Battery-Powered Cable Puller With Capstan Tension Control
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Solution Overview
Problem
Existing methods for pulling wires and cables through conduits are inefficient and time-consuming, lacking advanced tools to enhance installation speed and efficiency.
Innovation Solution
A battery-powered cable puller with a motor-driven capstan assembly, self-tailing mechanism, and adjustable boom angle, designed to reduce tension and facilitate smooth wire/cable extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual rope pulling or mechanical tuggers are used, then the installation process can be completed, but the installation speed and efficiency are slow and time-consuming
Solution Approach 1:
The patent replaces manual rope pulling and mechanical tuggers with an electric motor-driven capstan system. The motor provides automated rotational force to the capstan, which winds the rope to pull cables through conduits, eliminating manual labor and significantly increasing installation speed and productivity.
Solution Approach 2:
The cable puller is designed as a self-contained unit with integrated motor, capstan, and cable gripping mechanisms. The device automatically performs the cable pulling operation without requiring external assistance or manual intervention during the pulling process, enabling single-operator deployment and reducing installation time.
2Reliability
If traditional pullers are used, then cable pulling can be performed, but tension management is difficult and the working environment is less safe
Solution Approach 1:
The patent incorporates a tension sensing system that provides feedback to the control mechanism. The motor speed and capstan rotation are automatically adjusted based on real-time tension measurements, preventing excessive force that could damage cables or create safety hazards, while ensuring consistent pulling force throughout the operation.
Solution Approach 2:
The cable puller features a dynamically adjustable pulling mechanism where the motor speed and capstan rotation vary automatically during operation. The system transitions from high-speed initial pulling to controlled low-speed tensioned pulling, and finally to gradual release, optimizing both safety and ease of operation throughout the entire cable installation process.
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
Enhances the efficiency of wire/cable installation by reducing tension and improving the ease of pulling through conduits, providing a safer and more efficient working environment.
Implementation Method 1
a motor disposed in the motor housing, the motor rotating about a motor axis
Implementation Method 2
a capstan assembly rotationally driven by the motor about the motor axis
Data Source
AI summary
A cable puller includes a motor housing and a motor disposed in the motor housing. The motor rotates about a motor axis. The cable puller further includes a capstan assembly rotationally driven by the motor about the motor axis and a handle housing coupled to the motor housing. The handle housing has a battery receptacle for removably receiving a rechargeable battery pack. Moreover, the cable puller includes a boom coupled to the motor housing opposite the handle housing.