Electric Wire Puller Capstan Mechanism for Conduit Threading
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Solution Overview
Problem
The existing methods for threading wires through conduents with changes in elevation and turns around corners require significant human effort due to the weight and length of the wires, as well as the need for multiple iterations of lighter lines to guide heavier lines, which can be labor-intensive and inefficient.
Innovation Solution
A wire puller device with a gear box, capstan, and electric drill attachment that allows for mechanical assistance in pulling wires through conduents, enabling a single operator to manage the process without holding the drill, using a rotating capstan and geared mechanism to reduce manual effort and improve ergonomics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lighter lines are pulled through first to guide heavier lines, then the wire can be threaded through the conduit, but significant human effort is required due to weight and distance
Solution Approach 1:
The patent replaces manual mechanical pulling with a motorized capstan system. The capstan, driven by an electric motor, rotates to wind the line onto its drum, providing mechanical advantage and substituting human muscle force with electromagnetic force. This directly addresses the contradiction by maintaining the threading function while eliminating the need for significant human pulling effort.
Solution Approach 2:
The capstan system provides dynamic mechanical advantage through its rotating drum mechanism. As the capstan rotates, it progressively winds the line onto the drum, creating a variable pulling force that adapts to the resistance encountered in the conduit. This dynamic mechanism allows a single operator to control the pulling force, resolving the contradiction between ease of operation and required force.
2Productivity
If multiple iterations of lighter lines are used to pull heavier lines through, then the wire can be installed, but the process becomes labor-intensive and inefficient
Solution Approach 1:
The motorized capstan system eliminates the need for multiple manual pulling iterations by providing sufficient power in a single operation. The electric motor can generate the necessary force to pull heavy wire through long conduit runs directly, without requiring preliminary lighter lines or repeated attempts. This substitution of mechanical power dramatically improves productivity while reducing the time lost to iterative processes.
Solution Approach 2:
The invention changes the power parameter from human-scale manual force to motor-scale electromagnetic force. This parameter change allows the system to handle heavier loads and longer distances in a single operation, eliminating the need for multiple iterations with progressively heavier lines. The result is a single-pass wire installation process that significantly improves efficiency and reduces time loss.
3Ease of operation
If machine force is used to substitute human force, then human effort is reduced, but the device complexity increases
Solution Approach 1:
The capstan device is designed as a multi-functional tool that combines several functions into a single unit: it serves as a mechanical advantage device, a wire guide, a pulling mechanism, and a tensioning device. The capstan can handle various line types and weights, and the same device can be used for both pulling and tensioning operations. This universality justifies the added complexity by providing multiple functions that would otherwise require separate tools or manual operations.
Solution Approach 2:
The capstan acts as an intermediary device between the operator and the wire. Instead of the operator directly pulling the wire, the capstan mediates the force application through its rotating drum mechanism. This intermediary provides mechanical advantage and controls the pulling force, reducing the physical effort required while managing the complexity through a well-defined mechanical interface. The capstan serves as a force amplifier and control mechanism that bridges the gap between human capability and the demands of wire installation.
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 wire puller significantly reduces human effort required to pull wires through conduents by utilizing an electric drill to rotate the capstan, allowing efficient and ergonomic operation, enabling easier handling and installation of wires in complex conduit paths.
Implementation Method 1
The capstan may comprise a hook pin. A line may be attached to the hook pin and wrapped around the capstan. Rotating the capstan may pull the line
Data Source
AI summary
A wire puller may be provided. The wire puller may comprise a middle portion, a restraint frame, and a front portion. The middle portion may comprise a gear box, a front bracket, a back bracket, and a capstan. The gear box may comprise a drive shaft and the capstan may comprise a hook pin. The restraint frame may be attached to the back bracket. The front portion may be attached to the front bracket. The front portion may comprise a pivot frame, a tube, an arm, a first side plate, a second side plate, a roller, and a flip out support. The pivot frame may comprise a locking mechanism.