Battery powered wire puller

Abstract

An electric fish tape with a rotatable drum for pulling an electrical wire through a conduit or other enclosed area is described. The fish tape uses an electric motor and gear assembly to extend or retract the fish tape and wire attached thereto. The fish tape includes an electric mode and a manual mode. When in the manual mode, an operator can manually rotate the drum to extend or retract the fish tape.

Description

TECHNICAL FIELD

[0001] The present subject matter relates to a tool commonly referred to as a "fish tape." Electrical contractors use this tool when running electrical wire in conduit. BACKGROUND

[0002] Fish tapes have been known for many years and are available from tool suppliers including Greenlee Tool Company, Klein Tools, and Southwire Tools. There are also many lesser quality brands on the market. All known products have many similar features and generally rely on manual operation to extend and retract the fish tape from a barrel housing.

[0003] The primary function of a fish tape is to pull electrical wire through conduit or a hollow space such as inside a wall. The basic operating principle of such a tool relies on manually extending a relatively stiff wire and rotating the housing barrel relative to the handle. The fish tape is fed out in a similar manner to a tape measure. The relatively stiff fish tape wire is able to extend into a proposed path such as a hollow electrical conduit to run wire. Typically, an assistant will be at the other end of the conduit and when the end of the fish tape wire is exposed, the assistant will attach a wire to be run through the conduit. The operator then manually pulls or retracts the fish tape that drags the conductor into and through the hollow conduit. When retracting the fish tape, the user must manually pull the fish tape wire while simultaneously rotating the barrel housing to wind the fish tape wire back into the barrel. This is a tedious process. Some fish tapes extend as far as 200 feet. Therefore, pulling or retracting the wire requires a significant amount of human effort and attention. SUMMARY

[0004] In one aspect, the present subject matter provides a fish tape tool including a housing having a handle including a battery receptacle configured to receive at least one battery. The tool further includes a rotatable barrel. The barrel defines a hollow interior region and provides an aperture into the interior region of the barrel. The tool further includes an electric motor disposed in the housing. The electric motor provides an output shaft that is rotatably powered. The tool further includes a drive assembly configured to transfer rotational power from the output shaft of the electric motor to the rotatable barrel. And, the tool includes a drive selector positionable between an electric mode and a manual mode, (i) in the electric mode, rotation of the output shaft of the electric motor causes rotation of the barrel, and (ii) in the manual mode, rotation of the output shaft of the electric motor is independent of rotation of the barrel.

[0005] In another aspect, the subject matter provides a fish tape tool including a handle and a barrel defining a hollow interior region. The barrel is supported by the handle and defines a central axis, and the barrel is rotatable about the central axis. The tool also includes a ring gear fixed to the barrel. The tool also includes an electric motor supported by the handle. The electric motor provides rotatable drive. The tool also includes a pinion assembly rotatably powered by a drive of the electric motor. The pinion is axially positionable between a first position in which the pinion and the ring gear are engaged and a second position in which the pinion and the ring gear are disengaged.

[0006] In yet another aspect, the subject matter provides a method for pulling a flexible member through an enclosed region. The method includes providing a fish tape tool including (i) a handle, (ii) a barrel defining a hollow interior region, the barrel being supported by the handle and defining a central axis, and the barrel being rotatable about the central axis, (iii) a ring gear fixed to the barrel, (iv) an electric motor supported by the handle, the electric motor providing rotatable drive, and (v) a pinion assembly rotatably powered by a drive of the electric motor, the pinion being axially positionable between a first position in which the pinion and the ring gear are engaged and a second position in which the pinion and the ring gear are disengaged. The method also includes extending a fish tape line through the enclosed region. The method also includes attaching the flexible member to a distal end of the fish tape line. And, the method includes retracting the fish tape line through the enclosed region, thereby pulling the flexible member through the enclosed region.

[0007] In the subject matter, the difficulties and drawbacks associated with previous approaches are addressed as follows:

[0008] As will be recognized, the subject matter described herein is capable of other and different embodiments and its several details are capable of modifications in various respects, all without departing from the spirit of the claimed subject matter. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not restrictive. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1 is a perspective view of a fish tape according to an embodiment of the subject matter.

[0010] Figure 2 is a perspective view of a fish tape according to an embodiment of the subject matter. Figure 1 is a schematic side view of a fish tape.

[0011] Figure 3 is a schematic end view of a fish tape. Figure 1

[0012] Figure 4 is a partial cross-sectional view taken along line IV-IV in Figure 3

[0013] Figure 5 ​​is a partial cross-sectional view taken along line V-V in Figure 2

[0014] Figure 6A and Figure 6B is a partial cross-sectional view taken along line VI- VI in Figure 2

[0015] Figure 7 is a schematic side view of another embodiment of a fish tape according to the present subject matter.

[0016] Figure 8 is a cross-sectional view taken along line VIII-VIII in Figure 7 DETAILED DESCRIPTION

[0017] The present subject matter fish tape employs a similar configuration as known manual fish tapes prevalent in the electrical construction industry. However, embodiments of the present subject matter fish tape also utilize a motor and drive assembly configured to transfer rotational power from the motor to a rotatable barrel. In many embodiments, the drive assembly includes a gear box incorporated into the handle or housing, and an annular gear positioned along the outer diameter of the rotatable barrel. In certain embodiments, the handle also contains a battery receptacle or "boot" for a commercially available lithium ion battery, such as the 18 volt lithium ion battery available from Ridge Tool under the RIDGID name. Alternatively, the device can be configured to accept a 12 volt lithium ion battery available from different vendors to reduce power and run time. Typically, the handle includes a trigger and switch arrangement to regulate operation of the motor. A variety of electric motors can be used, including but not limited to permanent magnet DC type or brushless DC type. If a brushless DC motor is used, an electronic circuit board for controlling commutation of the motor can be used and incorporated into the handle or housing of the tool.

[0018] Generally, Figure 1 ​​​-6 shows an embodiment of a threader according to the present subject matter. The handle and / or housing components include a slide action switch that causes the drive pinion to move axially along the spool shaft. This allows the drive pinion to engage or disengage with the ring gear that is fixed to the rotatable barrel. When the motor is activated, the drive pinion rotates in the engaged position. The threader can also include a set of gears in a planetary gear box. Typically, the set of gears is disposed between the motor output shaft and the pinion. The final output shaft of the gears rotates the drive pinion. If the drive pinion and ring gear are in the engaged position, rotation of the drive gear causes the ring gear to rotate relative to the fixed handle. Rotation of the ring gear causes rotation of the barrel, which thus retracts (or advances) the threader line into the barrel and causes the threader line to be wound in an orderly fashion. In many versions, the motor rotation can be changed to cause the barrel to rotate in the opposite direction, thus advancing or dispensing the threader line out of the barrel. The trigger switch can be of the type that allows variable speed operation of the motor for maximum control. The slide action switch, typically located in the handle, allows the drive pinion to disengage from the ring gear to allow the barrel to be freely rotated manually, thus using the threader in the traditional manner for such tools.

[0019] In particular, Figure 1 and Figure 2 One embodiment of a threader 2 according to the present subject matter is shown. The threader 2 includes a handle 20, a barrel 10 that is rotatable relative to the handle, and a motor and gear assembly disposed within a housing 64. Typically, the handle 20 is integral with or otherwise fixed to the housing 64. The threader 2 also includes a ring gear 50 that is fixed or otherwise secured to the barrel 10, the ring gear being engageable with a drive pinion 40 that is at least partially disposed in the housing 64 in some versions. It will be appreciated that alternative assemblies and configurations (e.g., a friction drive wheel) can be used. The drive pinion 40 is typically in the form of a gear having a plurality of teeth. The drive pinion 40 is rotatably powered by a motor 60, a gear assembly 70, and an output shaft 80 disposed in the housing 64. As noted above, the handle 20 can include a battery receptacle or boot 22 and one or more batteries 24 engaged therein. The barrel 10 defines a generally hollow interior in which a threader line 90 is disposed.

[0020] The wire puller 2 also generally includes various control devices. A slide action switch or drive selector 30 is movably mounted or otherwise disposed along the housing 64 or handle 20 to enable the operator to selectively position the drive pinion 40 relative to the ring gear 50. As described in greater detail herein, the slide action switch 30 enables the operator to select between a power or manual mode of operation. The wire puller 2 also includes an actuation switch 26 for controlling the on / off operation of the motor 60. In certain versions, the actuation switch 26 is also capable of controlling the speed of operation (i.e., rotational speed) of the motor 60. The actuation switch 26 can be in the form of a variable position trigger switch. Although generally positioned along the handle 20, the actuation switch can be positioned elsewhere, such as on the housing 64. The wire puller 2 can also include a direction switch 62 that enables the operator to select the rotational direction of the motor 60. As can be appreciated, this enables the wire puller line 90 to be selectively retracted or advanced relative to the barrel 10. Similarly, the direction switch 62 can be located elsewhere, for example on the housing 64. It is also contemplated that the actuation switch 26 can be a dual action type motion switch, allowing the user to rotate the motor forward or reverse by moving the switch from neutral (off) to a first position (forward) or a second position (reverse) in a single trigger.

[0021] Figure 3 The wire puller 2 is further illustrated. The barrel 10 is rotatable about a central axis X. The barrel 10 is generally rotatably supported by one or both of the handle 20 and / or the housing 64. The barrel 10 defines a generally hollow interior in which the wire puller line 90 is disposed. The barrel 10 defines an aperture 14 for providing access to the hollow interior of the barrel. The wire puller line 90 generally extends through the aperture 14.

[0022] Figure 3 And Figure 4 Further aspects of the slide action switch 30 are illustrated. Generally, the slide switch 30 is selectively movable or positioned along the housing 64. In many versions, the slide action switch 30 is movable in a direction generally parallel to the axis X. However, it should be appreciated that the subject matter is not limited to such a switch configuration and includes a wide range of other arrangements. In certain versions, the slide action switch 30 can include one or more extension rails 32 that are slidably received in corresponding recesses 66 defined in the housing 64. In alternative arrangements, the selection switch 30 can be an electromagnet actuated switch configured to be energized by depressing the trigger 26. Energizing the motor can energize the solenoid and move the switch 30 to position A. A spring clip (not shown) will return the switch and pinion 40 to position B when the motor is not energized.

[0023] Figure 5is a partial cross-section of the barrel 10. The ring gear 50 is generally fixed or otherwise secured to the barrel 10 and is configured such that the teeth 52 of the ring gear 50 extend radially outward from the barrel 10. The teeth 52 of the ring gear 50 are configured to mesh with corresponding teeth of the drive pinion 40 when the electric mode is selected using the switch 30. The present subject matter also includes versions in which the teeth of the ring gear protrude radially inward or laterally outward relative to the axis X of the barrel.

[0024] Figure 6A and Figure 6B Other aspects of the drive pinion 40, motor 60, output shaft 80, and slide action switch 30 are shown. Figure 6A The mechanism is shown in a position in which the ring gear 50 and pinion 40 are engaged. Figure 6B The slide switch 30 is shown in an operating position in which the ring gear 50 and pinion 40 are disengaged. As noted with reference to the figures, an optional gear assembly 70 is disposed between the motor 60 and the pinion 40. As will be appreciated, the output shaft 80 rotates when the motor 60 is actuated. The pinion 40 is thus rotated. The slide action switch 30 is selectively positioned between a first position A and a second position B. As will be appreciated, the switch 30 also includes a grip member 34 and a carrier 36. A user pushes the grip member 34 to either the position A or the position B, which also moves the carrier 36 and the pinion 40 to that position. As noted previously, the pinion 40 can be moved axially along the output shaft 80 through the use of a key or other configuration.

[0025] Referring to Figure 3 and Figure 6A When the switch 30, carrier 36, and pinion 40 are positioned to the position A, the pinion 40 is engaged with the ring gear 50. Thus, when the motor 60 is actuated, the ring gear 50 and barrel 10 are rotated about the axis X. And, as Figure 6BAs shown, when the switch 30, the carriage 36, and the pinion 40 are positioned to position B, the pinion 40 is disengaged from the ring gear 50. Thus, the barrel 10 can be manually rotated about the axis X. Thus, position A corresponds to the electric mode of the fish tape tool 2, while position B corresponds to the manual mode of the fish tape tool 2. The subject matter is not limited to the particular slide action switch 30. Generally, many embodiments include a drive selector that can be positioned between an electric mode in which rotation of the output shaft of the electric motor causes rotation of the barrel and a manual mode in which rotation of the output shaft of the electric motor is independent of rotation of the barrel. The aforementioned switch 30 and carriage 36 are examples of one type of drive selector according to the subject matter. It will be appreciated that the subject matter includes various types of drive selectors. For example, a mechanism that relies on rotation of the motor 60 to push the pinion 40 into engagement with the ring gear 50 is an alternative configuration. This type of centrifugal activation mechanism is commonly referred to as a “Bendix drive” and is commonly used in internal combustion engine starters to engage the gears only when the motor is rotating and disengage the gears when the motor is not energized.

[0026] Figure 7 and Figure 8 Another embodiment of a fish tape 2' according to the subject matter is shown. In the description of this alternative embodiment, the same reference numbers are used where applicable, but including an apostrophe. In this version of the tool 2', a different configuration of handle 20' and different positioning of the drive pinion 40' is used. In addition, the barrel 10' includes a plurality of gripping members 12 for facilitating manual rotation of the barrel 10' by an operator about the central axis X' when the tool is used in the manual mode. The gripping members 12 are generally disposed along the outer surface of the barrel 10'. However, the subject matter includes other locations and configurations for the gripping members 12.

[0027] The subject matter also provides a method for pulling a flexible member, such as an electrical wire, through an enclosed area, such as a conduit or an interior wall region. The method utilizes a fish tape according to the subject matter. Generally, such a method includes providing a fish tape tool that includes a handle and a barrel that defines a hollow interior region. The barrel is supported by the handle and defines a central axis about which the barrel is rotatable. The fish tape tool also includes a ring gear that is fixed to the barrel, and an electric motor that is supported by the handle. The electric motor provides rotatable drive. The fish tape tool also includes a pinion assembly that is rotatably powered by the drive of the electric motor. The pinion is axially positionable between a first position in which the pinion and the ring gear are engaged and a second position in which the pinion and the ring gear are disengaged. The method also includes extending a fish tape line through the enclosed area. The method also includes attaching the flexible member to a distal end of the fish tape line. And, the method includes retracting the fish tape line through the enclosed area, thereby pulling the flexible member through the enclosed area.

[0028] The methods of the present subject matter include operating the fish tape in an electric only mode, a manual only mode, or in a hybrid mode where the fish tape or in an electric mode and a manual mode. For example, extending can be performed by positioning the pinion gear in a first position where the pinion gear is engaged with the ring gear and actuating the electric motor. Similarly, retracting can be performed by positioning the pinion gear in the first position where the pinion gear is engaged with the ring gear and actuating the electric motor. Alternatively, extending can be performed by positioning the pinion gear in a second position where the pinion gear is disengaged from the ring gear and manually rotating the barrel. Also, retracting can be performed by positioning the pinion gear in the second position where the pinion gear is disengaged from the ring gear and manually rotating the barrel.

[0029] The fish tape tool of the present subject matter can utilize one or more of the following aspects. A trigger assembly can be used to control the on / off operation of the electric motor contained within the fish tape to drive the advancement or retraction of the fish tape line. A direction switch can be used to selectively and positionally advance the fish tape line to one switch position and retract the fish tape line to another switch position. If desired, a sliding action switch or a gear assembly can enable manual operation. Although the operation of the fish tape is typically powered, in many embodiments, the operator can utilize a manual mode to retract or advance the fish tape line. The manual mode can also be used to manually move or position the fish tape line (e.g., move or position a small distance, such as 0.25 inches) or in situations where slow and precise movement of the fish tape is desired.

[0030] The present subject matter includes many alternative configurations that utilize a motor to rotate the barrel or similar components in the fish tape tool. These alternative configurations include means for bi-directional motor rotation that will extend and retract the fish tape line from the barrel under power. In addition, there are alternative configurations that can be used to engage and disengage the drive pinion and ring gears, such as a toggle mechanism that radially disengages the gears rather than axially separating the gears. Ring wheel teeth can be molded into the barrel housing rather than using a separate component to provide.

[0031] Another alternative drive can be used to position the ring gear on the inside diameter of the barrel rather than the outside diameter of the barrel. A friction drive such as a rubber wheel can also be used that relies on friction with the barrel (rather than a toothed design) to transfer rotation. A ring and pinion set can also be designed that engages and disengages by radial movement of the pinion relative to the gear rather than the axial movement described previously.

[0032] Although battery power is preferred, a continuous operation can also be used with a wired type motor without the need to replace or recharge the battery.

[0033] Another alternative configuration for the fish tape is to use a worm drive where the output shaft from the motor gear box is a worm gear that engages a matching gear on the outside diameter of the barrel. The worm gear and matching gear can be radially disengaged by a toggle like mechanism.

[0034] Various embodiments of battery-powered wire pullers reduce the manual labor required to retract the puller back into the conduit. These embodiments also mechanize the process of pulling wire through conduits, which speeds up the process and reduces the manual labor needed to retract the puller. Battery-powered tools are used in many parts of the construction industry, and surprisingly, many construction sites currently still use manual puller lines for small-scale wire pulling. It is believed that if a suitable battery-powered wire puller is provided, it will be well-received by end users.

[0035] For versions of the threader using planetary gear assemblies, a disengagement device can be used to disengage the planetary gear element for manual threading or retraction. This provides a significant operational advantage compared to known control switching mechanisms. In particular, the threader of this subject remains operational even if the electromechanical components of known threaders fail.

[0036] The main advantages of the cable puller in this subject include, but are not limited to, reduced operator fatigue and increased speed when pulling cables. Compared to the start-stop-start type of movement caused by manual operation, using an electric actuator allows for continuous movement of the spool / puller.

[0037] It is also envisioned that the slide switch component or assembly could be automated, powered, or otherwise displaced by a solenoid or cam component, such that the slide shifter engages its corresponding gear only when the trigger switch is pressed or otherwise actuated.

[0038] In some versions of this type of threader, a rotating cylinder (e.g.) Figure 1 The cylinder 10 shown does not have one or more handles, knobs, or other gripping components. Furthermore, in certain versions, this rotatable cylinder also lacks additional parts and components such as levers and / or latching mechanisms, retaining clips for such levers or latches, and similar components. Providing, fitting, and assembling such handles, knobs, or gripping components (especially with external parts) results in significant complexity, cost, and increased manufacturing time, all of which are undesirable.

[0039] Furthermore, significant operational benefits are achieved in the version of this threader that features a manual mode where the rotation of the drum is independent of the rotation of the drive motor's output shaft. This allows for complete separation between the drive motor and the drum, enabling the user to manually rotate the drum without any resistance load from the drive motor and associated transmission. This is particularly important for applications involving prolonged use of the threader and manual feeding of the threader cable.

[0040] While clutch assemblies are known in the art to separate a rotatable component from a drive motor; the clutch assemblies are complex, often require maintenance, and add cost to the final assembly. Versions of the wire puller using a drive selector such as the slide action switch 30 and associated components are able to selectively engage and disengage between the pinion and ring gears without the complexity, maintenance requirements, and added cost of a clutch assembly.

[0041] The present subject matter, particularly the wire puller tools and related methods, will have broad industrial utility. For example, the tools and methods can be used in the construction and industrial building fields. It is also contemplated that the tools and methods can also be used in a wide variety of other fields, such as residential applications, manufacturing operations, and renovations or remodels where wires must be managed through conduits or other enclosed areas.

[0042] Many other benefits will no doubt become apparent from future application and development of the technology.

[0043] All patents, applications, standards, and articles referenced herein are incorporated by reference in their entirety.

[0044] The present subject matter includes all possible combinations of the features and aspects described herein. Thus, for example, if a feature is described as associated with one embodiment, and another feature is described as associated with another embodiment, it is understood that an embodiment incorporating both features is also contemplated.

[0045] As described above, the present subject matter addresses many of the problems associated with previous strategies, systems, and / or devices. It will be appreciated, however, that those skilled in the art will be able to devise various arrangements of the components, materials, and arrangements of the components described herein for the purposes herein without departing from the principles and scope of the claimed subject matter as expressed in the appended claims.

Claims

1. A fish tape tool comprising: a housing having a handle, the handle including a battery receptacle configured to receive at least one battery; a rotatable drum defining a hollow interior region and an aperture providing access to the interior region of the rotatable drum; an electric motor disposed in the housing, the electric motor providing a rotatably powered output shaft; a drive assembly configured to transmit rotational power from the output shaft of the electric motor to the rotatable drum; a drive selector positionable between (i) an electric mode in which rotation of the output shaft of the electric motor causes rotation of the rotatable drum and (ii) a manual mode in which rotation of the output shaft of the electric motor is independent of rotation of the rotatable drum; wherein the drive selector is movably mounted along the housing of the fish tape tool to enable an operator to selectively position the drive selector; wherein the drive assembly includes a pinion gear engageable with the output shaft of the electric motor and a ring gear fixed to the rotatable drum, and the ring gear includes radially outwardly extending teeth.

2. The fish tape tool of claim 1, wherein, the pinion gear is axially positionable relative to the output shaft of the electric motor.

3. The fish tape tool of claim 2, wherein, the drive selector includes a slide action switch engaged with the pinion gear such that displacement of the switch causes axial displacement of the pinion gear relative to the output shaft of the electric motor.

4. The fish tape tool of any one of claims 1-3, further comprising: at least one battery disposed in and engaged with the battery receptacle.

5. The fish tape tool of any one of claims 1-3, further comprising: an actuation switch configured to control on / off operation of the electric motor.

6. The fish tape tool of claim 5, wherein, the actuation switch is further configured to control rotational speed of the electric motor.

7. The fish tape tool of any one of claims 1-3, further comprising: a direction switch configured to control rotational direction of the electric motor.

8. The fish tape tool of any one of claims 1-3, further comprising: a gear assembly disposed between the output shaft of the electric motor and the drive assembly.

9. The fish tape tool of claim 8, wherein, the gear assembly is a planetary gear assembly.

10. The fish tape tool of any one of claims 1-3, further comprising: a fish tape line at least partially disposed in the interior region of the rotatable drum.

11. A fish tape tool comprising: a handle; a drum defining a hollow interior region, the drum supported by the handle and defining a central axis, and the drum rotatable about the central axis; a ring gear fixed to the drum; an electric motor supported by the handle, the electric motor providing rotatable drive; a pinion assembly rotatably powered by the drive of the electric motor, the pinion assembly axially positionable between a first position in which the pinion assembly and the ring gear are engaged and a second position in which the pinion assembly and the ring gear are disengaged. a slide action switch in meshing engagement with the pinion assembly, wherein displacement of the slide action switch causes axial positioning of the pinion assembly between a first position and a second position, wherein the slide action switch is movably mounted along a handle of the fish tape tool to enable an operator to selectively position the pinion assembly; wherein the ring gear includes radially outwardly extending teeth.

12. The fish tape tool of claim 11, wherein, the handle includes a battery receptacle.

13. The fish tape tool of claim 12, further comprising: a battery disposed and engaged in the battery receptacle.

14. The fish tape tool of any of claims 11-13, further comprising: an actuation switch configured to control on / off operation of the electric motor.

15. The fish tape tool of claim 14, wherein, the actuation switch is further configured to control a rotational speed of the electric motor.

16. The fish tape tool of any of claims 11-13, further comprising: a direction switch configured to control a rotational direction of the electric motor.

17. The fish tape tool of any of claims 11-13, further comprising: a gear assembly disposed between a rotatable drive of the electric motor and the pinion assembly.

18. The fish tape tool of claim 17, wherein, the gear assembly is a planetary gear assembly.

19. The fish tape tool of any of claims 11-13, further comprising: a fish tape line at least partially disposed in an interior region of the barrel.

20. A method for pulling a flexible member through an enclosed area, the method comprising: providing a fish tape tool according to claim 19; extending the fish tape line through the enclosed area; attaching a flexible member to a distal end of the fish tape line; retracting the fish tape line through the enclosed area, thereby pulling the flexible member through the enclosed area.

21. The method of claim 20, wherein, the extending is performed by positioning the pinion assembly in a first position in which the pinion assembly is in meshing engagement with the ring gear and actuating the electric motor.

22. The method of claim 20, wherein, the retracting is performed by positioning the pinion assembly in a first position in which the pinion assembly is in meshing engagement with the ring gear and actuating the electric motor.

23. The method of claim 20, wherein, the extending is performed by positioning the pinion assembly in a second position in which the pinion assembly is disengaged from the ring gear and manually rotating the barrel.

24. The method of claim 20, wherein, the retracting is performed by positioning the pinion assembly in a second position in which the pinion assembly is disengaged from the ring gear and manually rotating the barrel.

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