Line Puller Engagement Assembly for Multi-Line Alignment
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Solution Overview
Problem
Existing line pulling equipment in the electrical utility industry faces risks due to high forces and stresses, inefficiencies in manual engagement, and inability to reliably handle multiple lines, leading to potential injuries and equipment damage.
Innovation Solution
An engagement assembly with an over-center design and a level wind head using side rollers and hydraulic actuation to ensure alignment and prevent tangling, along with a control system for managing multiple drums and lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual engagement of line pulling drums using cablevers is used, then the device complexity is reduced, but the reliability of engagement and safety of operators deteriorates
Solution Approach 1:
The engagement system automatically engages and disengages the drum with the puller drum without requiring manual intervention. The system uses sensors to detect line tension and automatically controls the engagement mechanism, eliminating the need for operators to manually operate cablevers while maintaining high reliability through automated monitoring and control.
Solution Approach 2:
The patent replaces manual mechanical cablever operation with an automated system that uses sensors, controllers, and automated engagement mechanisms. This substitution of manual mechanical control with an automated control system improves reliability while managing complexity through integrated control electronics and software.
2Productivity
If existing line pulling equipment is used to pull multiple lines simultaneously, then productivity increases, but the risk of line misalignment and tangling increases
Solution Approach 1:
The system uses sensors to continuously monitor the position and tension of each line being pulled. This feedback information is fed to the controller, which adjusts the drum rotation and engagement to maintain proper line alignment and prevent tangling, enabling safe simultaneous pulling of multiple lines at high productivity.
Solution Approach 2:
The engagement system is designed to handle multiple lines simultaneously through a universal drum configuration that can engage with multiple puller drums. The system provides multi-functional capability to pull different numbers and types of lines while maintaining alignment through automated control, increasing productivity without compromising reliability.
3Productivity
If high forces and stresses are applied during line pulling operations, then the productivity of line installation increases, but the risk of equipment failure and operator injury increases
Solution Approach 1:
The system automatically monitors line tension and equipment status, and can automatically disengage the drum if abnormal conditions are detected. This self-monitoring and self-protection capability allows the system to operate at high forces for improved productivity while automatically protecting operators from equipment failure and injury risks.
Solution Approach 2:
The system includes safety mechanisms and monitoring that prepare for potential failures before they occur. Tension sensors and control systems are ready to detect and respond to abnormal conditions, providing a safety buffer that allows high-force operations to proceed with reduced risk to operators and equipment.
4Device complexity
If engagement systems rely solely on lever-based locking mechanisms, then the device complexity is minimized, but the reliability of maintaining engagement deteriorates
Solution Approach 1:
The engagement system automatically maintains engagement through automated monitoring and adjustment. Sensors detect engagement status and line tension, and the system automatically makes adjustments or disengages if problems are detected, eliminating the need for complex manual lever systems while improving reliability through continuous automated monitoring.
Solution Approach 2:
The patent replaces simple lever-based mechanical locking with an automated engagement system that uses sensors, actuators, and control electronics. This substitution improves reliability by eliminating human error and providing continuous automated monitoring, while managing complexity through integrated control systems.
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 reliability and safety of line pulling operations by minimizing operator effort, ensuring positive engagement, and allowing simultaneous handling of multiple lines without tangling, thereby reducing the risk of injury and equipment damage.
Implementation Method 1
a hydraulic arm connected to the level wind head and the chassis and configured to move the level wind head laterally as the line is wound around the drum
Implementation Method 2
An engagement assembly with an over-center design which further ensures positive lock with the drum
Implementation Method 3
a hinged linkage connected to the support member and the engagement cable and configured to partially rotate in response to a push or pull from the engagement cable
Data Source
AI summary
The disclosed technology includes a line pulling system that may include an engagement assembly, which may include an engagement cable configured to be pushed or pulled. The assembly may also include a cable mounting assembly connected to the support member and the engagement cable, a hinged linkage connected to the support member and the engagement cable and configured to partially rotate in response to a push or pull from the engagement cable, an engagement arm connected to the hinged linkage and configured to move according to the rotation motion of hinged linkage, a coupling ring connected to the engagement arm and configured to transition between an engaged position and a disengaged position in response to movement from the engagement arm.