Patent Publication Number: US-8991736-B2

Title: Cable tensioning cycling system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of co-pending U.S. patent application Ser. No. 12/886,762, filed Sep. 21, 2010, which claims benefit of U.S. provisional patent application Ser. No. 61/244,563, filed Sep. 22, 2009. Each of the aforementioned related patent applications is herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present embodiments generally relate to a hydraulically and/or electrically operated system for testing cable under variable tensions and speeds with lower input horsepower requirements. 
     A need exists for a system that can cycle test long-length cable samples at variable cable tensions and speeds. 
     A need exists for a system that can reduce the amount of horsepower required to cycle cable. 
     A need exists for a closed loop tensioning system that can effectively close the loop and allow cable to be tensioned and cycled with less horsepower. 
     The present embodiments meet these needs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description will be better understood in conjunction with the accompanying drawings as follows: 
         FIG. 1  is an illustrative hydraulic cycle test system. 
         FIG. 2  is an illustrative electrically operated cycle test system. 
         FIG. 3  is a hydraulic drive. 
         FIG. 4  is a electric drive. 
         FIG. 5  is an illustrative hydraulic power source. 
         FIG. 6  is a simplified schematic representation of a portion of the hydraulic cycle test system shown in  FIG. 1 . 
     
    
    
     The present embodiments are detailed below with reference to the listed Figures. 
     DETAILED DESCRIPTION 
     Before explaining the present system in detail, it is to be understood that the system is not limited to the particular embodiments, and the system can be practiced or carried out in various ways. 
     The present embodiments relate to a hydraulically and/or electrically operated system for testing cable under variable tensions and speeds with a lower input horsepower requirement. 
     The present embodiments further relate to a hydraulic operated system that can include: a first storage reel, a second storage reel, a first moveable sheave, a second moveable sheave, a third moveable sheave, a fourth moveable sheave, a first clutch, a second clutch, a clutch controller, and a moveable tensioning moveable sheave. 
     One or more embodiments relate to a long-length cable sample testing system. The system can utilize a parallel moveable sheave system and a hydraulically and/or electrically powered tensioning turning sheave assembly that allows for transfer of long-cable sample lengths at variable cable tensions and speeds with a low input horsepower. The system can be used for from about a few hundred feet of cable to about several miles of cable in a single setting. The system can require a lower amount of horsepower to move cable for testing as compared to normal systems known in the art. 
     A first storage reel can be used for paying out cable to be tested. The first storage reel can be adapted to apply tension to the cable, and allow the tension in the cable to be multiplied up to a test tension. 
     The system can include a first moveable sheave in series with a second moveable sheave. The first moveable sheave can be rotated by a first hydraulic drive or a first electric drive. The second moveable sheave can be rotated by a second hydraulic drive or a second electric drive. The first moveable sheave can receive the cable and can pass the cable to the second moveable sheave. 
     The third moveable sheave can be in series with a fourth moveable sheave. The third moveable sheave can be rotated by the second hydraulic drive or the second electric drive. In embodiments, the third moveable sheave can be in parallel with the second moveable sheave. The fourth moveable sheave can be rotated by the first hydraulic drive or the first electric drive, and can further be in parallel with the first moveable sheave. 
     In embodiments, each moveable sheave can have grooves for receiving the cable and for containing the cable in each of the grooves. In one or more embodiments, each sheave can have at least six grooves. The grooves can be disposed in parallel, and can transfer the cable from one moveable sheave to another moveable sheave without otherwise touching or contacting additional cable. 
     Both the second moveable sheave and the third moveable sheave can be tilted in part, thereby enabling at least two opposing grooves to be lined-up or aligned at bottoms of the sheaves, but to be offset at tops of the sheaves to facilitate cable transfer without sliding the cable on a face of the moveable sheaves. 
     The second moveable sheave and the third moveable sheave can be connected and/or coupled with a first clutch. The first clutch can be operated by the second hydraulic drive. The first clutch can also disengage the second moveable sheave from the third movable sheave. 
     The first moveable sheave and a fourth moveable sheave can be connected and/or coupled with a second clutch. The second clutch can be operated by the first hydraulic drive. The second clutch can disengage the first moveable sheave from the second moveable sheave. The first clutch and the second clutch can be controlled by a clutch controller that can be in communication with a power source. Each clutch can be operable by one of the drives, a hydraulic power source, or combinations thereof. 
     A first friction material can be disposed between the first moveable sheave and the fourth moveable sheave. A second friction material can be disposed between the second moveable sheave and the third moveable sheave. The friction material can provide coupling of each pair of moveable sheaves with the clutch. The first friction material and the second friction material can include a wearable brake material that can lock each pair of moveable sheaves together during testing of the cable. 
     The hydraulic drives and/or electric drives can be connected to or coupled with a moveable tensioning moveable sheave, also referred to as a moveable tensioning sheave. In embodiments, the moveable tensioning sheave can include a load measuring sensor and a speed detector. 
     In embodiments, each of the hydraulic drives can have at least one hydraulic pump connected to a hydraulic motor for rotating each moveable sheave. From about one hydraulic pump to about eight hydraulic pumps can be used in connection with each hydraulic drive. The hydraulic pump can have a fluid reservoir, and can be operated by an electric motor. The electric motor can be powered by an electric power source, such as a four hundred sixty volt three-phase power supply. 
     The moveable tensioning sheave can receive the cable from the second moveable sheave and can pass the cable to the third moveable sheave, which can sequentially pass the cable to the fourth moveable sheave. 
     In embodiments, a second storage reel can be used for receiving the cable and can be adapted to apply a second tension to the cable to be tested, which can allow the tension in the cable to be multiplied up to the test tension. 
     In embodiments, the cable can be wrapped or reeved around the first moveable sheave and the second moveable sheave five times prior to passing the cable to the moveable tensioning sheave. The cable can move from the moveable tensioning sheave to the fourth moveable sheave, and can then be wrapped or reeved around the third moveable sheave and the fourth moveable sheave five times prior to passing the cable to the second storage device. 
     The tensioning of the cable can occur at a speed from about one tenth of a foot per minute to about one thousand feet per minute. The tensioning of the cable can occur at a load from about one hundred pounds of force to about sixty thousand pounds of force. 
     In embodiments, a first electric drive and a second electric drive can be used to rotate the moveable sheaves in addition to, or in replacement of, the first and second hydraulic drives. 
     In embodiments, a hydraulic power source can be connected to the moveable tensioning sheave. The hydraulic power source can have at least one hydraulic pump connected to a hydraulic motor and/or a linear actuator. The hydraulic pump can have a fluid reservoir and can be operated by an electric motor, which can be powered by an electric power source. 
     The system can have a processor for receiving signals from the load measuring sensor and the speed detector. The processor can be in communication with a network, at least one client device, and a data storage. The network can include the internet, an intranet, a local area network, a wide area network, a virtual private network, a satellite network, a cellular network, other similar networks, or combinations thereof. The client devices can be laptops, cell phones, pagers, or another network. In embodiments, the client device can have computer instructions for continuous remote monitoring of one or more compared signals from one or more processors simultaneously. The client devices can be in communication with the processor through the network for receiving load signals, speed signals, compared signals, notifications, or combinations thereof. 
     Computer instructions can be located in the data storage and can be used for storing preset stress data for the cable to be tested. For example, data associated with loads that a cable can withstand can be stored in the data storage. Data associated with speeds that a cable can withstand can be stored in the data storage. 
     Computer instructions can be stored in the data storage to instruct the processor to compare received signals from the load measuring sensor and the speed detector to the stored preset stress data, thereby forming compared signals. The processor and can determine if the received signals exceed or fall below the stored preset stress data. For example, if the stored preset stress data includes a maximum load amount of one thousand pounds, and the measured and received load signal is a load of two thousand pounds, then the processor can determine that the preset stress data has been exceeded. 
     The system can have computer instructions in the data storage to instruct the processor to provide a notification when the compared signals exceed or fall below the stored preset stress data. For example, if the compared signals exceed or fall below the stored preset stress data, the processor can transmit the notification over the network to one or more client devices, thereby notifying users of the deviation from the stored preset stress data. 
     The system can include computer instructions to instruct the processor to display the compared signals, the notification, or combinations thereof within client devices. 
     In one or more embodiments, each drive of the system can be either a hydraulic drive or an electric drive. The first moveable sheave can be configured to receive the cable from the first storage reel. The first drive can be coupled with the first moveable sheave, and can be configured to rotate the first moveable sheave. The rotating first moveable sheave can be configured to pass the cable to the second moveable sheave in series with the first moveable sheave. The second moveable sheave can be configured to receive the cable from the first moveable sheave. The second drive can be coupled with the second moveable sheave, and can be configured to rotate the second moveable sheave. The moveable tensioning sheave can be coupled to at least one of the drives and can be disposed in series with the second moveable sheave. The second moveable sheave can be configured to pass the cable to the moveable tensioning sheave, which can be configured to receive the cable from the second moveable sheave. The third moveable sheave can be disposed in series with the moveable tensioning sheave, and can be configured to receive the cable from the moveable tensioning sheave. The second drive can be coupled with the third moveable sheave for rotating the third moveable sheave. The fourth moveable sheave can be disposed in series with the third moveable sheave and coupled with the first drive for rotating the fourth moveable sheave. The rotating fourth moveable sheave can be configured to receive the cable from the rotating third moveable sheave. The second storage reel can be configured to receive the cable from the fourth moveable sheave, and can be adapted to apply a second tension to the cable, thereby allowing tension in the cable to be multiplied up to the test tension. 
       FIG. 1  depicts a schematic representation of an illustrative hydraulic cycle test system  100  according to one or more embodiments. The hydraulic cycle test system  100 , which can also be referred to as a hydraulic operated system for testing cable under tension, can include one or more first storage reels  10 , one or more first moveable sheaves  14 , one or more first friction materials  80 , one or more fourth moveable sheaves  24 , one or more second clutches  28 , one or more second moveable sheaves  16 , one or more second friction materials  82 , one or more third moveable sheaves  22 , one or more first clutches  26 , one or more first hydraulic drives  18 , one or more second hydraulic drives  20 , one or more clutch controllers  30 , one or more power sources  32 , one or more second storage reels  49 , one or more moveable tensioning moveable sheaves  34 , one or more hydraulic power sources  70 , one or more client devices  52 , and one or more processors  40  in communication with one or more data storages  42 . 
     Each of the moveable sheaves  14 ,  16 ,  22 , and  24  can have six grooves for receiving the cable  12  to be tested. The cable  12  can be contained in each of the grooves in parallel, thereby allowing for the transfer of at least a portion of the cable  12  from one moveable sheave to another moveable sheave without contacting additional portions of the cable  12 . For example, grooves of the first moveable sheave  14  can contain the cable  12  as the cable  12  is transferred from the first moveable sheave  14  to the second moveable sheave  16 . The grooves of the moveable sheaves can be tilted in part, thereby enabling at least two opposing grooves to be aligned at the bottoms thereof but offset at the tops thereof. The tilt of the grooves can facilitate the transfer of a portion of the cable  12  from one moveable sheave to another moveable sheave, and can prevent the portion of the cable  12  from sliding about the face of the associated moveable sheaves. 
     The first friction material  80  can be disposed between the first moveable sheave  14  and the fourth moveable sheave  24 . The second friction material  82  can be disposed between the second moveable sheave  16  and the third moveable sheave  22 . The first friction material  80  can couple together the first moveable sheave  14  and the fourth moveable sheave  24  with at least one of the clutches  26  and  28  utilizing a frictional force. The second friction material  82  can couple together the second moveable sheave  16  and the third moveable sheave  22  with at least one of the clutches  26  and  28  utilizing a frictional force. The friction materials  80  and  82  can include wearable brake material that can lock the pairs of moveable sheaves together during testing of the cable  12 . 
     The first clutch  26  can connect the second moveable sheave  16  to the third moveable sheave  22 . Accordingly, the first clutch  26  can disengage the second moveable sheave  16  from the third moveable sheave  22 . In one or more embodiments, the first clutch  26  can be operated by the second hydraulic drive  20 . 
     The second clutch  28  can connect the first moveable sheave  14  to the fourth moveable sheave  24 . Accordingly, the second clutch  28  can disengage the first moveable sheave  14  from the fourth moveable sheave  24 . In one or more embodiments, the second clutch  28  can be operated by the first hydraulic drive  18 . 
     In one or more embodiments, the clutch controller  30  can control the first clutch  26  and the second clutch  28 . The clutch controller  30  can be in communication with the power source  32 . 
     The moveable tensioning moveable sheave  34  can be connected to and/or in communication with at least one of the hydraulic drives  18  and  20 , the hydraulic power source  70 , or combinations thereof. The moveable tensioning moveable sheave  34  can include a load measuring sensor  36  and a speed detector  38 . The load measuring sensor  36  can be a stress gauge, a strain gauge, or a similar device for measuring load. The speed detector  38  can be tachometer, encoder, or similar device. 
     In operation, the first moveable sheave  14  can receive the cable  12  from the first storage reel  10 . The second moveable sheave  16  can receive the cable  12  from the first moveable sheave  14 . The moveable tensioning moveable sheave  34  can receive the cable  12  from the second moveable sheave  16 . 
     In one or more embodiments, the processor  40  can be in communication with: the client device  52 , the load measuring sensor  36 , the speed detector  38 , the data storage  42 , or combinations thereof. Accordingly, the processor  40  can communicate with the client device  52 , the load measuring sensor  36 , and the speed detector  38 . The processor  40  can receive signals from the load measuring sensor  36  and the speed detector  38  and can store the signals in the data storage  42 . The processor  40  can monitor the tension loads of the cable  12 , the speed of the cable  12 , or combinations thereof. 
     The data storage  42  can have: computer instructions  43  to instruct the processor to store preset stress data for the cable  12 ; computer instructions  44  to instruct the processor to compare received signals from the load measuring sensor  36  and the speed detector  38  to the stored preset stress data, and to form compared signals; computer instructions  45  to instruct the processor to provide a notification  46  when the compared signals exceed or fall below the stored preset stress data; and computer instructions  47  to instruct the processor to display the compared received signals, the notification, or combinations thereof within the client device  52 . The data storage  42  is shown with preset stress data  48  stored therein. 
     The processor  40  can be in communication with the client device  52  via a network  50 . The network  50  can be the Internet, a local communication network, a satellite network, a cellular network, a wired network, a wireless network, or any other communication network. Data  53  is shown being transmitted from the processor  40  to the client device  52  over the network  50 . The data  53  can include a notification, a load signal, a speed signal, a compared signal, other data associated with the cable, or combinations thereof. 
     The client device  52  can have computer instructions  54  to allow for continuous remote monitoring of a plurality of compared signals from the processor and/or a plurality of processors. The processor  40  can be in communication with a plurality of client devices simultaneously. The client device  52  can be a laptop, a cell phone, a pager, or another electronic device. 
     In operation, the cable  12  can be connected to the first storage reel  10  and to the first moveable sheave  14 . Accordingly, the first storage reel  10  can be used to payout the cable  12 , and to apply a first tension  11  to the cable  12 . Accordingly, the cable  12  can be tensioned up to a test tension. 
     The first hydraulic drive  18  can rotate the first moveable sheave  14  and the fourth moveable sheave  24 . The second hydraulic drive  20  can rotate the second moveable sheave  16  and the third moveable sheave  22 . Accordingly, the cable  12  can be passed from the first moveable sheave  14  to the second moveable sheave  16 . For example, the cable  12  can be configured to reeve around the first moveable sheave  14  and the second moveable sheave  16 , such as five times, after which the cable  12  can pass from the second moveable sheave  16  to the moveable tensioning moveable sheave  34 . Within the moveable tensioning moveable sheave  34 , the load measuring sensor  36  can measure the load on the cable  12 , and the speed detector  38  can measure the speed of the cable  12 , forming signals and transmitting the signals to the processor  40  for storage in the data storage  42 . The moveable tensioning moveable sheave  34  can pass the cable  12  to the third moveable sheave  22 . 
     The third moveable sheave  22  can be connected in series with the fourth moveable sheave  24 , and in parallel with the second moveable sheave  16 . The third moveable sheave  22  can be configured to be rotated by the second hydraulic drive  20 . The fourth moveable sheave  24  can be in parallel with the first moveable sheave  14 , and can be configured to be rotated by the first hydraulic drive  18 . Accordingly, the cable  12  can pass from the third moveable sheave  22  to the fourth moveable sheave  24  as the moveable sheaves rotate. The cable  12  can then pass from the fourth moveable sheave  24  to the second storage reel  49 . In one or more embodiments, the cable  12  can be configured to reeve around the third moveable sheave  22  and the fourth moveable sheave  24  five times prior to passing to the second storage reel  49 . 
     The second storage reel  49  can be configured to receive the cable  12 , and to apply a second tension  51  to the cable  12 , thereby allowing tension in the cable  12  to be multiplied up to the test tension. 
     The tensioning of the cable  12  can occur at a speed from about one tenth of a foot per minute to about one thousand feet per minute. The tensioning of the cable  12  can occur at a load from about one hundred pounds of force to about sixty thousand pounds of force. 
     A simplified schematic representation of the hydraulic cycle test system  100  shown in  FIG. 1  is shown in  FIG. 6 . The cable  12  is released from the first storage reel  10 . The cable  12  then winds between the first moveable sheave  14  and second moveable sheave  16  before coupling to the moveable tensioning sheave  34 . The cable  12  then winds between the third moveable sheave  22  and fourth moveable sheave  24  prior to storage in the second storage reel  49 . The moveable tensioning sheave  34  is shown coupled to the hydraulic power source  70 . 
       FIG. 2  depicts a schematic representation of an illustrative electrically operated cycle test system, according to one or more embodiments. The electrically operated system  200  can include a first electric drive  66  and a second electric drive  68  for driving the moveable sheaves  14 ,  16 ,  22 , and  24 . In addition, the hydraulic power source  70  can be in fluid communication with the first clutch  26  and the second clutch  28 . 
     The operation of the electrically operated system  200  can be substantially similar to the operation of the hydraulically operated system  100  in  FIG. 1 . The first electric drive  66  can drive the first moveable sheave  14  and the fourth moveable sheave  24 . The second electric drive  68  can drive the second moveable sheave  16  and the third moveable sheave  22 . The hydraulic power source  70  can operate the first clutch  26  and the second clutch  28 . 
       FIG. 3  depicts a schematic of the first hydraulic drive  18 , according to one or more embodiments. The first hydraulic drive  18  can include a hydraulic fluid reservoir  62 , a hydraulic motor  58 , a hydraulic pump  56   a , and an electric motor  60 . The electric motor  60  can be in communication with an electric power source  64 . The second hydraulic drive can be substantially similar to the first hydraulic drive  18 . 
     The hydraulic fluid reservoir  62  can be any fluid containment source, and can contain any hydraulic fluid. The hydraulic fluid reservoir  62  can be in fluid communication with the hydraulic pump  56   a . The hydraulic pump  56   a  can be a centrifugal pump or another fluid pump. The hydraulic pump  56   a  can be in fluid communication with the hydraulic motor  58 . The hydraulic pump  56   a  can be driven by the electric motor  60 . The electric motor  60  can be a squirrel cage electric motor or another type of electric motor. The electric motor  60  can receive power from the electric power source  64 , which can be an alternating current or direct current power source depending on the type of electric motor  60  used. 
     As the electric motor  60  drives the hydraulic pump  56   a , the hydraulic pump  56   a  can provide a pump head to the fluid in the hydraulic fluid reservoir  62  and can flow the fluid from the hydraulic fluid reservoir  62  to the hydraulic motor  58 . As such, the hydraulic pump  56   a  can drive the hydraulic motor  58  by moving the fluid in the hydraulic fluid reservoir  62  to the hydraulic motor  58 . The hydraulic motor  58  can be directly and/or indirectly coupled to one or more of the moveable sheaves and can drive the coupled moveable sheaves. 
       FIG. 4  depicts a schematic of an illustrative first electric drive  66 , according to one or more embodiments. The first electric drive  66  can include an electric motor  83 , a gear reduction mechanism  84 , and an electronic motor controller  88 . The electric motor  83  can be in communication with an electric power source  90 . 
     The electric motor  83  can be an alternating current electric motor or a direct current motor. The electric motor  83  can be powered by the electric power source  90 , and controlled by the electronic motor controller  88 . The electronic motor controller  88  can be a variable speed controller, a digital speed controller, an on/of switch, or a combination thereof. The gear reduction mechanism  84  can directly and/or indirectly couple the electric motor  83  to one or more of the moveable sheaves and can drive one or more of the coupled moveable sheaves. The gear reduction mechanism  84  can be a speed reducer or a similar device, and can convert a portion of the speed of the electric motor to torque. The second electric drive can be substantially similar to the first electric drive. 
       FIG. 5  a schematic of an illustrative hydraulic power source  70 , according to one or more embodiments. The hydraulic power source  70  can include one or more hydraulic pumps  56   a , a linear actuator  61 , one or more electric motors  60 , and one or more hydraulic fluid reservoirs  62 . The electric motor  60  can engage an electric power source  64 . 
     The hydraulic power source  70  can include a plurality of hydraulic pumps. For example, the hydraulic power source  70  can have from about one hydraulic pump to about eight hydraulic pumps. The hydraulic pump  56   a  can be in fluid communication with the hydraulic fluid reservoir  62  and with the linear actuator  61 . The electric motor  60  can be configured to drive the hydraulic pump  56   a . Accordingly, the electric motor  60  can provide power to the hydraulic pump  56   a  to flow fluid from the hydraulic reservoir  62  to the linear actuator  61 . 
     The electric power source  64  can be a four hundred sixty volt three-phase power supply or another power supply depending on the type of electric motor  60  used. The linear actuator  61  can be coupled to the moveable tensioning moveable sheave through a mechanical linkage. 
     While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.