Tension Stringing Control for Single-Operator Conductor Pulling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tension stringing operations for electrical or fiber optic conductor installation require two skilled operators, one for each machine, leading to safety risks due to delayed adjustments and potential equipment or property damage from communication delays.
Innovation Solution
A wireless communication network between a pulling machine (puller) and a tensioning machine (tensioner) allows a single skilled operator on the puller to control the tensioner's operating parameters in real time, enabling automatic adjustments without the need for a second operator on the tensioner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two skilled operators are used (one on each machine), then operational control is maintained, but response time delays occur due to communication requirements
Solution Approach 1:
The patent combines the control functions of two separate machines (puller and tensioner) into a single integrated control system. The automated control system on the puller machine now manages both the puller and tensioner operations, eliminating the need for separate operators on each machine and reducing communication delays while maintaining operational reliability
Solution Approach 2:
The patent implements automated feedback mechanisms where the control system continuously monitors operational parameters from both machines and automatically adjusts settings. This closed-loop feedback system replaces manual communication between operators, enabling real-time adjustments without response time delays
2Ease of operation
If manual adjustments are made based on operator observations, then operational flexibility is maintained, but safety risks increase due to communication delays
Solution Approach 1:
The patent enables the control system to monitor and adjust operational parameters automatically without human intervention during operation. The automated system self-regulates tension and pulling parameters based on real-time feedback, eliminating safety risks associated with delayed manual responses while preserving operational flexibility through programmable control
Solution Approach 2:
The patent replaces the manual mechanical adjustment system with an automated electronic control system. This substitution eliminates the delays inherent in manual observation and adjustment, providing immediate response to operational conditions while maintaining flexibility through programmable control parameters
3Reliability
If a second operator is required on the tensioner, then machine monitoring is adequate, but equipment complexity and operational cost increase
Solution Approach 1:
The patent makes the puller's control system universal by enabling it to control both the puller and tensioner machines. This multi-functional control system consolidates monitoring capabilities into a single operator interface, reducing operational complexity while maintaining adequate machine monitoring through integrated sensors and control algorithms
Data Source
AI summary
The process and apparatus for tension stringing a conductor through above-ground supports uses a length of rope affixed to the conductor wound on the tensioning machine and pulled by the puller machine. Each of the first and second stringing apparatuses includes an onboard control system which controls each of the first and second stringing apparatuses in pulling mode or in tensioning mode. Each of the first and second stringing apparatuses includes a motor/regenerative brake or other means of inducing tension into the conductor. Each of the machines includes a wireless transceiver which is hard-wired to said onboard control systems. A first operator resides on the puller machine and selects the machine as a puller machine operating in pulling mode using an onboard control system. An observer resides on the tensioner and selects the second machine to be the tensioner. Each of the wireless transceivers communicates with the other wireless transceiver enabling control of both the machines by the onboard control system of the puller machine.