Multi-Speed Electric Jack Control for Stable Line Puller Leveling
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Solution Overview
Problem
Existing line pulling equipment jacks are cumbersome, time-consuming to deploy, and prone to operator error, especially in unlevel or soft ground conditions, leading to equipment instability and safety risks.
Innovation Solution
A multi-speed electric jack system with sensors and a controller that automatically adjusts speed based on load and level, using an electric motor and sensors to extend or retract the jack quickly and safely while maintaining equipment stability without user input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual jacks are used for leveling line pulling equipment, then the equipment can be stabilized, but the deployment becomes cumbersome and time-consuming
Solution Approach 1:
The patent replaces manual mechanical jack operation with an automated electric jack system. The electric jack uses an electric motor instead of manual threading, and incorporates sensors (level sensors, current sensors) with a controller to automatically adjust the jack position and speed, eliminating the need for manual intervention while maintaining equipment stability.
Solution Approach 2:
The electric jack system performs self-adjustment through automated control. The controller receives input from level sensors and current sensors, then automatically controls the electric motor to extend or retract the jack leg to the appropriate position, enabling the system to level itself without operator intervention.
2Extent of automation
If hydraulic actuators are used to extend or retract the jack, then the jack can be automated, but the system becomes bulky and adds weight
Solution Approach 1:
The patent substitutes hydraulic actuators with an electric motor-driven jack system. The electric motor, controlled by a controller receiving signals from level and current sensors, provides the necessary automation functionality while being more compact and lighter than hydraulic systems, thus reducing the overall weight of the line pulling equipment.
3Device complexity
If single-speed electric jacks are used, then weight and complexity are reduced, but the jack cannot automatically adapt to different ground conditions
Solution Approach 1:
The patent implements a multi-speed electric jack system where the electric motor can operate at different speeds based on real-time conditions. The controller adjusts the motor speed dynamically - using higher speeds when the jack is unloaded or on firm ground, and lower speeds when loaded or on soft ground - allowing the system to adapt to varying ground conditions while maintaining relatively simple hardware.
Solution Approach 2:
The system incorporates current sensors that monitor the current drawn by the electric motor and level sensors that detect equipment leveling status. This feedback is sent to the controller, which automatically adjusts the motor speed and jack position accordingly, enabling the jack to adapt to different ground conditions and load states without manual intervention.
4Productivity
If the jack operates at high speed continuously, then productivity is improved, but the risk of equipment damage and operator injury increases
Solution Approach 1:
The patent implements variable speed control in the electric jack system. The controller dynamically adjusts the motor speed based on real-time feedback from current sensors and level sensors. The jack operates at high speed when unloaded or on stable ground to maximize productivity, and automatically reduces speed when approaching loaded positions or unstable ground to prevent equipment damage and ensure safety.
Solution Approach 2:
Current sensors monitor the electrical current drawn by the motor, which indicates the load on the jack. Level sensors monitor the equipment leveling status. This feedback information is processed by the controller, which automatically adjusts the motor speed - maintaining high speed during safe, unloaded operation and reducing speed when loads are detected or leveling is approaching completion, thus balancing productivity and safety.
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 system enables rapid and safe lifting of line pulling equipment, protects the jack from damage, and maintains equipment stability across varying ground conditions without requiring user intervention, enhancing operational efficiency and safety.
Implementation Method 1
an electric motor in communication with the electric power source and configured to cause the leg to extend and retract axially from the housing
Implementation Method 2
a sensor or multiple sensors configured to detect a characteristic of the power supplied to the motor (e.g., a current sensor configured to detect a current supplied to the electric motor)
Data Source
AI summary
A line pulling system having a chassis, a reel carrier assembly, an electric power source, and an electric jack assembly. The electric jack assembly can include a housing, a leg configured to extend and retract axially from the housing, an electric motor, a current sensor configured to detect a current supplied to the electric motor, and a controller. The controller can receive current data and, if the current is less than a threshold current, supply a first voltage to the electric motor to cause the electric motor to extend or retract the leg at a first speed. If the current is greater than or equal to the threshold current, the controller can supply a second voltage to the electric motor. The second voltage can cause the electric motor to extend or retract the leg at a second speed that is less than the first speed.