Cable Puller Adapter With Feedback Tailing Force Control
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Solution Overview
Problem
Inconsistent tailing force and pulling force and speed in cable pulling operations lead to reduced efficiency and potential damage to electrical cables or wires, as operators manually adjust the tailing force, which can result in either slipping or binding issues.
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
1Ease of operation
If manual tailing force adjustment is used, then the operator can vary force and speed, but inconsistent tailing force and pulling force result, reducing efficiency and potentially damaging cables
Solution Approach 1:
The system uses a force sensor to automatically measure and adjust tailing force without requiring manual intervention. The controller receives feedback from the force sensor and autonomously modulates motor current to maintain optimal tailing force, eliminating the inconsistency caused by manual adjustment while preserving the ability to vary force and speed.
Solution Approach 2:
A force sensor provides real-time feedback on the actual tailing force applied to the pulling line. The controller continuously monitors this feedback and adjusts the adapter motor's current output accordingly, creating a closed-loop control system that maintains consistent and reliable tailing force while allowing operational flexibility.
2Force
If excessive tailing force is applied, then the pulling force increases, but the pulling line binds up against itself and the capstan base, creating excessive friction and reducing pull speed
Solution Approach 1:
The system dynamically adjusts the tailing force in real-time based on feedback from the force sensor and controller. Rather than applying fixed or excessive force, the adapter motor's current is continuously modulated to maintain optimal engagement between the pulling line and capstan, preventing binding while maximizing pull speed through adaptive force control.
3Ease of operation
If insufficient tailing force is applied, then the operator exerts less force, but the pulling line slips on the capstan, reducing pull speed
Solution Approach 1:
The force sensor and controller create a feedback loop that detects when tailing force is insufficient to prevent slippage. The controller responds by increasing the adapter motor's current output to apply the precise amount of additional force needed to maintain optimal friction between the pulling line and capstan, ensuring adequate pull speed without requiring excessive manual force from the operator.
4Reliability
If automated motor control is implemented, then consistent tailing force is achieved, but device complexity increases
Solution Approach 1:
The force sensor acts as an intermediary between the physical tailing force and the controller's decision-making process. It converts mechanical force into electrical signals that the controller can process, enabling automated consistent force control while keeping the system architecture modular and manageable through the use of this intermediate sensing component.
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, maximizing the pulling speed and efficiency while preventing damage to the cables by dynamically adjusting the torque applied to the gripping member, thus ensuring the cable is pulled through conduits or trays with minimal slippage and friction.
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.