Wireless Tension Stringing Control for Single-Operator Coordination
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Solution Overview
Problem
Conventional tension stringing operations require two skilled operators to communicate and manually adjust the tensioner's operating parameters, leading to safety risks and delays due to response time, which can increase the risk of equipment or property damage.
Innovation Solution
A wireless communication network between the puller and tensioner allows a single skilled operator to control the tensioner's operating parameters in real-time, enabling automatic adjustments based on input values from the puller, reducing the need for a second operator and minimizing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two skilled operators manually communicate and adjust tensioner parameters, then operational control is achieved, but response time is delayed and safety risks increase
Solution Approach 1:
The patent replaces the manual communication system (two-way radios or cellular telephones) with an automated electronic control system. The puller machine's control system automatically transmits operating parameter values to the tensioner machine's control system, which then automatically adjusts tensioner parameters without requiring manual intervention from operators on both machines. This substitution eliminates communication delays and reduces safety risks associated with manual operation.
Solution Approach 2:
The tensioner machine's control system is designed to automatically receive operating parameter values from the puller machine and autonomously adjust its own operating parameters. This self-service capability eliminates the need for a skilled operator on the tensioner machine to manually interpret communications and make adjustments, thereby reducing response time and minimizing human error.
2Reliability
If manual adjustments are made to tensioner parameters, then operational flexibility is maintained, but operator errors increase and equipment damage risk rises
Solution Approach 1:
The automated control system establishes a feedback loop where the puller machine's control system continuously monitors its operating parameters and automatically transmits these values to the tensioner machine's control system. The tensioner machine's control system then automatically adjusts its parameters based on this feedback, ensuring coordinated operation and preventing equipment damage without requiring manual intervention.
Solution Approach 2:
The control systems of the puller and tensioner machines serve as intermediaries between the operators and the actual mechanical operations. Instead of operators directly controlling both machines, the automated control systems mediate the coordination, receiving input from the puller operator and automatically managing the tensioner's parameters, thereby reducing operator workload and minimizing errors.
3Device complexity
If a single operator controls both machines, then operational complexity is reduced, but communication and coordination become more difficult
Solution Approach 1:
The patent merges the control functions of both machines into a single automated control system architecture. The puller machine's control system and the tensioner machine's control system are electronically integrated through automated communication, allowing a single operator to control both machines from one location. This merging eliminates the need for separate manual operations while maintaining coordinated control through electronic integration.
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 hardwired 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.