Automatic cable spooling device

1. An automatic spooling system, comprising:

a frame adapted to rotatably hold a spooling drum, wherein the spooling drum includes a rotational axis, and a spooling width bounded by a first flange and a second flange;

a drum motor operatively connected to the drum;

a levelwind arm positioned adjacent to the drum, wherein the levelwind arm is mounted to a single slew bearing adapted to allow pivoting motion of the levelwind arm in a plane aligned with the rotational axis of the drum, and wherein the slew bearing has a central opening for passage of a cable;

an arm motor operatively connected to the levelwind arm, wherein the arm motor is operatively connected to the slew bearing through a worm and worm gear system;

a microcontroller in communication with the arm motor;

an arm encoder adapted to sense a position of the arm motor and in communication with the microcontroller;

a drum encoder adapted to sense a position of the drum motor and in communication with the microcontroller; and

wherein the position of the levelwind arm is controlled by the microcontroller based on the position of the drum, the spooling width, and a predetermined cable diameter.

2. The spooling system of claim 1 , wherein the levelwind arm includes a plurality of sheaves adapted to guide the cable from a cable source into the drum.

3. The spooling system of claim 1 , wherein the drum encoder communicates a position of the drum motor through the microcontroller to identify a required cable position.

4. The spooling system of claim 1 , wherein the arm encoder is adapted to identify an actual cable position.

5. The spooling system of claim 1 , further including a display in communication with the microcontroller adapted to receive input from an operator of parameters required to achieve an optimum wind of a cable around the drum.

6. The spooling system of claim 1 , wherein the levelwind arm is controlled to spool the cable in half-wrap increments relative to a preceding wind of the cable around the spool.

7. A method of spooling a cable, comprising the steps of:

providing a spooling system comprising:

a frame adapted to rotatably hold a spooling drum, wherein the spooling drum includes a rotational axis, and a spooling width bounded by a first flange and a second flange;

a drum motor operatively connected to the drum;

a levelwind arm positioned adjacent to the drum, wherein the levelwind arm is mounted to a single slew bearing adapted to allow pivoting motion of the levelwind arm in a plane aligned with the rotational axis of the drum, and wherein the slew bearing has a central opening for passage of a cable;

an arm motor operatively connected to the levelwind arm, wherein the arm motor is operatively connected to the slew bearing through a worm and worm gear system;

a microcontroller in communication with the arm motor;

an arm encoder adapted to sense a position of the arm motor and in communication with the microcontroller;

a drum encoder adapted to sense a position of the drum motor and in communication with the microcontroller; and

wherein the position of the levelwind arm is controlled by the microcontroller based on the position of the drum, the spooling width, and a predetermined cable diameter;

setting a plurality of parameters in the microcontroller based on the position of the drum, the spooling width, and the predetermined cable diameter; and

operating the spooling system to spool the cable.

8. The method of claim 7 , wherein the levelwind arm includes a plurality of sheaves adapted to guide a cable from a cable source into the drum.

9. The method of claim 7 , wherein the drum encoder communicates a position of the drum motor through the microcontroller to identify a required cable position.

10. The method of claim 7 , wherein the arm encoder is adapted to identify an actual cable position.

11. The method of claim 7 , further including a display in communication with the microcontroller adapted to receive input from an operator of parameters required to achieve an optimum wind of a cable around the drum.

12. The method of claim 7 , wherein the levelwind arm is controlled to spool the cable in half-wrap increments relative to a preceding wind of the cable around the spool.