Electric Drive Puller-Tensioner for Conductor Stringing
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Solution Overview
Problem
High voltage utility transmission line conductor stringing operations generate noise and pollution due to internal combustion engines used in traditional puller-tensioners, necessitating an environmentally compatible and efficient alternative.
Innovation Solution
An electric drive system powered by an on-board battery bank is used for a drum puller-tensioner, employing magnetic coupling for tensioning and incorporating a resistor bank for energy management, with pulse width modulation control to minimize noise and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an internal combustion engine is used to power the puller-tensioner, then sufficient power and torque are achieved, but noise and pollution are generated
Solution Approach 1:
The patent replaces the internal combustion engine (mechanical system) with an electric motor system. The electric motor is driven by a battery bank and controlled by a microprocessor that regulates power delivery to match the torque and speed requirements of the puller-tensioner, thereby eliminating noise and pollution while maintaining sufficient power output.
Solution Approach 2:
The patent changes the power source parameters from combustion-based to electricity-based. By using a battery bank with controlled voltage and current output, regulated through pulse width modulation and microprocessor control, the system achieves the required power parameters without the harmful emissions and noise associated with internal combustion engines.
2Object-affected harmful factors
If an electric drive system with battery bank is used, then zero emissions and reduced noise are achieved, but system complexity increases
Solution Approach 1:
The microprocessor serves multiple functions: it controls the electric motor's torque and speed, manages battery bank charging and discharging, monitors system parameters, and coordinates the operation of various components. This multi-functionality reduces the need for separate control systems and simplifies the overall control architecture despite the increased system complexity.
Solution Approach 2:
The system incorporates automatic control features where the microprocessor continuously monitors and adjusts operating parameters without manual intervention. The battery bank automatically charges during tensioning operations and discharges during pulling operations, reducing the need for external control and simplifying operation.
3Loss of energy
If traditional hydraulic systems are used, then torque control is achieved, but energy efficiency is reduced
Solution Approach 1:
The patent replaces the hydraulic system with an electric drive system. The electric motor directly converts electrical energy to mechanical torque without the energy losses associated with hydraulic fluid compression, leakage, and heat generation. The microprocessor controls the electric motor to provide precise torque control, matching the performance of hydraulic systems while significantly improving energy efficiency.
Solution Approach 2:
The patent changes the energy transmission medium from hydraulic fluid to electricity. By using electrical parameters (voltage, current, frequency) controlled through pulse width modulation and microprocessor management, the system achieves the same torque control function with substantially reduced energy losses throughout the power transmission chain.
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 solution provides zero emissions and significantly reduces noise, enabling efficient conductor stringing operations while maintaining maximum rated torque and speed for extended periods.
Implementation Method 1
An electric motor is affixed to the frame and coupled to the conductor reel. The electric motor transforms electrical energy to mechanical energy when pulling the conductor in the pulling mode
Implementation Method 2
The electric motor generates electrical energy when tensioning the conductor in the tension mode. The processor applies electrical energy generated by the electric motor to the plurality of batteries when in the tensioning mode
Implementation Method 3
The processor periodically applies electrical energy to the resistor bank using a pulse width modulation control signal. Energy produced during tensioning is stored in the battery bank or converted to heat by a resistor bank
Data Source
AI summary
A line stringing apparatus includes in combination an electric motor, motor controller and a processor switchable between a pulling mode and a tensioning mode. An electric motor expends electrical energy when pulling the line and generates electrical energy when tensioning the line. The processor outputting commands to the motor controller for control thereof and for application of electrical energy from the batteries to the electric motor when in the pulling mode and for application of electrical energy generated by the electric motor to the plurality of batteries when in tensioning mode. The processor limits electric motor torque and speed based on operator commands for speed and torque in said pulling mode; and, the processor controlling electric motor torque in the tensioning mode.