Wireless Tension Meter for Conduit Pulling
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Solution Overview
Problem
During the installation of conductors through conduit networks, the tension exerted by puller systems on guiding members can exceed safe limits, leading to damage and failure, and existing methods lack effective real-time monitoring and control to prevent such issues.
Innovation Solution
A wireless-enabled tension meter system that includes a pulley arrangement, sensors, and a control module to measure and transmit tension data via a wireless network to a communication device, allowing for real-time monitoring and control of the tension force exerted on guiding members during the pulling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a puller system is used to expedite the pulling process, then productivity increases, but the tension force may exceed safe limits causing damage to conductors and guiding members
Solution Approach 1:
The patent implements a tension monitoring system with sensors that continuously measure the tension force on the guiding member and provide real-time feedback to a controller. This feedback mechanism enables the system to adjust the puller's operation to maintain tension within safe limits while maximizing pulling speed, thus resolving the contradiction between productivity and harmful tension forces
Solution Approach 2:
The system dynamically adjusts the pulling process based on real-time tension measurements. The controller modifies pulling parameters such as speed and force in response to changing conditions in the conduit installation, allowing the system to operate at high productivity while preventing excessive tension that could damage conductors or guiding members
2Productivity
If the guiding member is pulled faster through the conduit, then productivity increases, but friction increases causing more wear and potential damage
Solution Approach 1:
The tension sensors provide continuous feedback on the friction forces generated during pulling. The controller uses this information to adjust pulling speed and force in real-time, optimizing the balance between productivity and minimizing friction-induced wear on conductors, guiding members, and conduit
Solution Approach 2:
The system dynamically changes operating parameters including pulling speed, tension force, and potentially lubrication application based on real-time measurements. This allows the system to maintain high productivity while adapting parameters to minimize friction and wear under varying installation conditions
3Reliability
If real-time tension monitoring and control is implemented, then reliability improves by preventing damage, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical tension control mechanisms with electronic sensors and a control system. This substitution achieves reliable real-time monitoring and automatic tension control while reducing mechanical complexity, as electronic systems can provide precise measurement and control with fewer moving parts
Solution Approach 2:
The system incorporates automatic self-regulation where the controller automatically adjusts pulling parameters based on sensor feedback without requiring constant manual intervention. This self-service capability improves reliability by maintaining optimal tension automatically while reducing the operational complexity for users
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
Enables real-time monitoring and control of tension forces, preventing damage to conductors and guiding members, and optimizing the pulling process by providing accurate data on tension, length, and speed, thereby ensuring safe and efficient conductor installation.
Implementation Method 1
A tension force is exerted on the linear element as the linear element traverses through the pulley arrangement
Data Source
AI summary
A wireless-enabled tension meter is disclosed. The wireless-enabled tension meter can include a pulley arrangement through which a portion of a guiding member is routed for use during a pull of conductor through a conduit network. A tension force is exerted on the guiding member during the pull as the guiding member is pulled through the pulley arrangement. The wireless-enabled tension meter can also include a sensor for measuring the tension force, a wireless network interface, and a control module for performing operations. The operations performed by the control module can include capturing data corresponding to the tension force and causing the wireless network interface to send the data to a wireless communication device.