer ring section <NUM> and used to orient the inside plate <NUM> with respect to the housing. The inside plate <NUM> also includes one or more holes <NUM> that receive the fastener <NUM> (shown in <FIG>) so as to secure the plate <NUM> to the housing section <NUM> at the mounting posts <NUM> (shown in <FIG>).

The inside plate <NUM> also includes keys <NUM> and lugs <NUM> to ensure assembly of the stator assembly in the correct north-south polarity configuration of the magnets <NUM>. The male pins <NUM>, <NUM> of each plate <NUM>, <NUM> are configured to selectively engage with the housing section <NUM> so that the plates <NUM>, <NUM> and magnets <NUM> can only be mounted in a single orientation and to prevent incorrect assembly. In an aspect, both plates <NUM>, <NUM> can be formed from a ferritic material so that the magnets <NUM> are attracted to the plate and can be attached without glue, and the thickness of both the outside plate <NUM> and the inside plate <NUM> can be substantially equal so as to increase manufacturing efficiencies.

<FIG> is an exploded perspective view of the line drum <NUM>. The line drum <NUM> is configured to house the main line <NUM> (shown in <FIG>) as it extends and retracts from the line dispensing device. As the line extends and retracts from the line dispensing device, the line drum <NUM> rotates around the rotational axis <NUM> (shown in <FIG>) and drives corresponding rotation of the rotatable shaft <NUM>. In the example, the line drum <NUM> includes a pair of drum plates <NUM>, <NUM> that are spaced apart from one another so that the line can be disposed therebetween. The drum plate <NUM> includes the hub <NUM> extending from one side that the line is wrapped around. The hub <NUM> is mounted to the rotatable shaft <NUM> by bearings <NUM>. The bearings <NUM> enable the hub <NUM> and the drum plate <NUM> to rotate around the rotational axis and the rotatable shaft <NUM> to rotate. However, the hub <NUM> and the drum plate <NUM> can also rotate relative to the rotatable shaft <NUM> and at a different rotational speed.

The line drum <NUM> also includes the transmission <NUM> that translates rotation of the hub <NUM> and drum plate <NUM> to rotation of the rotatable shaft <NUM>. The transmission <NUM> includes the internal gear <NUM> that is statically mounted to the housing section <NUM> (shown in <FIG>) by fasteners <NUM>. In an aspect, fasteners <NUM> are used to mount both the inside plate <NUM> of the stator assembly <NUM> (shown in <FIG>) and the internal gear <NUM> to the housing section. The sun gear <NUM> is coupled to the rotatable shaft <NUM> and rotatable around the rotational axis of the shaft. Meshed with both the internal gear <NUM> and the sun gear <NUM> are three planet gears <NUM>. Each planet gear <NUM> is rotatably mounted to the drum plate <NUM> with bearings <NUM> on a shaft projection <NUM>. The shaft projections <NUM> extend on the opposite side of the drum plate <NUM> from the hub <NUM> and are positioned radially outward from the rotational axis. In operation, rotation of the drum plate <NUM> via the extension and retraction of the line, drives rotation of the rotatable shaft <NUM> via the transmission <NUM>. In an aspect, the transmission <NUM> may increase the rotational speed of the shaft <NUM> from the drum plate <NUM>. In other examples, the transmission <NUM> can decrease the rotational speed, or maintain substantially the same rotational speed, of the shaft <NUM> from the drum plate <NUM>, as required or desired. The rotational speed of the shaft <NUM> is based on the gear ratio between the gears <NUM>, <NUM>, and <NUM>.

In the example, three planet gears <NUM> are shown and by using a plurality of planet gears <NUM> a redundant load bearing system is formed. Additionally, by transferring torque over three gears <NUM> instead of one gear, the torque is distributed over three components instead of one component so that the life-cycle of the transmission <NUM> is increased. Furthermore, the transmission <NUM> can operate with increased torque loads. It should be appreciated that any other number of planet gears, for example, two, four, five, etc., can also provide similar benefits to the transmission <NUM> described herein.

<FIG> is a plan view of the transmission <NUM> of the line drum <NUM>. Certain components are described above, and thus, are not necessarily described further. As illustrated in <FIG>, the planet gears <NUM> are disposed radially outward from the rotatable shaft <NUM>. Each planet gear <NUM> is coupled to the drum plate <NUM> and has its own rotation axis that is substantially parallel to, but radially offset, from the rotation axis of the rotatable shaft <NUM>. In the example, the internal gear <NUM> is mounted and fixed to the housing section <NUM> (shown in <FIG>). In other examples, the internal gear <NUM> may be mounted to the drum plate <NUM> to drive rotation of the rotatable shaft <NUM> and the planet gears <NUM> floating between. The internal gear <NUM>, the sun gear <NUM>, and the rotatable shaft <NUM> are all co-axial. Additionally, the transmission <NUM> (e.g., internal gear <NUM>, planet gears <NUM>, and sun gear <NUM>) are all aligned on the same reference plane.

<FIG> is a plan view of the hub <NUM> of the line drum <NUM> (shown in <FIG>). The hub <NUM> extends from the drum plate <NUM> and is co-axial with the rotatable shaft <NUM> (shown in <FIG>). The hub <NUM> and the drum plate <NUM> are configured to house the main line <NUM> (shown in <FIG>) and the line <NUM> is wrapped at least partially around the hub <NUM>. In the example, the line <NUM> is coupled to the hub <NUM> by a short webbing <NUM>. This configuration enables for the line <NUM> to be replaced as required or desired without disassembly of the line dispensing device. The short webbing <NUM> includes a loop <NUM>, a thickened reinforced section <NUM>, and a shackle <NUM>. The shackle <NUM> is used to attach the main line <NUM> to the short webbing <NUM>. The hub <NUM> includes two opposing planer surfaces <NUM> and two opposing arcuate projections <NUM> spaced from the hub <NUM>. In operation the loop <NUM> of the short webbing <NUM> is coupled to one arcuate projection <NUM> without the requirement of a pin.

When the short webbing <NUM> is wrapped around the hub <NUM>, the thickened reinforced section <NUM> and the shackle <NUM> are thicker sections that can form bumps in the line <NUM> as it wraps around the hub <NUM>. As such, the planer surfaces <NUM> are used so that when the short webbing <NUM> is wrapped around the hub <NUM>, the thickened reinforced section <NUM> and the shackle <NUM> are disposed proximate the planer surfaces <NUM> so that the line <NUM> can more concentrically wrap around the hub <NUM> without any undesirable bumps. That is, the planer surfaces <NUM> form space in the hub <NUM> for the thickened reinforced section <NUM> and shackle <NUM> to sit within the line drum. The hub <NUM> also includes one or more openings <NUM> that are configured to receive fasteners <NUM> (shown in <FIG>) for coupling the other drum plate <NUM> (shown in <FIG>) to the hub <NUM>. The configuration of the hub <NUM> and the transmission <NUM> (shown in <FIG>) are also configured so that the line drum can only be installed in one configuration to increase assembly efficiencies.

<FIG> is an exploded perspective view of the retraction assembly <NUM>. The retraction assembly <NUM> is coupled to the drum plate <NUM> of the line drum <NUM> (shown in <FIG>) and is configured to rotate the line drum <NUM> to retract the main line <NUM> (shown in <FIG>) into the line dispensing device. The retraction assembly <NUM> includes a hub <NUM> that couples to the hub <NUM> of the line drum <NUM> (shown in <FIG>) with fasteners <NUM> so that the hub <NUM> rotates directly therewith. In the example, the drum plate <NUM> has one or more center openings <NUM> that can receive features of the hub <NUM>. The hub <NUM> couples to a coil spring <NUM> that provides the retracting force for the system. A spacer <NUM> is disposed between the hub <NUM> and the rotatable shaft <NUM> so that while the hub <NUM> is co-axial with the rotatable shaft <NUM> each component can rotate at different speeds. In the example, the hub <NUM> couples to the drum plate <NUM>. In other examples, the hub <NUM> may be integrally formed with the drum plate <NUM>.

In the example, the coil spring <NUM> of the retraction assembly <NUM> is axially positioned between two plates <NUM>. The plates <NUM> can be formed from a flexible light weight plastic-based material that is not coupled to the coil spring or the hub <NUM>. By sandwiching the coil spring <NUM> between two plates <NUM>, the coil spring <NUM> can more easily be assembled onto and removed from the hub <NUM> without the coil spring <NUM> axially de-coiling. In an aspect, the plates <NUM> are identically circular in shape with a center opening <NUM> that the hub <NUM> is disposed within. In another aspect, the plates <NUM> may have different shapes and/or each plate <NUM> may have a different shape. The plates <NUM> also enable the coil spring <NUM> to be more easily inspected without disassembly and removal. For example, the housing section <NUM> may include one or more slots <NUM> that allow the coil spring <NUM> within the plates <NUM> to be inspected and that assist in removing the coil spring <NUM> from the housing.

<FIG> is another side view of the line dispensing device <NUM>. Certain components are described above, and thus, are not necessarily described further. Additionally, the cover <NUM> (shown in <FIG>) has been removed for clarity. The housing section <NUM> has a center opening <NUM> that aligns with the rotatable shaft <NUM>. The opening <NUM> allows access to the rotatable shaft <NUM> from the exterior of the housing <NUM> as required or desired. For example, the rotatable shaft <NUM> may include a female spline connector <NUM> that allows another shaft to be coupled thereto and rotation driven. It should be appreciated that the rotatable shaft <NUM> may include any other type of connector that allows another shaft to be coupled to it and rotational movement transferred therebetween. This accessibility to the rotatable shaft <NUM> allows for accessory mechanism(s) to be coupled to the line dispensing device <NUM>. In an aspect, a secondary braking device (e.g., an electromagnetic braking device) may be coupled to the line dispensing device <NUM> to provide lock-off functionality as described in <CIT>. In another aspect, a counter mechanism can be attached to the line dispensing device <NUM> so as to count, for example, loading cycles or climber cycles.

<FIG> is a perspective view of the nozzle <NUM> in a partially open configuration. <FIG> is a perspective view of a portion of the nozzle <NUM>. Referring concurrently to <FIG>, the nozzle <NUM> is disposed at the bottom of the housing <NUM> and is the location where the main line <NUM> (shown in <FIG>) extends from the housing <NUM>. The nozzle <NUM> defines a slit <NUM> that the line <NUM> extends through. In the example, the slit <NUM> is lined with a low-fiction liner <NUM> so as to reduce wear on the line and to reduce or prevent twisting of the line during use. The nozzle <NUM> is formed from two covers <NUM> that engage with the housing <NUM> and a pin <NUM> that locks the covers <NUM> in place. When the pin <NUM> is removed, the covers <NUM> can pivot open relative to the housing <NUM> so as to allow access to the line disposed therein. For example, the nozzle <NUM> is opened to replace the line and access the shackle <NUM> on the short webbing <NUM> (shown in <FIG>). The covers <NUM> can then close back up and locked via the pin <NUM> extending through holes <NUM>. Each cover <NUM> can include a pivot pin <NUM> that engages with the housing <NUM> and allows the cover <NUM> to pivot between an open and a closed configuration. In some examples, the cover <NUM>, via the pivot pins <NUM>, can slide within a track <NUM> defined in the housing <NUM> as required or desired. By engaging the covers <NUM> with the housing <NUM>, the nozzle <NUM> stays attached to the housing <NUM> during opening, thereby increasing accessibility to the line and decreasing lost components during maintenance operations. In some examples, the pivot pins <NUM> can be formed on a resilient arm so that the covers <NUM> can be releasably coupled to the track <NUM>.

<FIG> is a partial cross-sectional view of the guide roller <NUM>. The guide roller <NUM> is disposed within the housing <NUM> proximate to the nozzle <NUM> (shown in <FIG>) so as to guide the main line (shown in <FIG>) as it extends from and retracts into the housing <NUM>. The guide roller <NUM> is substantially cylindrical with two symmetric ends <NUM> that have a countersunk bore. Additionally, a through hole <NUM> extends the entire length of the guide roller <NUM>. The guide roller <NUM> is supported by the fastener <NUM> (shown in <FIG>) that extends through the through hole <NUM> and is freely rotatable therearound. Both housing sections <NUM>, <NUM> have a shoulder <NUM> that the ends <NUM> of the guide roller <NUM> can be supported on. This increases assembly efficiencies of the line dispensing device as it is easier to keep the roller <NUM> properly positioned with when coupling together the housing sections.

<FIG> is a side view of a mount damper <NUM> coupled to the housing <NUM> of the line dispensing device <NUM>. <FIG> is a perspective view of the mount damper <NUM>. Referring concurrently to <FIG> and as described above in reference to <FIG>, bushings my line one or more mounting apertures <NUM> that are used to couple the line dispensing device <NUM> to a support structure. The bushing decreases wear on the housing <NUM> from the coupling device used and are replaceable as required or desired. Additionally, the bushing can decrease friction and reduce dynamic vibrations on the coupling device. In this example, the mount damper <NUM> is one example of a bushing that can be used with the line dispensing device <NUM>.

The mount damper <NUM> has a substantially hollow cylindrical body <NUM> with a first end <NUM> and a second end <NUM>. The first end <NUM> has a first flange <NUM> extending therefrom and the flange <NUM> is continuous around the perimeter of the first end <NUM>. The second end <NUM> has a second flange <NUM> extending therefrom and the flange <NUM> is discontinuous around the perimeter of the second end <NUM>. For example, the second flange <NUM> is separated into four discrete sections. The flanges <NUM>, <NUM> protect at least a portion of the sides of the housing <NUM> from the coupling device. Additionally, the body <NUM> is formed from an elastomeric material so that the second flange <NUM> can be inserted into the aperture <NUM> by at least partially compressing its diameter to be smaller than the aperture <NUM> via the sectional second flange <NUM>.

In operation, the coupling devices (e.g., carabiner) utilized to couple the line dispensing device <NUM> to a support structure can induce wear on the housing <NUM> at the mounting aperture <NUM>. The mount damper <NUM> is a sacrificial component that is easily replaceable to protect the housing <NUM> and absorb the wear from the coupling device. Additionally, the mount damper <NUM> provides shock absorption such that vibrations are reduced or prevented from being transmitting between the housing <NUM> and the coupling device.

<FIG> is a plan view of another hub <NUM> that can be used with the line drum <NUM> (shown in <FIG>). Similar to the example described above in <FIG>, the hub <NUM> extends from the drum plate <NUM> and is co-axial with the rotatable shaft <NUM> (shown in <FIG>). The hub <NUM> and the drum plate <NUM> are configured to house the main line <NUM> (shown in <FIG>) and the line <NUM> is wrapped at least partially around the hub <NUM>. In this example, the hub <NUM> is cylindrical with a single arcuate projection <NUM> spaced from the hub <NUM>. In an aspect, the projection <NUM> may extend between about <NUM>° to <NUM>° around the hub <NUM>. In another aspect, the projection <NUM> may extend approximately <NUM>° around the hub <NUM>. In operation, the projection <NUM> is utilized to attach the line <NUM> to the hub <NUM>. In some examples, a short webbing can be used. The free end of the hub <NUM> can include one or more lugs <NUM> used to engage and transfer rotation to the other drum plate <NUM> (shown in <FIG>).

It will be clear that the systems and methods described herein are well adapted to attain the ends and advantages mentioned as well as those inherent therein. Those skilled in the art will recognize that the methods and systems within this specification may be implemented in many manners and as such is not to be limited by the foregoing exemplified embodiments and examples, but only by the appended claims. It is to be understood that terminology employed herein is used for the purpose of describing particular examples only and is not intended to be limiting. It must be noted that, as used in this specification, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

Claim 1:
A line dispensing device (<NUM>) comprising:
a housing (<NUM>) defining an interior cavity (<NUM>) and an external cavity (<NUM>);
a rotatable shaft (<NUM>) rotatably supported by the housing and defining a rotational axis (<NUM>), wherein one end of the rotatable shaft is cantilevered within the external cavity;
a line drum (<NUM>) disposed about the rotational axis and configured to extend and retract a line (<NUM>) from the housing;
a transmission (<NUM>) extending between the line drum and the rotatable shaft so that rotation of the line drum drives corresponding rotation of the rotatable shaft;
a retraction assembly (<NUM>) disposed about the rotational axis and configured to generate a retraction force and retract the line from the housing; and
a braking assembly (<NUM>) disposed about the rotational axis and configured to generate a braking force on the rotatable shaft and during extension of the line from the housing, the braking assembly at least partially disposed within the external cavity, wherein the braking assembly comprises:
a stator assembly (<NUM>) coupled to the housing; and
a rotor assembly (<NUM>) coupled to the cantilevered portion of the rotatable shaft and rotatable around the rotational axis.