Apparatus and method for using conventional aerial rollers for stringing power lines with aerial vehicles

Abstract

The present invention discusses about an apparatus and method for the use of conventional aerial rollers that for stringing power transmission lines with aerial vehicles. Further, the designing of the apparatus involves developing a drone line collector arm to replace the helicopter straight line collector arm. The design involved retaining the drone line on rollers with low rolling resistance which allow smooth pull of a light-weight drone line across the towers. The drone line would be used to pull the pilot wire using a winch on the ground. As the drone line pulled the heavier pilot wire over rollers on the collector arm, the weight of the pilot wire on both sides presses the rollers down and convey the pilot line into the helicopter stringing block from where the regular stringing operation would begin.

Description

APPARATUS AND METHOD FOR USING CONVENTIONAL AERIAL ROLLERS FOR STRINGING POWER LINES WITH AERIAL VEHICLESFIELD OF THE INVENTION

[0001] The present invention relates to a field of stringing of power transmission lines across towers, and in particular to an apparatus and methods which enables using the conventional aerial rollers for stringing with helicopters and other aerial vehicles. Further, the apparatus also enables using helicopter stringing blocks for stringing with drones and the apparatus, which is adaptable and versatile, can be attached with conventional aerial rollers of various sizes, configurations, makes and types for stringing overhead power transmission line using light aerial vehicles ranging from small drones to helicoptersBACKGROUND OF THE INVENTION

[0002] Stringing is the process of installation of high voltage overhead power lines across power transmission towers. It is typically carried out by pulling the conductors with a wire rope also known as pilot wire through aerial rollers, attached to the towers on which the conductors are to be installed. These Aerial rollers are pulley blocks which are also known as running out blocks, travellers or stringing blocks.

[0003] The aerial rollers comprise of one or more number of sheaves (also known as pulleys), depending on number of conductors to be strung simultaneously through each aerial roller. When two or more conductors are pulled simultaneously on separate sheaves through the same aerial rollers, they are termed as bundled conductors. The sheaves are usually odd in number with central sheave used primarily for pulling line called a pilot wire through aerial rollers attached to the towers on which the conductors are to be installed. The aerial rollers are mounted at each tower at each of the points where the overhead lines need the stringing through.

[0004] Generally, the aerial rollers are mainly of two types. One such type of aerial rollers are the conventional aerial rollers for conventional ground and tower-based stringing. Second type of aerial rollers are Special purpose helicopter stringing blocks which are designed to carry out stringing using helicopters or heavy-duty aerial vehicles.

[0005] For most types of stringing, a pilot wire is first introduced into each of the aerial rollers through which the conductors are to be strung. The pilot line is then used to pull the conductors using a coupling device called headboard. The headboard conveys the pulling load from pilot wire to the conductors and also facilitates the placement of the conductors on the respective sheaves of the aerial rollers. The pilot wire is pulled across towers by of device called “Puller” (a drum winch) which is placed on the ground beyond the last tower in the stringing leg. As the pilot wire is pulled, the conductors are released from conductor reels through a device called “Tensioner” on the ground before the first tower. The tensioner maintains and controls pulling force on the conductors to prevent both excessive load as well as excessive sag on both the conductors and the pilot wire. Once the conductors are pulled through aerial rollers across the desired number of towers, they are clamped to the insulators of the respective tower at requisite tension and sag values.

[0006] With the advent and prolific use of advanced conductors such as HTLS (High Temperature Low Sag) conductors, the span of conductors between towers are increasing dramatically. Accordingly, the pulling loads in stringing are also increasing creating a need for aerial rollers with higher load carrying capacity. Most of these new conductors are very sensitive to any deviation from stringing parameters. These factors pose a new set of challenges in design and execution of newer and effective methods in stringing.

[0007] Further, there are various methods of stringing based on how the pilot wire is introduced into the aerial roller and the device used to carry out this function. Further, one of the methods of stringing is that of conventional stringing, using conventional aerial rollers.

[0008] In this method the travelling passage, for the travel of pilot wire, headboard and conductors, is enclosed between the sheave grooves, two vertical arms and the top bracket of the aerial roller.

[0009] Typically, the pilot wire is manually introduced into the aerial roller while attached to the tower at a considerable height by manually opening yoke plate free from one of the arms of the aerial roller frame. The pilot wire is placed in the groove of the desired sheave or pulley and the aerial roller is then closed with the help of rigging tools. This process is repeated for each aerialroller that the conductor must pass through. The stringing is carried out then, with pilot line pulling the conductors using headboard, from the “tensioner” end to the puller end.

[0010] Further, due to the characteristics of the equipment and method, conventional aerial roller stringing has the following constraints and drawbacks: a. This operation is carried out manually by skilled operators at the tower height. b. This method requires very high level of safety precautions and equipment because it entails cumbersome work at hazardous heights. c. This process is laborious and time consuming because pilot wire must be introduced into each roller before stringing can begin. d. This method also requires high volumes of hoisting and rigging tools and tackles e. Also, this method requires extensive ground activity throughout the path of the towers. f. Further this method is prone to being hampered by the terrestrial obstructions such as geographical features like hilly terrain, rivers, forests etc. g. It is also subject to man-made constraints such as urban structures, buildings, other powerlines, roads, bridges, railway tracks rural settlements, farmlands, h. Yet another constraint is displacement of people, ROW and environmental permissions related to working on public and private properties that lie on the path between the towers. ROW (Right of Way) refers to the designated strip of land where the transmission line is constructed, operated, and maintained. It's essentially a corridor of land with specific clearances for safety, including minimum ground clearances, electromagnetic field exposure limits, and other safety requirements.

[0011] Further, there is another method, that of stringing the overhead transmission lines by using helicopters.

[0012] In helicopter stringing, special purpose helicopter stringing blocks of rotary gate or hinge flap type are used. This operation is generally controlled by a skilled operator perched on the side of a helicopter. The pilot line is manipulated on the receiving arm into the ingress gate which allows it to transfer into the aerial roller and on to the desired sheave groove. Following this, the remainder of the stringing operation is carried out in the same manner as conventional stringing. Therefore, helicopter stringing can overcome some of the challenges faced in conventional stringing especially where conventional stringing is not even feasible.

[0013] However, helicopter stringing is used only where absolutely necessary or where conventional aerial roller stringing is not possible or feasible mainly due to following reasons: a. Very high cost of helicopter running. b. Limited availability of specialized helicopter stringing services. c. It has a very high cost of special purpose helicopter stringing blocks. d. The helicopter stringing blocks are impractical for use in conventional stringing. f. Helicopters stringing cannot be carried out in areas with airspace restriction. g. Helicopter stringing is not feasible for pilot line insertion below the cross arms of the tower or close to other power lines without elaborate contraptions and set up. h. Rotary gates in typical helicopter stringing blocks are prone to inadvertent or premature triggering. Rectifying this requires intensive manual intervention from the ground to reset the rotary gate in receiving position. The resetting becomes even more difficult if the towers are at a great height or in areas with limited access or during unfavorable. The stringing operation is interrupted, and costly helicopter flight time is also lost. Therefore, a system is required which prevents premature or inadvertent triggering of the rotary gates.

[0014] Further, there is yet another method of stringing operations with heavy lifting drones using traditional helicopter stringing blocks.

[0015] This method of using drones in combination with helicopter stringing blocks is also known as drone stringing or aerial vehicle stringing. A high strength pre-pilot line carried by drone is used in this type of stringing. The pre -pilot wire is then used to pull the pilot wire which in turn is used to pull the conductors across aerial rollers. The advantage of this method is that it replaces expensive helicopter services. Another advantage of this method is that drones and drone operators are widely available. However, with advantages this method also has following challenges: a. Drone stringing is still carried out with traditional but expensive special helicopter stringing blocks.b. That, the typical helicopter stringing blocks are designed for manual insertion from tower or helicopter with a heavy pilot wire and not for lighter more flexible pre -pilot wires used by drones. These lighter flexible pre -pilot lines are prone to getting jammed damaged or even cut in the sliding part of rotary gate and its block. This usually happens due to flailing, incomplete or oblique entry, bouncing back after triggering, oblique entry or cross movement and swaying of the roller itself during activation of the rotary gate. c. Highly skilled drone operator is needed to position the pre -pilot wire such that it lands into the capture area of the aerial roller in the right alignment. Any malfunction in activation of the gate requires manual rectification. Also, the entire stringing operation is interrupted and leads to costly downtime. In areas with limited access, such rectification can be even more time-consuming and difficult. d. Further, Ingress gates of helicopter stringing blocks require the use of high activation force. This means the drone operator has to tug the line to provide sufficient force on the entry gates to activate them consuming energy at the expense of the flying time and flying range of the drone. Increasing the sensitivity of the gate to facilitate easy insertion of the pre -pilot wire further increases the risk of premature activation of the rotary gates leading to interruption in stringing operation. e. Further, in this method too it is difficult for large drones to safely insert the pre -pilot wire below the cross arms of the towers or below power lines.Further, the sheaves of helicopter stringing blocks have a high rolling resistance which is acceptable for pulling pilot wire with a helicopter but very high with respect to the pulling power of the drone. This necessitates use of a pre-pilot wire with higher strength which is heavier, leading to higher tugging load on the drone.

[0016] This increases the power consumption and reduces the range with each tower covered by the drone. Further this reduces the speed with which the drone can lead the pre -pilot wire.Therefore, even with higher load capacity drones, the number of towers that can be strung using drones is limited by tugging load required to actuate the entry gate of the stringing block, the weight of the pre-pilot wire and the high rolling resistance encountered at each helicopter stringingblock. This leads to a greater number of drone flights and more stop stations for inserting the prepilot across large number of towers.Further, despite the limitations drone stringing with special purpose helicopter stringing blocks, this method becoming more and more prolific.

[0017] Further, since only helicopter stringing blocks or custom blocks are used drone stringing, it leads to large idle inventory of conventional aerial rollers with the operators switching over from the conventional stringing to drone stringing.

[0018] Further, substantial capital is needed for replacing conventional stringing blocks with new special purpose helicopter stringing blocks and heavy lifting drones.

[0019] Further, users are compelled to buy separate helicopter stringing blocks of different sizes configuration, for each size and type of conductor and number of conductors (bundled) in stringing operation.

[0020] Further, the aerial rollers that may have been modified for stringing with drones which suitable only for specific aerial rollers, but such modifications are generally irreversible, and the modified rollers may not be used again in conventional mode.

[0021] Further, there is no general information or product or mechanism available in the industry which enables the use of conventional aerial rollers for stringing overhead transmission lines with both the helicopters and drones.

[0022] Typically, there are no special aerial rollers available specifically for stringing with drones. The stringing is carried out using the helicopter stringing blocks as mentioned above using high load capacity drones.

[0023] Also, there are instances of using a device in combination with helicopter stringing blocks, which allows a pre-pilot wire to be introduced into the device which has lighter rollers with lower rolling resistance, and is activated by a wedge type mechanical actuation which releases the pre -pilot wire. Such device may be located outside or inside the helicopter stringing block. The advantage of using this device is that lower rolling resistance of the device permits longer range of travel for the drone. However, a limitation of this device is that it cannot be used withconventional aerial roller. Further, another limitation of such a device is that it cannot be used with lighter drone.

[0024] A patent application W02023004475A1 titled “Line attachment devices and methods for use thereof’ discloses about a transmission tower line attachment device. The transmission tower line attachment device is provided for facilitating installation of a line on a hanging sheave. The line attachment device comprises a first guide arm and an upper frame spaced from the first guide arm. The upper frame defines a throat between the first guide arm and the upper frame. A resilient first gate is arranged at an outer end of the upper frame between the upper frame and the first guide arm and is adapted to open inwardly into the throat in response to an external force and to close when the external force is removed. The line attachment device is adapted to be mounted on the hanging sheave at an inner end of the upper frame and first guide arm.

[0025] A patent application AU2021106947A4 titled “Power line stringing system and method” discloses about a power line stringing system and method. The method for installing power line cables on transmission towers is provided. A primary line spooled at a first end on a primary winch is provided and is attached at a second end to an Unmanned Aircraft System (UAS). The primary winch and UAS are operated to pay out the primary line and deliver the second end of the primary line sequentially to a plurality of transmission towers and to thread or otherwise attach the primary line onto the supports of each transmission tower. The second end of the primary line is connected to a power line cable and the primary winch is operated to wind in the primary line, thereby drawing the power line cable in place of the primary line.

[0026] The aforementioned systems and methods are inadequate for efficient stringing of conductors in utilisation of existing equipment for stringing with light drones.

[0027] Hence, there is a need required for a set of systems, methods and devices which permits use of the conventional aerial rollers with light drones, heavy drones as well as helicopters, that is adaptable and versatile to be used on most types and sizes of aerial rollers without permanent modification or physical changes to the conventional aerial rollers.

[0028] Also, there is a need for an attachment or device which enables use of light drones with helicopter stringing blocks in place of heavy drones.

[0029] Also, there is a need for an attachment or device that increases the range of heavy drone by virtue of ease of operation and low power consumption.

[0030] Also, there is a need for an attachment or device which can be adjusted for varying requirements of actuation loads of respective relay and gate mechanisms.

[0031] Also, there is a need for a device which is so designed as to prevent inadvertent actuation of gates and relay mechanisms by means of interlocks and other design features.OBJECTIVE OF THE INVENTION

[0032] The primary objective of the present invention is to provide a versatile apparatus which could be conveniently installed without using complicated methods or very high level of expertise, for conventional aerial rollers of various makes, sizes, and configurations for stringing power transmission lines to convert into drone enabled stringing blocks.

[0033] Another objective of the present invention is to provide the method and apparatus, for conventional aerial rollers for stringing power transmission lines, for facilitating use of very light capacity drones and very small diameter lines used as pulling line for pre -pilot or pre-pre-pilot wire.

[0034] Another objective of the present invention is to provide the method and apparatus for helicopter stringing type aerial rollers for stringing of Power transmission lines, for facilitating the use of very light capacity drones and very small diameter lines used as pulling lines for pre -pilot or pre-pre- pilot wire.

[0035] Another objective of the present invention is to provide methods and the apparatus, for conventional aerial rollers for stringing power transmission lines, for stringing with various pulling loads like helicopters or heavy drones or dropped / slung lines.

[0036] Yet another objective of the present invention is to provide the apparatus, for aerial rollers for stringing power transmission lines, for eliminating need of replacing or modifying the components of the conventional aerial roller block.

[0037] Yet another objective of the present invention is to provide method and the apparatus, for helicopter stringing blocks for stringing power transmission lines, for eliminating need of replacing or modifying the components of the helicopter stringing block.

[0038] Yet another objective of the present invention is to provide the apparatus, for aerial rollers for stringing power transmission lines, which is conveniently configured for the aerial rollers with non-standard geometries and configurations.

[0039] Yet another objective of the present invention is to provide the apparatus, for aerial rollers for stringing power transmission lines, which can also be conveniently removed to restore the aerial rollers to their original configuration as conventional aerial rollers.

[0040] Yet another objective of the present invention is to provide the apparatus, for aerial rollers for stringing power transmission lines, which does not reduce the working capacity or load bearing characteristics of the original aerial rollers.

[0041] Yet another objective of the present invention is to provide the apparatus that is rugged, compact and light and does not involve any substantive accommodative changes in installation and operation upon integration with the aerial rollers.

[0042] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines, for controls and interlocks for tuning its operation to various operational requirements in its working and for safety.

[0043] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines with fewer constraints compared to conventional and heavy aerial vehicle stringing to cover terrains not easily accessible or small corridors such as between the vertical and cross members of the towers.

[0044] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines, for using intermediate capacity drones so that more towers can be strung in a single flight.

[0045] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines, further increased number towers covered by using even heavier capacity drones with light lines.

[0046] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines for higher speeds in stringing and increasing the productivity in terms of number of towers through which conductors can be strung per day.

[0047] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines that allows for round trip in laying the light pre -pilot line on separate series of rollers bringing the drone back to the base.

[0048] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines with provision of Optical and RF tags can autonomously guide the drones with less effort on the drone operator.

[0049] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines, to utilise the higher manoeuvrability, ease of control of lighter drones for fast-track training of new operators.

[0050] Yet another objective of the present invention is to provide the apparatus and methods, for aerial rollers for stringing power transmission lines is to provide safer working conditions because lighter drones are less likely to cause damage in case of collision or crash due to unexpected events.

[0051] Other objects and advantages of the present invention will become apparent from the following descriptions taken in connection with the accompanying drawings, illustrations, and examples to disclose the aspects of the present invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawingsillustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0053] In the figures, similar components and / or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0054] Figure 1 illustrates a schematic front view of a typical conventional Aerial Roller with seven sheaves.

[0055] Figure 2 illustrates a schematic isometric view of a typical conventional Aerial Roller with seven sheaves.

[0056] Figure 3 illustrates a front view of a complement of subassemblies of the present invention in relation to the conventional aerial roller with disassembled yoke plate in accordance with an embodiment of the present invention.

[0057] Figure 4 illustrates a part front view of the assembly of the invention with first version of headboard gates with conventional aerial roller in accordance with an embodiment of the present invention.

[0058] Figure 5 illustrates a schematic front view of a typical Helicopter Stringing Block with rotary gate, integrated with the drone line collector arm and two sets of toggle roller mechanisms.

[0059] Figure 6 illustrates a schematic front view of a typical Helicopter Stringing Block with a hinged flap gate, integrated with the drone line collector arm and two sets of toggle roller mechanisms.

[0060] Figure 7 illustrates a cut out front view of the assembly of the present invention with a single toggle roller on the line collector arm, with both the rotary gate and toggle roller in receiving position, in accordance with an embodiment of the present invention.

[0061] Figure 8 illustrates a cut out front view of the assembly of the present invention with a single toggle roller on the line collector arm, with rotary gate in receiving position and toggle roller in relaying position, in accordance with an embodiment of the present invention.

[0062] Figure 9 illustrates a cut out front view of the assembly of present invention with both the rotary gate and toggle rollers in activated state.

[0063] Figure 10 illustrates a front view of the assembly of the invention with first version of headboard gates with a seven-sheave conventional aerial roller in accordance with an embodiment of the present invention.

[0064] Figure 11 illustrates a front view of the assembly of the invention with the first version of headboard gates with three sheave conventional aerial roller in accordance with an embodiment of the present invention.

[0065] Figure 12 illustrates a front view of the assembly of the invention with second version of line guides with seven-sheave conventional aerial rollers in accordance with an embodiment of the present invention.

[0066] Figure 13 illustrates a front view of the assembly of the invention with second version of line guides with three-sheave conventional aerial rollers in accordance with an embodiment of the present invention

[0067] Figure 14 illustrates the isometric view of the intermediate side members in accordance with an embodiment of the present invention.

[0068] Figure 15 illustrates a view of a detail of the intermediate side member in accordance with an embodiment of the present invention

[0069] Figure 16 illustrates a view of a detail of the intermediate side member in accordance with an embodiment of the present invention

[0070] Figure 17 illustrates an isometric view of the line collector arm in accordance with an embodiment of the present invention

[0071] Figure 18 illustrates an isometric view of the swing over toggle roller assembly before activation in accordance with an embodiment of the present invention.

[0072] Figure 19 illustrates anisometric view of the swing over toggle roller assembly after activation in accordance with an embodiment of the present invention.

[0073] Figure 20 illustrates an isometric view with cut section of the swing over toggle roller assembly with internal parts in accordance with an embodiment of the present invention

[0074] Figure 21 illustrates a front view of the first version of line guide headboard gate subassembly in accordance with an embodiment of the present invention

[0075] Figure 22 illustrates a view of a detail of the first version of the line guide headboard gate in accordance with an embodiment of the present invention.

[0076] Figure 23 illustrates a cross-sectional view of a detail of the first version of line guide headboard gate in accordance with an embodiment of the present invention.

[0077] Figure 24 illustrates a front view of the second version of line guide headboard gate subassembly in accordance with an embodiment of the present invention

[0078] Figure 25 illustrates a view of a detail of the second version of the line guide headboard gate in accordance with an embodiment of the present invention.

[0079] Figure 26 illustrates a cross-sectional view of a detail of the second version of line guide headboard gate in accordance with an embodiment of the present invention.

[0080] Figure 27 illustrates an isometric view of the assembly of the invention with the first version of headboard gates with conventional aerial roller with headboard gate in headboard passing position in accordance with an embodiment of the present invention

[0081] Figure 28 illustrates an isometric view of the assembly of the invention with the first version of headboard gates with conventional aerial roller with headboards in conductor extraction position, in accordance with an embodiment of the present invention

[0082] Figure 29 illustrates assembly of the invention with second version of headboard gates with conventional aerial roller with the line guides in headboard passing position in accordance with an embodiment of the present invention

[0083] Figure 30 illustrates assembly of the invention with second version of headboard gates with conventional aerial roller with the line guides in conductor extraction position in accordance with an embodiment of the present invention.SUMMARY OF THE INVENTION

[0084] Accordingly, the present invention discusses about an apparatus for enabling a wide variety of conventional aerial rollers (101) and helicopter stringing blocks (201, 301) with light to heavy aerial vehicles of different capacities in stringing of power transmission lines. Further, the design of the apparatus enables using conventional aerial rollers as helicopter stringing blocks.

[0085] Further, the design of the apparatus involves its universality for a wide range of aerial rollers and integration of functions and controls in a unique manner. Further, the design of the apparatus involves enabling a conventional aerial roller for stringing by light drones with development of a set of two universally mounting intermediate side members (102, 103) of a novel design. Further, the design of the apparatus involves one of the intermediate side members (102) as a direct load bearing extension of the side arm (2) of the aerial roller and another intermediate side member (103) comprising of a unique design modification, of a slotted cam rotary gate ( 103D) that incorporates a two-step safety lock (103E, 103F) and also incorporates a novel activation load adjustment mechanism.

[0086] Further, in a novel aspect of the design of the apparatus, both intermediate side members (102, 103) are provided with multiple sets of fasteners and adapter bushes (6D, 6E) with bores and lengths in discreet increments for compatible fitment with the mounting points in a wide variety of aerial rollers.

[0087] Further, a suitable set of adapter bushes (6D, 6E) is selected and affixed to each intermediate side member. Further, each intermediate side member is mounted between the respective side arms (1, 2) of the aerial roller and the top bracket (8) of the aerial roller and sidemembers are aligned to the side arms of the aerial roller and fixed in position with help of centring and aligning clamps (102A, 103A).

[0088] Further, the design of the apparatus involves development of a novel and unique drone line collector arm (104) with detachable toggle roll mechanism (105) with two locks and having a dual activation load adjustment. The drone line collector arm (104) is affixed to the pilot wire receiving area of the rotary cam gate (103D) by means of a C-bracket (104 A) and clamping screws. Further, the design of the apparatus involves development of a secondary line collector arm (106) positioned such that it lets the drone line into the receiving area of the toggle rolls (105).

[0089] Further, the design involves the development of two alternate versions of line guides or headboard gates (107, 108) which are fitted to intermediate side members at the designated mounting plate (102B, 103B) by means of fasteners. Further, the design of the apparatus involves alternate versions of novel integrated but detachable bidirectional, dual-axis, configurable Line guides (headboard gates) which also allow the passage of headboard from either direction through the aerial rollers. Further, the headboard gates are so designed that they can be configured and adjusted to match the aerial rollers dimensions.

[0090] The aerial rollers fitted with the apparatus in the present invention are then prepared for operation by setting the slotted cam transfer mechanism (103D) and the collector arm toggle rolls (105) in desired position and, at desired respective activation loads. Once in position on the tower, the locks (103E, 103F) in the apparatus are released.

[0091] Further, the design involves passing the drone line pulled by drone from ground reel over set of toggling rolls (105) with low rolling resistance on the drone line collector arm (104) which allows smooth pull of a lightweight drone line across the towers. From there onwards the drone line would be used to pull the pilot wire using a puller winch on the ground. Further, in an aspect of the design, as the drone line pulls the heavier pilot wire over toggle rollers (105) on the collector arm (104), the weight and pull of the pilot wire would press the toggle rollers which swing over and let the pilot line slide into the receiving slot of the rotary gate (103D). The rotary gate will activate due to the weight and tension of the rope on trigger arms and transfer the pilot wire into the stringing block, over the line guides (107, 108) and into the groove of the designatedsheave (5C) from which point the remainder of stringing operation would be carried out. Further in an aspect of design, the toggle rolls mechanism (105) can be affixed at any position on the line collector arm (104B) and is also detachable. The line collector arm zone is affixed with optical and RF tags for autonomous drone navigation. The line collector arm (104) itself is detachable and its design allows its clamping to most sizes of other aerial rollers. This design feature is salient in integrating the collector arm with helicopter stringing blocks.

[0092] Further, the apparatus in this invention is novel and in terms of its overall assembly, in design of its main components namely the universally adaptable side intermediate members (102, 103), lockable and activation load adjustable rotary transfer gate (103D), articulated dual-axis bidirectional line guides / headboard gates (107, 108), toggle rolls (105) mounted on line collector arm (104) as well as the integration of the system and functions with aerial rollers. The invention also opens new possibilities for numerous iterations of stringing methods.DETAILED DESCRIPTION OF THE INVENTION

[0093] The following description describes various features and functions of the disclosed system and methods. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system and apparatus can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.

[0094] The following description of preferred embodiments of the invention is not intended to limit the invention to these preferred embodiments, but rather to enable any person skilled in the art to make and use this invention.

[0095] These and other features and advantages of the present invention may be incorporated into certain embodiments of the invention and will become more fully apparent from the following description as set forth hereinafter.

[0096] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0097] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0098] It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0099] It should be emphasized that the term "comprises / comprising" when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0100] The present invention relates to a nearly universal, adaptable and versatile system comprising of a new 'bolt-on' conversion kit (100) for a wide variety of conventional standard aerial rollers (101) used in overhead power line stringing and method of application. The present invention converts conventional aerial rollers (101) and helicopter stringing blocks (201 and 301) into drone stringing blocks. The present invention can also convert conventional aerial rollers into helicopter stringing blocks. The apparatus enables using conventional aerial rollers of various sizes, configurations, makes and types for stringing overhead power transmission lines using light aerial vehicles ranging from small drones to helicopters.

[0101] The line or wire to be used in drone stringing with this invention can be very light, and allows covering greater number of power transmission towers in a single flight because of very low rolling resistance of the smaller lighter toggle rollers (105) on antifriction bearings that are mounted on the collector arm (104) of the present apparatus. The aerial rollers have heavy sheaves (5, 5C) and greater rolling resistance so even the heavy lifting drone has limited tugging power, and its range of towers covered can be limited by the rolling resistance of the sheaves of the aerial roller. The apparatus also enables using helicopter stringing blocks for stringing with drones.

[0102] The invention involves designing of the apparatus to also integrate with special helicopter blocks (201, 301) to operate them with drones by using the novel design of universalclamping C-bracket (104A) of drone line collector arm (104) having toggle rollers (105) with low rolling resistance. The design of the apparatus involves its universality for a wide range of aerial rollers and integration of functions and controls in a unique manner.

[0103] In this method, universal mounting intermediate member arms (102, 103) with matching set of adapter bushes (6D, 6E) replace the yoke plate (8) and are mounted onto each vertical arm (1, 2) of the aerial roller with the already existing load bearing handles (7). The intermediate members are then aligned and clamped to the respective side arms ( 1 , 2) of the aerial roller block with fasteners and adjustment screws. The yoke plate (8) is then mounted at the top end brackets of the extension members with a matching set of adapter bushes (6D, 6E) and fasteners. The extension members thus become integral load bearing members between the yoke plate (8) and the arm of frame the aerial roller frame. Both the extension members comprise a universal adapter plate (102A, 103A) with mounting points for line guide / headboard gates (107, 108). One intermediate extension member (102) has a straight bracket, and the other side member (103) has a slotted cam rotary gate (103D) for receiving the line from outside the block and conveying it to the inside of the block.

[0104] The apparatus comprises of a universal mounting intermediate member (102, 103), slotted cam line transfer mechanism (103D) with an 'On-Cam Trigger Lock' (103F), triggering sensitivity adjustment system and provision for remote unlocking and actuation. The design of the apparatus involves enabling a conventional aerial roller for stringing by light drones with development of a set of two universally mounting intermediate side members (102, 103) of a novel design. One of the intermediate side members (102) acts as a direct load bearing extension of the side arm (2) of the aerial roller and another intermediate side member (103) comprises of a unique design modification, of a slotted cam rotary gate (103D) that incorporates a two-step safety lock (103E, 103F) and also incorporates a novel activation load adjustment mechanism.

[0105] The slotted cam rotary gate (103D) is designed with a novel dual step locking system (103E, 103F) that prevents inadvertent actuation to be released when the aerial roller is ready for stringing operation after hoisting and suspending. The locking system may be operated manually by lowering a lever (103E) on the side of the cam holding bracket (103C). The locking systemmay also be unlocked remotely, wired, or wireless, with provision for electromechanical actuator such as solenoid. The wireless remote locking system may also be operated by a drone operator through drone itself as it approaches the aerial roller. The locked or unlocked status of the slotted cam rotary gate ( 103D) is clearly visible from reasonable distance or from drone camera. In a novel aspect of the design of the apparatus, both intermediate side members (102, 103) are provided with multiple sets of fasteners and adapter bushes (6D, 6E) with bores and lengths in discreet increments for compatible fitment with the mounting points in a wide variety of aerial rollers.

[0106] Another novelty in the present design is the trigger assembly in the slotted cam rotary gate (103D) that can be adjusted for triggering force by means of special configuration of springs, coaxial adjustment screw and axial spacers. The rotary gate adjusted to set load is actuated upon triggering by the ingressing pilot wire which pushes the two trigger rods flanking the slot in the cam (103D), this releases the cam stopper (103F) and the eccentrically loaded slotted cam (103D) rotates by gravity under the weight of the block and conveys the pre-pilot / pilot line through its rotating slot to inside the block. A suitable set of adapter bushes (6D, 6E) is selected and affixed to each intermediate side member. Each intermediate side member is mounted between the respective side arms (1, 2) of the aerial roller and the top bracket (8) of the aerial roller and side members are aligned to the side arms of the aerial roller and fixed in position with help of centring and aligning clamps (102A, 103 A).

[0107] The rotary gate (103D) has provision for detachable pivoting safety hood to avoid accidental activation and injury through unintended contact. The rotary gate also has provision for using blinder guides mounted on the holding brackets (103C) of the rotary gate for safety as well as controlled ingress of pilot line into the cam slot. The design of the apparatus involves development of a novel and unique drone line collector arm (104) with detachable toggle roll mechanism (105) with two locks and having a dual activation load adjustment. The drone line collector arm (104) is affixed to the pilot wire receiving area of the rotary cam gate (103D) by means of a C-bracket (104A) and clamping screws.

[0108] The designing of the apparatus also involves developing a novel special line collector arm (104) is designed with universal type C-bracket clamp (104A) to attach it to the intermediateside member (103) with the slotted cam rotary gate (103D). The line collector arm (104) is designed to be affixed to other type of aerial rollers as well. The design of the apparatus involves development of a secondary line collector arm (106) positioned such that it lets the drone line into the receiving area of the toggle rolls (105).

[0109] The line collector arm (104) is attached with novel low rolling resistance toggle rolls (105) of L-shape configuration in the present apparatus, to allow smooth pull of a lightintermediate drone line across the towers. This novel method involves passing the drone line over the collector arm receiving zone, from where it slides towards, and starts rolling on the said toggle rolls (105). The drone then flies the drone line to pass over the receiving zone of the line collector arm (104) mounted on the next set of aerial rollers at the next tower and so on till the last tower in its flight from where it lands to the ground. The design involves the development of two alternate versions of line guides or headboard gates (107, 108) which are fitted to intermediate side members at the designated mounting plate (102B, 103B) by means of fasteners.

[0110] The drone line is detached from the drone and hooked to a pulling winch of suitable capacity. The drone line is used to pull the pilot wire across towers, using the pulling winch on the ground. On passage of pilot wire, the weight and pulling load of pilot wire exceeds the actuation load of the L-shape toggle rollers (105) which then toggle down and below the collector arm (104B). At this point the pilot wire while still being pulled ahead simultaneously slides down the collector line and into the receiving area for ingress into the slotted cam mechanism (103D). The slotted cam rotary gate (103D) is then triggered by the pilot wire and conveys the pilot line into the aerial roller block. The pilot wire then slides down on the line guides (107, 108) into the groove of the designated sheave (5C) from where the regular stringing operation can begin. The aerial rollers fitted with the apparatus in the present invention are then prepared for operation by setting the slotted cam transfer mechanism (103D) and the collector arm toggle rolls (105) in desired position and, at desired respective activation loads. Once in position on the tower, the locks (103E, 103F) in the apparatus are released.

[0111] A method using toggled rollers (105) in a two-stage configuration is developed. Two stage pre-pilot wires involving use of the two sets of the toggle rollers (105) are used in thismethod. This method allows drone stringing over a greater number of towers with an ultra-light first pre-pilot line which is passed over the collector arm (104B) on to the first set of toggle rollers (105) which are set to a predetermined load across the towers to the winch on the ground after the last tower in the flight. The design involves passing the drone line pulled by drone from ground reel over set of toggling rolls (105) with low rolling resistance on the drone line collector arm(104) which allows smooth pull of a lightweight drone line across the towers. From there onwards the drone line would be used to pull the pilot wire using a puller winch on the ground.

[0112] Using the puller winch, the first stage light pre -pilot line is the used to pull the second stage pre-pilot line of higher or intermediate capacity. The first set of toggle rollers (105) actuate and toggle down upon the passage of thicker second stage pre -pilot. The second stage pre -pilot wire slides further down the collector arm (104B) and starts rolling over second set of the toggle rollers (105). Once the second stage pre -pilot reaches the ground station, it is attached to a puller winch. The second stage pre -pilot then pulls the main pilot wire across the towers over the respective second stage toggle rollers (105). The second set of toggle rollers (105), set at a higher actuation load, then activate upon passage of the main pilot wire which then passes through the ingress gates of the rotary slotted cam gate (103D) on to the line guide (107, 108) and into the designated groove of the aerial roller sheave (5C) from where the regular stringing operation can begin. In an aspect of the design, as the drone line pulls the heavier pilot wire over toggle rollers(105) on the collector arm (104), the weight and pull of the pilot wire would press the toggle rollers which swing over and let the pilot line slide into the receiving slot of the rotary gate (103D). The rotary gate will activate due to the weight and tension of the rope on trigger arms and transfer the pilot wire into the stringing block, over the line guides (107, 108) and into the groove of the designated sheave (5C) from which point the remainder of stringing operation would be carried out.

[0113] A sliding and pivoting secondary collector arm (106) is attached over to the intermediate side arm (103) on the rotary gate side traversing over the yoke plate (8). This guidebar is so designed such that its height, reach and angle of inclination can be adjusted and directs the drone line towards the desired zone of the collector arm (104) over the yoke plate and swing-over rolls (105) of the line collector arm in case it falls in that general area. It also increases the capture area of the drone line for easier traverse of the drone over the aerial roller. In an aspect of design, the toggle rolls mechanism (105) can be affixed at any position on the line collector arm (104B) and is also detachable. The line collector arm zone is affixed with optical and RF tags for autonomous drone navigation. The line collector arm (104) itself is detachable and its design allows its clamping to most sizes of other aerial rollers. This design feature is salient in integrating the collector arm with helicopter stringing blocks.

[0114] Another novelty in the design of present apparatus provides for bi-directional line guides (107, 108), also called headboard gates that direct the pilot wire from the slotted cam mechanism (103D) to the designated sheave groove (5C). They also allow passage of a device called the headboard when the conductor stringing operation begins. The headboard is designed to be pulled by the pilot wire and distribute the pulling load evenly to the conductors being strung. It also carries the conductors to the designated sheaves (5, 5C) while passing through the aerial roller blocks. The design of the apparatus involves alternate versions of novel integrated but detachable bidirectional, dual-axis, configurable line guides (headboard gates) which also allow the passage of headboard from either direction through the aerial rollers. The headboard gates are so designed that they can be configured and adjusted to match the aerial rollers dimensions.

[0115] The conventional aerial rollers have very little gap between outer most roller and the side arms (1, 2). Therefore, the positioning and working path of the gates (107, 108) are of importance. The conventional aerial roller (101) comprises vertical load bearing side arms (1, 2) that support the roller shaft (4) and are integral with bottom member (3). The side arms have a slot at the top and have holes (6) to hold the load bearing pin with a handle (7). The roller shaft (4) is a load bearing member over which the sheaves (5, 5C) are mounted. The sheaves are pulleys that rotate freely over the shaft (4) by means of ball bearings and have a grooved profile on outer diameter through which the rope and conductors travel. The central sheave (5C) carries the load of pilot wire and may have stronger load bearing capacity than the side sheaves which carry the conductors.

[0116] At least two versions, having a first version (107) and a second version (108) of the headboard are designed. The line guides in both the versions, are designed to be mounted to the mounting plates (102B, 103B) provided on the intermediate side members (102, 103). The yoke plate (8) is a lifting bracket for bearing the load on the aerial rollers through the handles (7) connected to side arms (1, 2). It conveys the load to a set of hanging plates (9) by means of fasteners (10). The handle or cotter (7) is a pin that couples the side arms (1, 2) through holes (6) with yoke plate (8). The handles are removable manually for releasing the yoke plate (8) for opening the roller.

[0117] In one embodiment of the first version of line guides (107), double axis swiveling rope / line guides with detachable flaps are integrated into both gated and non-gated arm. The line guides with smooth, inclined top surface guide the pre-pilot / pilot line introduced into the block from the rotary gate (103D) to the groove of the designated sheave (5C) which may be the center sheave. The line guides have adjustable polymer restrictors (107 A) at the interface between line guide path and the lip of the sheave to ensure the placement and retention of the pilot line in the designated sheave groove. The intermediate side member (102) includes an adapter plate with centering and clamping bracket (102A) that fits, aligns and holds the intermediate side member in line with the extension arm. It also includes a gate mounting plate (102B) for affixing the gate docking plate (107B or 108B) with fasteners, and a side extension arm (102C) that acts as a load bearing spacer arm to keep required spacing between side arm (2) and yoke plate (8).

[0118] The headboard gates in the first version (107) have drop flaps lined with nonscratching material on bottom edge to prevent any incidental scuffing of the conductors passing below it. The rugged configuration allows bi-directional passage of the headboard by swinging forward and above the headboard in the direction of the pull. During regular operation, it is prevented from opening sideways by slot and indexing pin mechanism. The intermediate side member (103) includes an adapter plate with centering and clamping bracket (103A), a gate mounting plate (103B), and a cam bracket (103C) that is attached to the yoke plate (8) and houses the rotary gate locking, adjustment and activation mechanism. The eccentric slotted cam (103D)is attached to the cam bracket (103 C) by means of a shaft and has a notch against which the spring loaded actuation stopper (103F) holds its rotation.

[0119] The headboard is centered in receiving and guiding position with an internal centering spring follower and internal cam with ball catch mechanism. A distinguishing feature in this design is elimination of external springs for headboard centering, which interferes with the general handling, and which can also entangle drone line in breezy conditions. The headboard gates (107) can also be opened horizontally outwards on by disengaging the index pin in sleeve bush and rotating it to the side around the vertical pivot. This provides clear passage for lifting the conductors out of the block and hanging them to the insulators on the towers. The headboard gate may also be completely detached and kept out of the way during the conductor hanging operation. Accordingly, this design also enables use of conventional headboards with minimum clearance. The cam lock lever (103E) is used to arm or disarm the stopper (103F) for safe locking / rotation of the cam (103D). The stopper plate (103F) stops the rotation of the cam in initial setting and is lifted by triggering action of the pilot wire. The cam housing (103G) is attached to the adapter plate (103A) by means of fasteners and has a groove and lip profile to hold the cam (103D) while allowing it to slide while rotating.

[0120] This first version of the headboard gate (107) with segmented gate flaps allows for some adjustment in discreet steps to suit the dimensions of various sizes and configurations of aerial rollers. The drone line collector (104) comprises a line collector clamp (104A) that acts as an adapter clamp which functions as a socket for the collector arm (104B) and attaches the collector arm to the rotary gate housing (103G). The line collector arm (104B) is a long tubular u-shaped part that provides a wide collection zone for the pilot wire or pre -pilot wire to rest and slide down to the toggle roller or ingress of the rotary gate as may be required. It also functions as an installation base for toggle roller assembly (105).

[0121] In another embodiment, of the second version of the line guides (108) are designed with inclined double pivoting axis and telescopic guide members affixed to the respective mounting plates (102B, 103B) of both the gated and non-gated intermediate side members (102, 103) for operation. In this case, both the length and inclination of the guide member may beadjusted and set to guide the pre -pilot or pilot wire coming in from the C-gate into the groove of the desired sheave (5C). The arms are adjusted by swiveling and adjusting the telescopic guides to lead the line and rope into the designated sheave groove and setting them in that position. The design allows for bi-directional passage of the headboard by swiveling forward, up, and outwards on either side of the aerial roller block. The line guide is centered in receiving and guiding position with an internal centering spring follower and internal cam mechanism. A feature in this design is self-centering of line guides without the use of external springs, which interferes with the general handling, and which can also entangle drone line in breezy conditions. The guides are manually moved simultaneously to outward position during extraction of conductors from the block after pulling. The second version of the headboard gate (108) is designed and consist of telescopic line guides swinging on an inclined axis. The inclination and reach of the of this second version of the line guide can be easily set for the aerial roller blocks of various sizes and configuration. In its operational mode and it swings up and out by virtue of its inclined axis. This the second version of the headboard gate (108), has the widest range and is unique in this aspect.

[0122] So, integration of the universal adapter plate (102A, 103A), side member arms (102, 103), specially configured slotted cam rotary gate (103D) and special line collector arm (104) with toggle rollers (105) is designed, improved enhanced and refined to the level of current submission. The apparatus in this invention is novel and in terms of its overall assembly, in design of its main components namely the universally adaptable side intermediate members (102, 103), lockable and activation load adjustable rotary transfer gate (103D), articulated dual-axis bidirectional line guides / headboard gates (107, 108), toggle rolls (105) mounted on line collector arm (104) as well as the integration of the system and functions with aerial rollers. The invention also opens new possibilities for numerous iterations of stringing methods.

[0123] An aspect involves a pre -pilot line collector arm (104) with set of lockable loads actuated swing-over or toggled rollers (105) with a set of rollers aligned in "L" shape configuration. The collector arm (104) is where the drone pays in the drone line also called the pre pilot line. The collector arm (104) fits onto the slotted cam rotary gate side extension member (103). The drone passes the pre -pilot line over the collector arm (104) in the capture zone where it slides and comesto rest over the toggle rolls or swing-over rolls (105). The swing-over or toggled rollers (105) on the collector arm (104) act as load actuated relays. They convey the pre-pilot / pilot line down the collector arm (104B) towards the receiving area of the slotted cam rotary gate (103D) upon reaching a set triggering load by toggling down below the guiding surface of the collector arm. The relay load is set to required level by use of adjusting the tension in toggle spring, and a tuneable load release clamp. The locking and load release mechanism is designed to accommodate remote controlled locking and actuation as well. The toggle rollers (105) can be used in single or multiple configurations on the same collector arm (104B) to actuate on receiving the pre-pilot / pilot lines of increasing diameters. Accordingly, the set loads are also increased for each successive toggle in the direction of the slotted cam gate (103D). The toggle roller relay mechanism or toggle rolls (105) comprises a set of inclined, almost perpendicular rollers with overlapping axes, mounted on a spring loaded toggle mechanism. The mechanism is affixed to the line collector arm (104B) with built in fastener clamping.

[0124] Two or more toggle rolls sets (105) may be mounted on the same collector arm (104B). This is applicable when two or more pre -pilots are used in increasing sizes, consecutively to pull the main pilot rope. This method is particularly ideal for starting with a very small diameter first pre -pilot on a light drone. With this method, pre -pilot wires of increasing diameters can be used without switching the collector arm or other intensive interventions at tower height in order to lead the main pilot wire to the pulling end. There is also a provision for a delayed pre-set toggling acting as a pre-roller for the main pilot rope which actuates only after the main pilot rope has crossed a pre-set distance beyond the aerial roller by disengaging the lock pin through a trigger which operates on set number of revolutions of the toggle rolls (105). The secondary collector arm (106) is an adjustable member that provides line capture area over the yoke plate and guides the pre -pilot wire to the desired toggle roll. It is mounted on the cam bracket or the yoke plate as desired with built in clamp.

[0125] The toggle rolls (105) on the collector arm (104B) may be locked in position till required, to prevent inadvertent actuation during hoisting and handling and can be unlocked right before use. In this design, the lock may also be operated from a distance with a manual pullingchord, a solenoid with wired or wireless remote control from ground or by a drone operator through drone itself as it approaches the aerial roller. The toggle rolls (105) on the collector arm (104B) have very low rolling resistance and can operate as idlers without power and / or additional controls. This means that a greater number of towers can be covered in a single drone flight. The 'swing- over rolls' (105) profile may be customised depending upon the characteristics and size of the prepilot line travelling over them if desired by user. In case of helicopter stringing directly with pilot wire, the collector arm (104) may be used without the toggle rollers (105). Counterweight for balancing the roller includes balance weight on the side opposite to the collector arm (104) which helps in adjusting the tilt or even provide reverse tilt to the aerial roller for appropriate inclination of the drone line collector arm.

[0126] In an embodiment, a method for operating the apparatus for using conventional aerial rollers for stringing power transmission lines with very light drones. The collector arm (104) with two (or more sets) of toggle rolls (105) on the collector arm of the present apparatus is used on the apparatus on each set of aerial rollers suspended from designated successive towers. A very light weight line that is the first line of suitable length with sufficient tensile strength, is used to pull successive lines across the towers. The first line is pre-wound on the payout reel on the ground. The first line is attached to the drone and tugged by the drone. The drone tugs this first line on a path so as to travel it over the first stage toggle rolls (105) of respective collector arms (104) of the apparatus on each set of aerial rollers suspended from successive towers till it travels over the final set of collector arm (104) of the apparatus at the final designated tower. After travelling over the final tower from the line is landed by the drone to the ground. The line is released from the drone and is attached to the puller for subsequent pulling. At the starting point, the first line is released from the payout reel and fastened to a higher strength and larger diameter pre -pilot line of suitable length. The pre pilot is pre-wound on its own reel tensioner on the ground. The first line is then pulled by the puller positioned on the ground after the final tower. The first line in turn, pulls the pre -pilot line over the first stage toggle rolls (105) on the respective collector arms (104) of the apparatus on successive towers. As the pre-pilot line passes over the first stage toggle rolls (105) of the respective, successive, collector arms (104), it actuates the toggle rolls to toggle down and allows the pre-pilot to slide down and travel on the second stage toggle rolls (105). The pre-pilotline travels across successive towers in similar fashion. The pre- pilot line after travelling to the final tower. It is pulled to the ground and attached to its designated puller with sufficient pulling capacity. In this fashion it is used to pull the second pre -pilot line or the pilot wire as the case may be. Subsequently as the pilot wire travels on final stage toggle rolls (105) of the respective collector arms (104) of the apparatus, in following sequence, toggles the last stage toggle rollers (105), enters the slot of the slotted gate rotary gate (103D), triggers the gate, enters the block, slides over the line guide (107, 108) and into the groove (5C). From here on, the stringing operation is carried out in conventional manner.

[0127] In another embodiment, a method for operating the apparatus for using conventional aerial rollers for stringing power transmission lines with medium / heavy lifting drones. The collector arm (104) with single set of toggle rolls (105), on the collector arm of the present apparatus is used on the apparatus on each set of aerial rollers suspended from designated successive towers. A pre -pilot line, of suitable length with sufficient tensile strength, is used to pull the pilot wire across the towers. The pre -pilot is pre-wound on the payout reel and a tensioner on the ground. The pre-pilot is attached to the drone and tugged by the drone. The drone tugs the pilot on a path so as to travel it over the toggle rolls (105) of respective collector arms (104) of the apparatus on each set of aerial rollers suspended from successive towers, till it travels over the final set of collector arm (104) of the apparatus at the final designated tower. After travelling over the final tower, the pr-pilot is landed by the drone to the ground. The pre -pilot is then released from the drone and is attached to the puller for subsequent pulling. At the starting point, the prepilot is released from the payout reel and tensioner and fastened to the pilot wire of suitable length. The pilot wire is pre-wound on its own reel and tensioner on the ground. Pre -pilot is then pulled by the puller positioned on the ground after the final tower, and the pre-pilot in turn, pulls the pilot line over the toggle rolls (105) on the respective collector arms (104) of the apparatus on successive towers. As the pilot wire travels on final stage toggle rolls (105) of the respective collector arms (104) of the apparatus, it toggles the toggle rolls (105), enters the slot of the slotted gate rotary gate (103D), triggers the gate, enters the block, slides over the line guide (107, 108) and into the groove (5C). From here on, the stringing operation is carried out in conventional manner. There isprovision for delayed activation of toggle rolls (105) with pilot wire which activate after certain length of pilot wire has travelled over the toggle rolls.

[0128] In another embodiment, a method for operating the apparatus for using conventional aerial rollers for stringing power transmission lines with helicopter. The collector arm (104) of the apparatus is used without the toggle rolls (105) attached. And the operation is carried out as it would be in normal helicopter stringing operation.

[0129] In another embodiment, a method for operating the apparatus for using conventional aerial rollers for stringing power transmission lines with special helicopter stringing blocks (201, 301) but operation is to be carried out by drones. The collector arm (104) of the apparatus with single or multi-stage toggle (105) is used with a custom adapter and replaces the previous collector arm. The remaining sequence of operations is similar to methods 1 and 2 mentioned above, as applicable.ADVANTAGES OF THE INVENTION:

[0130] For upgrading a wide variety of conventional aerial rollers (101) to drone enabled stringing blocks with the gated and non-gated side members (102, 103) with a toggled relay bearing drone line collector arm (104).

[0131] For upgrading a wide variety of conventional aerial rollers ( 101 ) to helicopter stringing blocks with the gated and non-gated side members (102, 103) with a plain line collector arm (104).

[0132] For upgrading a wide variety of existing special Helicopter Blocks (201, 301) to light drone stringing enabled aerial rollers by attaching only the Line collector arm (104) with one or more set of toggled rollers (105) and overhead guide arm (106).

[0133] Obviates the need for special equipment to use the methods

[0134] For Easier Automated drone path navigation with RF beacons because of possibility of light drones and a larger drone line capture area.

[0135] Features of any of the examples or embodiments outlined above may be combined to create additional examples or embodiments without losing the intended effect. It should beunderstood that the description of an embodiment or example provided above is by way of example only, and various modifications could be made by one skilled in art. Furthermore, one skilled in art will recognize that numerous further modifications and combinations of various aspects are possible. Accordingly, the aspects described are intended to encompass all such alterations, modifications, and variations that fall within the scope of the appended claims.

Claims

CLAIMS:

1. An apparatus (100) for using conventional aerial rollers (101) for stringing power transmission lines with aerial vehicles, the apparatus comprising: universal mounting means comprising a first intermediate side member (102) and a second intermediate side member (103) for removably attaching the apparatus to the conventional aerial roller (101) without permanent modification to the aerial roller, wherein each intermediate side member includes adapter bushes (6D, 6E) with bores and lengths in discrete increments for compatible fitment with mounting points in a wide variety of aerial rollers; an automated pilot wire ingress mechanism configured to receive a pilot wire from outside the aerial roller and transfer the pilot wire into the aerial roller; the first intermediate side member (102) mounted between a first side arm (1) and a top bracket (8) and the second intermediate side member (103) mounted between a second side arm (2) and the top bracket (8), wherein each intermediate side member includes centering and aligning clamps (102A, 103A) for alignment with respective side arms of the aerial roller; a slotted cam rotary gate (103D) mounted to the second intermediate side member (103), the slotted cam rotary gate configured to receive a line outside the block and conveying it to the inside of the block, wherein the slotted cam rotary gate includes a dual-step locking mechanism (103E, 103F) configured to prevent inadvertent actuation and an activation load adjustment mechanism for setting triggering force; a drone line collector arm (104) affixed to the pilot wire receiving area of the rotary cam gate (103D) by means of a universal C-bracket (104A) and clamping screws, the drone line collector arm extending outwardly from the slotted cam rotary gate mechanism to provide a line reception area accessible by aerial vehicles;• toggle roller means (105) mounted on the drone line collector arm (104), the toggle roller means configured in an L-shaped arrangement to support a drone line from an aerial vehicle and automatically release the drone line when a predetermined load is applied to the drone line, wherein the toggle roller means comprises antifriction bearings for low rolling resistance and includes a locking mechanism to prevent inadvertent actuation during installation;• line guide means (107, 108) for directing the pilot wire from the automated pilot wire ingress mechanism to a designated sheave groove (5C) of the aerial roller, wherein the line guide means comprises bidirectional line guides configured with dual-axis articulation and telescopic adjustment to allow passage of a headboard in either direction through the aerial roller; and• a secondary collector arm (106) positioned to guide the drone line toward a receiving zone of the toggle rollers (105).

2. The apparatus (100) as claimed in claim 1, wherein the universal mounting means comprises the pair of intermediate side members (102, 103) configured to mount between respective side arms (1, 2) of the aerial roller (101) and the top bracket (8) of the aerial roller using existing load bearing handles (7).

3. The apparatus (100) as claimed in claim 1, wherein the adapter bushes (6D, 6E) are configured to accommodate different handle diameters and mounting configurations of various aerial roller types, and wherein a suitable set of adapter bushes is selected and affixed to each intermediate side member for compatible fitment.

4. The apparatus (100) as claimed in claim 1, wherein the automated pilot wire ingress mechanism comprises the slotted cam rotary gate (103D) configured to rotate under gravity to transfer the pilot wire from an external receiving position to an internal position within the aerial roller (101), andwherein the slotted cam rotary gate is eccentrically loaded and rotates by gravity under the weight of the block.

5. The apparatus (100) as claimed in claim 4, wherein the dual-step locking mechanism (103E, 103F) includes a cam lock lever (103E) and a stopper plate (103F) configured to prevent inadvertent actuation of the rotary gate (103D), and wherein the stopper plate is lifted by triggering action of the pilot wire.

6. The apparatus (100) as claimed in claim 5, wherein the dual-step locking mechanism (103E, 103F) is configured for remote unlocking through wired or wireless control with provision for electromechanical actuator.

7. The apparatus (100) as claimed in claim 4, wherein the activation load adjustment mechanism of the slotted cam rotary gate (103D) comprises a special configuration of springs, coaxial adjustment screw and axial spacers for setting a triggering force required to actuate the rotary gate.

8. The apparatus (100) as claimed in claim 1, wherein the toggle roller means (105) comprises multiple toggle rollers arranged in stages, each stage configured to actuate at different predetermined loads to accommodate pre-pilot wires of increasing diameters.

9. The apparatus (100) as claimed in claim 8, wherein the multiple toggle rollers (105) are configured in the L-shaped arrangement on the drone line collector arm (104) with overlapping axes and mounted on a spring loaded toggle mechanism.

10. The apparatus (100) as claimed in claim 1, wherein the toggle roller means (105) includes the locking mechanism configured to prevent inadvertent actuation during installation and handling, and wherein the locking mechanism may be operated from a distance with manual pulling chord or wireless remote control.

11. The apparatus (100) as claimed in claim 1, wherein the line guide means (107, 108) comprises the bidirectional line guides configured to allow passage of a headboard in either direction throughthe aerial roller (101), and wherein the line guides include adjustable polymer restrictors (107 A) at the interface between line guide path and the lip of the sheave.

12. The apparatus (100) as claimed in claim 11, wherein the bidirectional line guides (107, 108) are configured with the dual-axis articulation and telescopic adjustment to accommodate different aerial roller configurations, and wherein the line guides are centered in receiving and guiding position with an internal centering spring follower and internal cam mechanism.

13. The apparatus (100) as claimed in claim 1, wherein the drone line collector arm (104) includes the universal C-bracket clamp (104A) configured to attach to different types of aerial rollers and helicopter stringing blocks (201, 301), and wherein the C-bracket functions as a socket for the collector arm (104B).

14. The apparatus (100) as claimed in claim 1, wherein the secondary collector arm (106) is configured as an adjustable sliding and pivoting member that guides the drone line toward the receiving zone of the drone line collector arm (104), and wherein the secondary collector arm has adjustable height, reach and angle of inclination.

15. The apparatus (100) as claimed in claim 1, wherein the toggle roller means (105) comprises the antifriction bearings configured to provide low rolling resistance for the drone line, and wherein the toggle rollers have very low rolling resistance and can operate as idlers without power.

16. The apparatus (100) as claimed in claim 1, further comprising optical and RF tags affixed to the line collector arm zone for autonomous drone navigation.

17. The apparatus (100) as claimed in claim 1, wherein the slotted cam rotary gate (103D) includes provision for detachable pivoting safety hood to avoid accidental activation and blinder guides mounted on holding brackets (103C) for controlled ingress of pilot line into the cam slot.

18. A method of converting a conventional aerial roller (101) for stringing power transmission lines with aerial vehicles, the method comprising:removably attaching universal mounting means comprising intermediate side members (102, 103) with adapter bushes (6D, 6E) to the conventional aerial roller (101) without permanent modification to the aerial roller; positioning an automated pilot wire ingress mechanism comprising a slotted cam rotary gate (103D) with dual-step locking mechanism (103E, 103F) to receive a pilot wire from outside the aerial roller; extending a drone line collector arm (104) from the universal mounting means using a universal C-bracket (104A); mounting toggle roller means (105) in L-shaped configuration on the drone line collector arm (104), the toggle roller means configured to support a drone line from an aerial vehicle and automatically release the drone line when a predetermined load is applied to the drone line; configuring bidirectional line guide means (107, 108) with dual-axis articulation to direct the pilot wire from the automated pilot wire ingress mechanism to a designated sheave groove (5C) of the aerial roller; setting the slotted cam rotary gate (103D) and toggle rollers (105) in desired position and at desired respective activation loads; releasing locks (103E, 103F) in the apparatus when the aerial roller is positioned on the tower; receiving the pilot wire at the automated pilot wire ingress mechanism from outside the aerial roller; transferring the pilot wire into the aerial roller via the automated pilot wire ingress mechanism;• supporting the drone line from the aerial vehicle with the toggle roller means (105); and• automatically releasing the drone line when the predetermined load is applied to the drone line, causing the toggle rollers to swing over and let the pilot line slide into the receiving slot of the rotary gate (103D).

Images