Wire Pulling Machine with Ratchet Capstan and Sheave Head
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Solution Overview
Problem
The process of pulling wires through conduits is laborious and dangerous due to high friction, often requiring significant human effort and resulting in muscle strains and injuries, as existing solutions are either complex, heavy, or limited in their ability to efficiently transfer pulling force.
Innovation Solution
A lightweight, portable machine with a capstan mechanism that uses a sheave head and conduit interface to efficiently pull wires through conduits, supported by a non-tension support bracket that transfers force directly to the conduit lip, allowing for constant pulling force without the need for complex arrangements or ground support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a machine is designed to pull wire through conduit, then the pulling force is improved, but the device complexity increases
Solution Approach 1:
The device is divided into functionally independent segments: a handle assembly for operator control, a ratchet mechanism for force multiplication, a reel for line storage, and a conduit interface for positioning. Each segment performs a specific function and can be independently optimized, resolving the contradiction by achieving high pulling force through modular force multiplication rather than complex integrated systems.
Solution Approach 2:
The ratchet mechanism provides dynamic force multiplication, allowing the operator to build up pulling force incrementally through repeated handle rotations. The reel dynamically adjusts line payout as wire is pulled through the conduit. This dynamic operation achieves high pulling force without requiring a complex static structure.
2Force
If a heavy-duty wire pulling machine is designed, then the pulling force is improved, but the weight of the device increases
Solution Approach 1:
The device replaces heavy hydraulic or electric winch systems with a manual ratchet-and-reel mechanical system. The ratchet mechanism provides mechanical advantage through its pawl-and-ratchet engagement, allowing a single operator to generate high pulling forces without the weight penalty of powered systems. This substitution resolves the contradiction by achieving heavy-duty pulling capability through lightweight mechanical principles.
3Productivity
If a complex arrangement of elements is used to control pressurized water, then the wire pulling capability is improved, but the device complexity increases
Solution Approach 1:
The invention extracts and eliminates the complex pressurized water control system entirely, replacing it with a direct mechanical pulling system. The ratchet-driven reel directly pulls wire through the conduit without requiring fluid power systems, complex valves, or electronic controls. This extraction resolves the contradiction by achieving wire pulling capability through a simpler direct mechanical approach.
4Force
If a large vehicle-mounted cable puller is used, then the pulling force is improved, but the ease of transport decreases
Solution Approach 1:
The device counteracts the need for vehicle mounting by distributing weight across multiple functional components that can be manually positioned. The handle assembly, ratchet mechanism, and reel are arranged to balance the device's center of gravity, allowing a single operator to carry and reposition the entire system without requiring vehicle-mounted heavy equipment. This weight distribution resolves the contradiction by enabling portable heavy-duty pulling.
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 machine significantly reduces physical labor required for wire pulling, enabling a single person to efficiently transport and operate it, while maintaining consistent pulling force over long distances without straining the operator, thus minimizing the risk of injury.
Implementation Method 1
there is significant friction between the wires and the interior of the conduit, especially at the points of transition from substantially vertical to substantially horizontal courses and vice versa
Data Source
AI summary
A device for pulling wire through a conduit with sheave head, sheave head support boom, wire puller frame, conduit interface, and wire pull assembly. The wire pull assembly further comprises a capstan, a gear box having an input axle and an output axle, and a means to interface a power source to impart rotating force to the capstan.