Motorized Cable Puller Adapter for Tailing Force Control
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Solution Overview
Problem
Inconsistent tailing force and pulling speed in cable pulling operations due to manual application by operators, leading to potential damage to electrical cables or wires and inefficiencies in the pulling process.
Innovation Solution
A cable puller adapter with a rotatable gripping member and an adapter motor, controlled by a controller that adjusts the tailing force by modulating the current provided to the motor to maximize the velocity of the pulling line, ensuring optimal engagement with the capstan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual tailing force is applied by operator, then the operator can vary force and speed by adjusting tailing force, but inconsistent tailing force and pulling speed occur leading to potential cable damage
Solution Approach 1:
The patent replaces the manual mechanical tailing system with an automated motorized tailing mechanism. The tailing motor (24) automatically applies controlled tailing force to the pulling line (26) through a tailing mechanism, eliminating the need for manual operator intervention. This substitution ensures consistent, repeatable tailing force while maintaining the ability to vary force and speed through automated control systems, thereby resolving the contradiction between adaptability and reliability.
Solution Approach 2:
The cable puller system performs self-tailing through the automated tailing mechanism. The system automatically monitors and adjusts the tailing force applied to the pulling line without requiring external operator input. The controller (44) continuously regulates the tailing motor (24) to maintain optimal tailing force, enabling the system to service itself and eliminate the inconsistency introduced by manual operation.
2Force
If high tailing force is provided, then pulling force is increased, but the pulling line binds up against itself and against the base of the capstan reducing pull speed
Solution Approach 1:
The patent implements dynamic control of tailing force through the automated tailing mechanism. The controller (44) continuously monitors pulling conditions and dynamically adjusts the tailing motor (24) output to apply only the necessary amount of tailing force. This dynamic adjustment prevents excessive force that would cause binding while maintaining sufficient force for effective pulling, thereby optimizing both force and speed throughout the pulling operation.
Solution Approach 2:
The system employs feedback control where the controller (44) monitors the operation status and pulling line conditions, then adjusts the tailing motor (24) accordingly. This closed-loop control ensures that tailing force is optimized in real-time, preventing the pulling line from binding against itself or the capstan base while maintaining adequate pulling force, thus resolving the force-speed trade-off.
3Ease of operation
If insufficient tailing force is provided, then the pulling line slips on the capstan, but pull speed is reduced
Solution Approach 1:
The patent replaces manual tailing with an automated motorized system that precisely controls the force applied to the pulling line. The tailing motor (24) automatically provides the exact amount of tailing force needed to prevent slipping on the capstan, eliminating the trial-and-error process of manual adjustment. This substitution ensures optimal engagement with the capstan is maintained throughout the pulling operation, maximizing pull speed while minimizing manual effort.
Solution Approach 2:
The automated tailing mechanism performs self-adjustment to maintain optimal pulling conditions. The controller (44) continuously monitors the pulling operation and automatically regulates the tailing motor (24) to apply sufficient force to prevent slipping, eliminating the need for operator intervention and ensuring consistent pull speed throughout the operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adapter system maintains consistent and optimal tailing force, enhancing the efficiency of cable pulling by maximizing speed and reducing the risk of damage to cables or wires, while allowing for dynamic adjustments based on changing conditions.
Implementation Method 1
an adapter motor mounted on the adapter frame configured to apply torque to the gripping member
Implementation Method 2
the friction of the pulling line on the capstan offloads most of the pulling force to the motor
Data Source
AI summary
A cable puller adapter includes a rotatable gripping member which receives and guides a tailing portion of a pulling line coupled between a capstan of a cable puller and the gripping member, an adapter motor which applies torque to the gripping member, and a controller operatively coupled to the gripping member and configured to measure an amount of current drawn by or provided to the adapter motor, and configured to determine a rotational speed of the adapter motor or the gripping member. The controller adjusts a tailing force on a tailing portion of the pulling line by modulating an amount of current provided to the adapter motor, so as to maximize a velocity of the tailing portion of the pulling line as the gripping member rotates. A method of use is also provided.