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Build guide

Spooler Smart

A measuring unwinder with display, AS5600 sensor and control board.

  • Head with display and AS5600 sensor, full guide and bill of materials
  • Wiring of the electronics (buy the electronics ready-made in the e-shop)

🔒 Production files and videos

The guide is free to read. You pay for access to the production files (STL, DXF, STEP, PDF, ZIP) and the assembly videos.

Finished Spooler Smart
Finished Spooler Smart

Downloads

  • Assembly guide (PDF)

    printable guide, all chapters

  • All files (ZIP)

    guide, 3D models, files and videos

  • 3D models Spooler Smart (STL)

    20 parts: body, head with electronics, rollers (the spool parts are in the spool guide)

Bill of materials

QtyItemCategoryNote
4Screw M4x10ScrewsLatch 2, catch 2
8Screw M5x16, countersunk headScrewsPackout holders
2Screw M5x20ScrewsBases
3Screw M5x50ScrewsJoins the arms
8Screw M8x20Screws4 axes, 2 screws per axis
16Washers 8x12 and 8x16Screws8 + 8, each end of 4 axes
4Insert M4InsertsLatch and catch
9+Insert M5Inserts
8Bearing 608-2RSMechanics4 axes, 2 bearings per axis
4Axis M8 aluminium, 71 mmMechanicsRoller, lathe
1Draw latch K2469 + catch K2468MechanicsKipp
6Screw M3x10, countersunk headScrewsBattery lid
2Screw M3x10, cheese headScrewsPUSHER-CLAMP
1Screw M4x40ScrewsEncoder wheel
1Screw M6x20ScrewsSpring housing
8Plastic screw 2.2x5ScrewsDisplay and AS5600
2Nut M4, self-lockingScrewsEncoder wheel
8Insert M3InsertsBattery 4, arms 2, pusher 2
1Insert M6InsertsSpring housing
4Bearing 624-2ZMechanicsPusher 2, encoder 2
1Spring (11.5 x 5.2 mm)MechanicsPusher
1Axis 4x40 stainlessMechanicsPusher roller
1Spooler B control board (ESP32-C3)Electronics75 × 28 mm, 76 components
1AS5600 board with magnetElectronicsEncoder
1OLED display 0.96", 4 pinsElectronics
1Panel buttonElectronics
118650 / 26650 battery holder + cellElectronics

What to buy and where

GuideSpooler Smart

Spooler measures and dispenses cable, keeps track of your stock and records the history of the measurements. You control it from an app for Android or Apple. You print most of the parts on a 3D printer; the rest are turned and laser-cut parts, threaded inserts and bought components such as screws and washers. You can print in ASA-CF or in material of the Spectrum brand. You can buy the electronics and the turned and laser-cut parts in the e-shop.

The finished Spooler Smart
The finished Spooler Smart
The display with the measured length of cable
The display shows the measured length of cable
The Spooler at work at a switchboard
The Spooler at work
The Spooler at work with tools
The Spooler at work with tools
The Spooler on a Packout trolley
The Spooler on a Packout trolley
The Spooler carried by its handle
The Spooler carried by its handle
Three Spoolers on a Packout
Three Spoolers on a Packout
The Spooler packed in a box
The Spooler packed in a box

The spool has a guide of its own and is built separately.

You can buy the electronics (the assembled control board, the display and the sensor) ready-made in our e-shop, as well as the turned and laser-cut parts.

What you will need

All STL models (ZIP) (3.6 MB) ·

Body

PartMade byNote
02-01-030d-BASE-LEFT3D print
02-01-031d-BASE-RIGHT3D print
02-01-032d-ARM-LEFT3D printarm, Spooler Smart
02-01-033d-ARM-RIGHT3D printarm, Spooler Smart
02-01-035d-BASE-FRONT3D print
02-01-040-Milwaukee_Packout3D printPackout holder
02-01-041-RYGL-L3D print
02-01-046d-BATERY-LID3D printbattery lid
02-01-061-CLIP_BASE-M4-assy3D printlatch base

Encoder head

PartMade byNote
02-01-007-SPRING HOUSING-M63D print
02-01-010-ENCODER-SPACER3D print
02-01-011d-ENCODER-BASE3D print
02-01-012a-ENCODER-VALEC-A3D print
02-01-013-MAGNET-HOLDER3D print
02-01-015-PUSHER-CLAMP3D print
02-01-016a-PUSHER3D print
02-01-018-PUSH-CYLINDER3D print
02-01-105-BOARD_HOLDER3D print

Rollers

PartMade byNote
02-01-020a-ROLLlathenylon, or printed
02-01-021-AXIS M8x15latheaxis, aluminium

Threaded inserts

Most joints use plastic threaded inserts (M3, M4, M5, M6). Press them in before you screw the parts together, always into the part named in the drawing next to the insert. The numbers are given with each assembly below. The inserts are heat-set with a soldering iron with a flat tip: place the insert on the hole, press it slowly into the part with the heated tip until it is flush, and let it cool before you load the part.

Next you build the head, the rollers, the body and wire the electronics.

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Step 1Encoder head

The head measures the length of the cable. The cable passes between a knurled wheel with a magnet and a pressure roller. The AS5600 sensor reads the rotation of the magnet.

1. Base, display, sensor and button

The encoder base with the display, the AS5600 board and the button
The base 02-01-011d
QtyPartNote
102-01-011d-ENCODER-BASE
1Display 0.96", LaskakitOLED, 4-pin connector
1AS5600 board (sensor)5-pin connector on the board
1ButtonInto the bottom hole, nut from behind
8Plastic screw 2.2x54 for the display, 4 for the AS5600
  1. Screw the display on with four 2.2x5 screws.
  2. Screw the AS5600 board on with four 2.2x5 screws so that it lies above the axis of the wheel with the magnet.
  3. Put the button into the bottom hole and tighten the nut.

2. The pressure clamp

The encoder base and the part PUSHER-CLAMP
The base and the part PUSHER-CLAMP 02-01-015
  1. Press two M3 inserts into the base.
  2. Screw 02-01-015-PUSHER-CLAMP on with two M3x10 screws. Do not tighten the clamp fully yet, the pusher goes in under it.

3. The pusher

Exploded view of the pressure mechanism
The spring-loaded pusher with a roller on bearings
QtyPartNote
102-00-206-PUSHER-assy (02-01-016a-PUSHER)Fork
102-01-018-PUSH-CYLINDERPressure roller
2Bearing ZKL 624-2Z
1Axis 4x40, stainless
102-01-007-SPRING HOUSING-M6Spring housing
1Spring 11.5 x 5.2 mm, wire 0.62 mm
1M6 insert + screw M6x20 (DIN 915 in the drawing)Adjusts the pressure
  1. Put both 624-2Z bearings into PUSH-CYLINDER and push the 4x40 axis through the fork of the pusher.
  2. Put the spring on the pin of the pusher.
  3. Press the M6 insert into SPRING HOUSING and screw in the M6x20. The screw sets the force of the pressure.
  4. Put the whole assembly under PUSHER-CLAMP and tighten the clamp.
Note. The drawing calls the screw DIN 915 (a screw with a cylindrical tip and a slot). Check which type you have bought.

4. The encoder wheel with the magnet

Exploded view of the encoder wheel
The knurled wheel, the bearings and the magnet from the AS5600
QtyPartNote
102-01-012a-ENCODER-VALEC-AKnurled wheel (green)
102-01-010-ENCODER-SPACERSpacer tube between the bearings
2Bearing ZKL 624-2Z
102-01-013-MAGNET-HOLDERMagnet holder (orange)
1Magnet from the AS5600Ring magnet, supplied with the board
1Screw M4x40
2Nut M4, self-locking
  1. Put the magnet into MAGNET-HOLDER.
  2. Put a bearing, the SPACER and the second bearing into the wheel.
  3. Push the M4x40 through and secure it with the self-locking M4 nuts. The wheel must turn without play.
  4. Put the assembly into the base so that the magnet faces the AS5600 board.
The video opens after you buy this guide.
Encoder head with electronics

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Step 2Rollers

The rollers carry the spool: the spool sides sit in them and the spool turns on them. They are the same in both versions of the device. There are eight in every device. One assembly is made of an aluminium axis, two 608 bearings and two rollers, so the device needs four assemblies, that is four axes. The axis is turned, 71 mm long, with an M8 thread 15 mm long at both ends.

Turned or bought. You can turn the rollers from nylon, or print them. The ready-made mechanical set (spacer posts and nylon rollers) is in our e-shop.

What you will need

QtyPartNote
2 (8 in all)02-01-020a-ROLLRoller. Turned from nylon, printed, or from the e-shop
1 (4 in all)02-01-021-AXIS M8x15Aluminium, 71 mm, M8 x 15 thread at both ends
2 (8 in all)Bearing ZKL 608-2RS
2 (8 in all)Washer 8x12As in the drawing, on each side
2 (8 in all)Washer 8x16
2 (8 in all)Screw M8x20
The table is for one assembly. The device has four axes, that is four assemblies. So there are 4 axes, and 8 rollers, bearings, washers and screws, because they go on each end of an axis.
Exploded view of the roller assembly
The roller assembly: axis, washers, bearings and rollers

Assembly

1. Fit the washers and bearings

On each end of the axis put a washer 8x12 and a washer 8x16, then a bearing 608-2RS.

2. Fit the rollers

Put a roller ROLL on each bearing. The roller must turn freely on the bearing.

3. Secure with the screws

Secure the assembly from both sides with an M8x20 screw into the thread at the end of the axis.

The video opens after you buy this guide.
Roller assembly

Putting it into the body

A roller in the part of the body
Where the assembly sits in the arm

4. Put the assembly into the arm

Put the finished assembly into the arm as in the picture. Check that both rollers turn freely.

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Step 3Body

The body is made of two halves of the arms with a base, a front part and holders. The procedure has five steps.

1. The battery holder

Exploded view of the battery holder and the lid
The battery holder in the arm 02-01-032d and the lid 02-01-046d
QtyPartNote
1Battery holder 26650 or 18650
102-01-046d-BATERY-LIDLid
4M3 insert
6M3x10 screwAs in the drawing
  1. Press the M3 inserts into the arm.
  2. Screw the battery holder on.
  3. Glue or secure the battery cables (see the chapter Electronics) and put the lid on.

2. The latch

Exploded view of the latch
The latch K2469 with the base CLIP_BASE
The finished latch on the body
The finished latch K2469 on the body
  1. Press in two M4 inserts.
  2. Put 02-01-061-CLIP_BASE-M4-assy and the latch K2469 in place and screw them on with two M4x10 screws.

3. The arms with the board

Exploded view of the joining of the arms
ARM-LEFT, ARM-RIGHT, BOARD_HOLDER and the board
QtyPartNote
102-01-032d-ARM-LEFT
102-01-033d-ARM-RIGHT
102-01-105-BOARD_HOLDER with the board (BOARD-ASM)See the chapter Electronics
3Screw M5x50
2M3 insert
2M5 insertAs in the drawing
  1. Press in the M5 and M3 inserts.
  2. Put the board in its holder into ARM-LEFT and connect it before you join the arms.
  3. Put ARM-RIGHT on and pull the arms together with three M5x50 screws.

4. The front part

Exploded view of the front part with the RYGL-L arms
BASE-FRONT 02-01-035d, 2x RYGL-L, the latch catch K2468
QtyPartNote
102-01-035d-BASE-FRONT
202-01-041-RYGL-LOrange
2M5 insertFor RYGL-L
2M4 insertFor the catch
1K2468_9142132 (catch)See Buying
2M4x10 screw

5. The bases and the Packout holders

Exploded view of the bases and the Milwaukee Packout holders
BASE-LEFT 030d, BASE-RIGHT 031d, 2x Milwaukee Packout 040
QtyPartNote
1+102-01-030d-BASE-LEFT, 02-01-031d-BASE-RIGHT
202-01-040-Milwaukee_PackoutEach to its base
8M5x16 countersunk screw4 for each holder
2Screw M5x20Joining the bases
  1. Press the M5 inserts into the bases.
  2. Screw each Packout on with four M5x16 countersunk screws.
  3. Join the bases with the M5x20 screws.
The video opens after you buy this guide.
Body: part one
The video opens after you buy this guide.
Body: part three

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Step 4Electronics

Power
inputUSB-C, USBLC6 protection
chargingTP4056, 1 A
battery18650 / 26650, DW01 protection
source selectideal diode LM66200
3.3 VTPS631000 buck-boost
Control and peripherals
processorESP32-C3-MINI-1, native USB
I²COLED display, RTC MCP7940N
encoderAS5600 analog, comparator MCP6546
input/outputbutton, buzzer
switchAP2191 cuts the peripherals

The control board carries the ESP32, the buzzer and the USB-C. Four connectors are plugged into the board.

The control board with labelled connectors
The board in the holder BOARD_HOLDER: battery, button, OLED, encoder
ConnectorPinsConnects to
BATTERY2, largeBattery holder 18650 / 26650
BUTTON2The button in the encoder head
OLED DISPLAY4Display 0.96"
ENCODER5The AS5600 board

Cable routing in the photos

The battery holder in the arm with the red and black cable routed
The battery holder, the cable routed in a channel and fixed
The board in its holder with the cables
The board in its holder, the bundle of cables going to the encoder head
The encoder head with the AS5600 board
The back of the head: the AS5600, the cables fixed
The encoder head from the front with the pusher
The front: the pusher, the wheel and the button
An overall view of the assembly in progress
The whole assembly before the arms are closed
  1. Connect the battery and put it into the holder. Lay the cables in the channel and fix them (in the photos with small drops of glue or tape).
  2. Connect the display, the AS5600 and the button to the connectors of the board as described above.
  3. Lead the bundle of cables from the encoder head to the arm with the board and leave some slack for opening.
  4. Before you close the arms check that no cable is pinched in the joint.
The video opens after you buy this guide.
Wiring and cable routing

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BuyingWhat to buy and where

You can buy the ready-made electronics (the assembled control board, the display and the AS5600 sensor) and the turned and laser-cut parts in our e-shop. The rollers and the spool sides are there too. What is left are ordinary fasteners and these components:

PartNote
Draw latch K2469Steel/stainless steel, round bail, up to 900 N, concealed holes. Hole spacing 14 mm, holes Ø 4.2 mm. Kipp
Catch K2468 (9142132)The catch for the latch. Kipp
Bearing 624-2Z (4x13x5)For example SKF 624-2Z, 624ZZ is fine too
Bearing 608-2RS (8x22x7)For example RS PRO 608-2RS, a skateboard bearing works too
Battery holder 18650/26650, 16 mm panel buttonOrdinary electronics suppliers
Springs (2 types), stainless axis 4x40The dimensions are in the bill of materials
Threaded inserts M3 to M6For example McMaster-Carr or CNC Kitchen inserts at 3DJake. The length of the insert must match the depth of the hole (CNC Kitchen standard: M3 5.7 mm, M4 8.1 mm, M5 9.5 mm, M6 12.7 mm)
Screws M3, M4, M5, M6, M8, M4 lock nuts, washers 8x12 and 8x16The numbers are with the steps and in the bill of materials
Drawing of the latch with dimensions
Dimensions of the latch K2469

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