Abstract: A winding machine having a user-defined pitch between rotation of a form and translation of a point of winding material along the form, reduces damaging accelerative forces on the machine components by a slight modulation of the pitch near travel-reversal of the point of winding. The pitch of the windings over most of the form is unaffected and rotational speed of the form need not be modified.

Abstract: A precision method is defined for identifying defective sections of a spoolable material for removal. Defective sections are noted during manufacture and the spool containing the material is subsequently unwound to allow removal of the defective sections. The invention uses rotation data corresponding to the location on the spool where the fiber contains defects. A process controller records rotational positioning data from the take-up spool during manufacturing and uses the information to locate the defect when unwinding the spool. In addition, the pitch of winding the fiber onto the spool may be altered during manufacturing to indicate the beginning and end of a defective section. In this instance, the defective portion of the fiber can be determined during unwinding by monitoring the pitch width of the material. Finally, an algorithm for defining cut out bands adjacent to the defective sections aid in ensuring that no remaining defective fiber remains.

Abstract: The present invention includes systems and methods for monitoring the spooling area of a rotatable reel for winding or unwinding an elongated material, for example, a cable. The monitoring system has a detector for sensing the presence and position of a cable surface or object or operator positioned between the detector and the reel. The detector can control rotation of the reel directly, or send a position signal to a computer where the position signal indicates the detected presence and/or position. The computer can have a memory and/or a processor for respectively storing and analyzing the position signal. The computer is operative to compare the position signal to previously received position signals to determine a condition, for example, the amount of cable on the reel, the presence of any object, and/or the existence of a safety-threatening condition. The computer can generate an output signal for use in, for example, controlling the reel speed and/or torque, or the application of brakes.

Abstract: The present invention includes systems and methods for monitoring the spooling area of a rotatable reel for winding or unwinding an elongated material, for example, a cable. The monitoring system has a detector for sensing the presence and position of a cable surface or object or operator positioned between the detector and the reel. The detector can control rotation of the reel directly, or send a position signal to a computer where the position signal indicates the detected presence and/or position. The computer can have a memory and/or a processor for respectively storing and analyzing the position signal. The computer is operative to compare the position signal to previously received position signals to determine a condition, for example, the amount of cable on the reel, the presence of any object, and/or the existence of a safety-threatening condition. The computer can generate an output signal for use in, for example, controlling the reel speed and/or torque, or the application of brakes.