Patent Abstract:
A line stringing apparatus includes in combination an electric motor, motor controller and a processor switchable between a pulling mode and a tensioning mode. An electric motor expends electrical energy when pulling the line and generates electrical energy when tensioning the line. The processor outputting commands to the motor controller for control thereof and for application of electrical energy from the batteries to the electric motor when in the pulling mode and for application of electrical energy generated by the electric motor to the plurality of batteries when in tensioning mode. The processor limits electric motor torque and speed based on operator commands for speed and torque in said pulling mode; and, the processor controlling electric motor torque in the tensioning mode.

Full Description:
This patent application is a division of application Ser. No. 12/109,191 filed Apr. 24, 2008, now U.S. Pat. No. 8,322,689 and this patent application claims the benefit of, and the priority to said  application Ser. No. 12/109,191 filed Apr. 24, 2008. 
    
    
     FIELD OF THE INVENTION 
     The invention is in the field of conductor stringing apparatuses and processes. 
     BACKGROUND OF THE INVENTION 
     High voltage utility transmission lines are capable of supplying power over tens or hundreds of miles (or further) with minimal losses because of the very high voltages used. Step-up transformers located at utility power generation plants boost the voltage transmission levels up, depending on the particular utility, to and beyond 745 kV AC. At high voltages, power can be transmitted effectively as power transmission is a function of voltage times the current times the cosine of the phase angle between the voltage and the current. Use of high voltage minimizes current in the lines which thus minimizes losses which can be generally expressed as current squared times the resistance of the transmission line (i.e., the conductor). 
     Electrical demand in the United States and worldwide has steadily grown. Larger and more conductors are needed. Utilities constantly upgrade their systems at choke points in the grid to add new conductors and/or to replace existing conductors with new conductors which may be able to carry more current. Conductor stringing apparatuses and processes are used between utility towers or poles which may be separated by large distances, for example, they may be a quarter of a mile to a half a mile apart. 
     In a conductor stringing operation, a device called a conductor or cable puller-tensioner is used. Two machines are necessary. One of the machines functions as a puller which supplies the energy to pull the conductor against the friction of fixtures on the poles, against the force of the cable by virtue of its mass and the earth&#39;s gravitational attraction (i.e., its weight) and against the resistance supplied by the other machine which functions as a tensioner. The tensioner is a necessary part of the equipment and process lest the cable/conductor would sag and get tangled up with foliage, trees or other structures located beneath the cable/conductor path. 
     Previously, a drum puller/tensioner was typically powered by an internal combustion engine driving a hydraulic pump. The resulting pressure and flow in the hydraulic system coupled with a mechanical gear reducer would rotate the drum at the specified torque and speed. Tensioning was hydraulically controlled. As the pulling rope began to rotate the drum, it created pressure in the hydraulic system that could be adjusted to create the desired line tension. 
     U.S. Pat. No. 3,326,528 to S. S. McIntyre entitled Cable Stringing and Tensioning System discloses at col. 3, lns. 34 et seq. “the operator of the vehicle initially energizes the stator coils with current that may be supplied from a storage battery 50. Eddy currents are then generated by the relative motion of rotors and stator that produce a magnetic field in the rotors. This tends to retard rotation of the rotors and shaft 40, and this retarding force on shaft 40 builds up through the train of gearing . . . and is transferred back therethrough the sheaves . . . to resist their turning for braking the outfeed of transmission cable thereover.” 
     Many high voltage utility transmission lines are located in or near cities. Some of these lines require periodic replacement and/or upgrade and considerable noise and pollution is generated by internal combustion engines which power existing conductor stringing puller-tensioners. The noise and pollution present nuisances for those living in proximity to the high voltage transmission lines. It is, therefore, desirable to have a conductor stringing apparatus which is environmentally compatible and efficient. 
     SUMMARY OF THE INVENTION  
     An electric drive system powered by an on-board battery bank to run a drum puller-tensioner used in the utility industry is disclosed and claimed. Further, a multi-drum puller-tensioner or bullwheel tensioner may be used employing the principles expressed herein. The battery bank (renewable energy storage) is to be of sufficient voltage and capacity to allow operation for a minimum of two hours at maximum rated torque and speed. Tensioning is achieved by magnetic coupling of the rotor and stator of the electric motor. Although it is preferred to use an alternating current motor it will be understood by those skilled in the art that a direct current motor may be used. Energy produced during tensioning is stored in the battery bank or converted to heat by a resistor bank and can be maintained indefinitely at the maximum rated tension and line speed. It was determined that an electrical solution could be applied to replace the internal combustion engine and hydraulics that are traditionally used in hydraulic puller-tensioner. The benefits of the instant invention include zero emissions and extreme reduction in noise. 
     There are three electrical circuits used in the puller-tensioner. First, the main high voltage circuit operates nominally at 180 volts dc and supplies the electric motor after being converted by the motor controller to three phase alternating current power. Twelve (12) and twenty-four (24) volt dc circuits are used for accessory components. 
     The high voltage power source is comprised of thirty 30 deep cycle 12 volt batteries that are rated at 150 amp-hours each. “Amp-hours” is a measure of electric charge. One Amp-second is equal to one coulomb. One Amp-hour is equivalent to 3600 coulombs of electric charge. Fifteen (15), 12 volt dc batteries are wired in series to form the nominal 180 volt dc circuit. Two of the fifteen, 12 volt battery strings are wired in parallel resulting in a 180 volt power supply with a 300 amp-hour capacity. Trojan T-1275, 12 volt dc, lead acid deep cycle batteries with a 150 amp-hour capacity are the preferred batteries. 
     When fifteen (15) Trojan T-1275 batteries are wired in series they combine for a total of 180 VDC. When two strings of 15 batteries are connected in parallel they double the capacity to 300 amp hours. At this voltage, the maximum amp draw will be about 115 amps to supply a 20.7 kW load. The maximum current draw will be reached close to the end of a conductor stringing operation. 
     The batteries store enough energy to operate the unit for two hours and the combined voltage of the batteries is in the range required by the motor/controller. Any energy storage device that does this would be suitable. In other words, it is specifically contemplated that other battery types such as Lithium Ion and/or Nickel Metal Hydride may be used. Energy storage devices such as capacitors may also be used. Price being a factor, deep cycle lead acid batteries are used. Lead acid batteries give the most energy storage per dollar. 
     The electric motor is a 3-phase AC motor and rated for 34 kW. When pulling, the motor controller converts the 180 volt direct current energy from the batteries into alternating current to drive the motor. When tensioning, the motor controller converts the alternating current energy produced by the motor to direct current energy that is either stored in the batteries or converted to heat by the resistor bank. 
     The resistor bank is rated for 20 kW and is controlled by pulse width modulation. In the tension mode, electric energy is produced by the motor from higher tension and speed, more energy is allowed to be dissipated by the resistors. This is automatically controlled in the CAN-Bus program by monitoring battery voltage and adjusting the pulse width modulation accordingly which controls relay contacts, a solid state relay containing no moving parts, or and insulated gate bipolar relay containing no moving parts. 
     Converters are used to create constant twelve (12) and twenty-four (24) volt dc supplies from the high voltage circuit (180 volt dc) for supplying energy at the appropriate voltages to the accessories. The 180 volt system is charged using a custom, on-board, high voltage charger that is specifically designed for the batteries that are being used. There are a couple of companies that manufacture chargers specifically for the Electric Vehicle industry that would be appropriate. Based on price and ease of use, the Zivan NG-5 was chosen. It requires a 30 amp-230 VAC source and can charge a fully discharged battery pack in 10 hours. This charger was preprogrammed by the manufacturer for the specific battery used to ensure the proper charge curve for longer battery life. Other chargers may be adapted for use. 
     Alternatively, fresh batteries may be brought to the machine on a trailer if longer usage times are desired. If the customer believes they need that option, a small additional trailer with a set of batteries pre-wired may be supplied. Then it is a matter of unplugging the one plug that connects the onboard batteries to the circuit and plugging in the auxiliary batteries. 
     There are several secondary devices that are needed for full functionality. A custom electric brake is used in conjunction with the electric drive. The electric brake is able to supply a braking torque of 150 ft-lbs or, expressed another way, 1800 in-lbs. When the speed reduction of 67.642 of the sprockets and gearbox are considered the electric brake provides approximately 121,755 inch-lbs of resistive torque. The torque is sufficient to hold the pulling reel at maximum line pull when the machine is manually or automatically shut down. The level wind is powered by a Duff-Norton electro-mechanical cylinder. 
     Controlling the unit is a Parker IQAN-MD3 Master Module (hereinafter sometimes referred to as the “processor”). A CAN program was written using the IQAN Design which integrated all the components with the Parker IQAN MD-3. This allows communication with the Azure Dynamics, Inc. DMOC motor controller so that speed and torque can be controlled by user inputs. Safety features are included in the program and are designed to warn the user when unsafe parameters exist and safely shut down the machine when necessary. 
     The processor, its modules and the monitors require twelve (12) and twenty-four (24) volt dc sources. To obtain these voltages required by the controllers and monitors, a dc-dc voltage converter is used to convert the 180 volt dc circuit into lower voltages. A dc-dc converter was chosen from Metric Mind Engineering that produces 45 amps at 12 volts. The dc-dc converter keeps a single 12 volt battery charged that is dedicated to the 12 volt circuit and is used to power all secondary control devices and monitors. 
     A conductor stringing apparatus includes a frame and a conductor reel about which the conductor is wound. An electric motor is affixed to the frame and coupled to the conductor reel. The electric motor expends electrical energy when pulling the conductor in the pulling mode and the electric motor generates electrical energy when tensioning the conductor in the tension mode. The conductor stringing apparatus includes a processor and a motor controller in combination with the electric motor. The processor is switchable between a pulling mode and a tensioning mode. The processor outputs commands to the motor controller for control of the electric motor. A plurality of batteries is used to apply power to the electric motor and to receive power from the electric motor. The processor applies electrical energy from the batteries to the electric motor when in the pulling mode. The processor applies electrical energy generated by the electric motor to the plurality of batteries when in the tensioning mode. The processor limits electric motor torque and speed based on operator commands for speed and torque in the pulling mode. The processor controls electric motor torque in the tensioning mode. 
     The three phase electric motor consumes electrical energy in the pulling mode. The Azure Dynamics Inc. motor controller converts direct current into alternating current according to a command message from the Parker IQAN MD-3 controller and applies it to the three phase alternating current electric motor. Other three phase electric motors may be used with separate stand-alone motor controllers. Further, direct current motors may be used with appropriate controls. 
     The conductor stringing apparatus includes a resistor bank. The processor applies electrical energy to the batteries and to the resistor bank. The processor periodically applies electrical energy to the resistor bank using a pulse width modulation control signal to a control relay. Alternatively, a solid state relay or an insulated gate bipolar transistor may be used. Pulse width modulation is employed wherein the processor controls the application of control signals to the gate of an insulated gate bipolar transistor. The electric motor is an alternating current motor and the motor controller converts direct current battery power to alternating current power. The motor controller converts alternating current power into direct current power for application to the battery or to the resistor bank. A charger for charging the batteries from an external AC power supply is used to charge the batteries at night or when the apparatus is not in use. 
     A battery temperature sensor generates a signal representative of the battery temperature and inputs the battery temperature signal into the processor. The processor, using the battery temperature sensor, decides whether to continue operation of the conductor stringing apparatus. If the temperature of the battery is greater than 120° F. then operation for the machine is discontinued. The battery temperature sensor may be a thermocouple in engagement with the first negative battery post of fifteen batteries connected in series. 
     A process for stringing a conductor is also disclosed and includes the initial step of switching between pulling and tensioning modes as desired. Further steps include controlling an electric motor using a processor and a motor controller. In the preferred embodiment the motor controller-motor combination are supplied by Azure Dynamics, Inc. Electrical energy from a plurality of batteries is consumed in the electric motor when pulling a conductor in pulling mode. The electric motor generates electrical energy and charges the plurality of batteries under certain conditions when tensioning a conductor in tensioning mode. Battery voltage is continuously monitored and when it reaches 198 volts dc, the processor begins applying current to the resistor bank to dissipate the energy in the form of heat. The processor limits the electric motor torque and speed based on operator commands for speed and torque in the pulling mode. The processor controls the electric motor torque in the tensioning mode and thus provides tension to the system. The process for stringing a conductor further comprises the steps of dissipating excess electrical energy in a resistor bank when the voltage measured across the string of 15 batteries in series is equal or greater than 198 volts dc. 
     Accordingly, the process for stringing a conductor includes the steps of measuring battery voltage, processing the battery voltage, and, controlling the dissipation of excess electrical energy in the resistor bank depending on the battery voltage. The step of controlling the dissipation of excess electrical energy in the resistor bank includes modulating the pulse width of a control signal to a switching device in series with the resistor bank. Preferably, the switching device is a control relay, an insulated gate bipolar transistor, or a solid state switching device. Application of the pulse width begins at 198 volts dc and continues and increases linearly up to and including 215 volts dc. 
     The process for stringing a conductor includes the steps of: monitoring battery temperature; and, discontinuing the stringing operation when the battery temperature exceeds a temperature limit of 120° Fahrenheit. The battery temperature is sensed from a thermocouple engaged with the first negative battery post of the string of 15 batteries. 
     It is an object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which is capable of energy recovery in the tensioning mode. 
     It is an object of the invention to provide an electric conductor stringing puller-tensioner which is of the multi-drum type for the electric utility industry which is capable of energy recovery in the tensioning mode. 
     It is an object of the invention to provide an electric bullwheel tensioner for the electric utility industry which is capable of energy recovery in the tensioning mode. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner with an energy management system for handling energy recovered in the tension mode. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which employs pulse width modulation control in dividing energy between storage batteries and a resistor bank for dissipating energy as heat. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which controls the speed of the reel between upper and lower torque values. 
     It is a further object of the invention to provide an electric bullwheel tensioner having positive control of the conductor or wire released under tension. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which employs an insulated gate bipolar transistor to implement pulse width modulation control of the resistor bank. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which employs a solid state switch device to implement pulse width modulation control of the resistor bank. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which employs a control relay to implement pulse width modulation control of the resistor bank. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner apparatus which employs an alternating current motor controlled by a motor controller which converts direct current to alternating current. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner for the electric utility industry which is environmentally compatible and efficient. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner apparatus for the electric utility industry which is capable of energy recovery in the tension mode. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner apparatus for the electric utility industry which is capable of energy recovery in the tension mode and which is controllable based on battery bus voltage. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner apparatus for the electric utility industry which is capable of battery management and protection based on the temperature of the batteries. 
     It is a further object of the invention to provide an electric conductor stringing puller-tensioner apparatus for the electric utility industry which employs a thermocouple attached to the negative post of the battery connected to the negative battery bus. 
     Further objects of the invention will be understood when reference is made to the drawings, description of the invention and claims which follow hereinbelow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a prior art illustration of a conductor stringing tensioner and puller. 
         FIG. 2  is a side view of the conductor stringing puller-tensioner of the instant invention. 
         FIG. 2A  is a view taken along the cross-sectional lines  2 A- 2 A of  FIG. 2 . 
         FIG. 2B  is a top view of the conductor stringing puller-tensioner of the instant invention. 
         FIG. 2C  is a cross-sectional view of the conductor stringing puller-tension of the instant invention taken along the lines  2 C- 2 C of  FIG. 2B . 
         FIG. 2D  is a rear view of the conductor stringing puller-tensioner of the instant invention. 
         FIG. 2E  is a sectional drawing taken along the lines of  2 E- 2 E of  FIG. 2B  illustrating the battery securement. 
         FIG. 2F  is a sectional drawing taken along the lines of  2 F- 2 F of  FIG. 2B  illustrating the battery securement. 
         FIG. 2G  is a perspective view of a battery and terminals. 
         FIG. 2H  is an enlargement of a portion of  FIG. 2G  illustrating a screw in the negative most terminal. 
         FIG. 3  is a schematic ladder diagram of the 180 volt dc circuit which includes the batteries, the resistor bank, the three phase electric motor and motor controller. 
         FIG. 3A  is a schematic ladder diagram of the 12 volt dc circuit which includes the modules of the processor, various relays, and the Insulated Gate Bipolar Transistor. 
         FIG. 3B  is a schematic illustrating: a processor module, rocker switches, joystick, the voltage transducer monitoring the 180 volt dc circuit and the temperature transducer monitoring the battery temperature. 
         FIG. 3C  illustrates operation of the resistor bank and the pulse width modulation control signal. 
         FIG. 3D  is a schematic ladder diagram of the 180 volt dc circuit which includes the batteries, the resistor bank, the three phase electric motor, motor controller and an ultra-capacitor in parallel. 
         FIG. 4  is an illustration of the control panel. 
         FIG. 5  is a schematic diagram of the master start sequence of the conductor stringing puller-tensioner. 
         FIG. 5A  is a schematic diagram of the motor control for the puller mode and the tension mode of the conductor stringing puller-tensioner. 
         FIG. 5B  is a schematic diagram of the energy control in the tension mode. 
     
    
    
     A better understanding of the drawings will be had when reference is made to the description of the invention and the claims which follow hereinbelow. 
     DESCRIPTION OF THE INVENTION  
       FIG. 1  is an illustration  100  of a conductor stringing tensioner  105  and puller  104 . Poles  101  and insulators  102  are illustrated as is a conductor pulling rope and conductor. Insulators  102  and stringer attachment  103  are illustrated in  FIG. 1  as is the traveling ground. 
       FIG. 2  is a side view  200  of the conductor stringing puller-tensioner of the instant invention illustrating the resistor bank cabinet  201 , control panel  211 , and control box housings  211 A,  211 B. An operator of the device is protected by a protective screen  213  in the event of a rope or conductor break under tension. Joystick  311 A can be seen in  FIG. 2  protruding from the control panel. Batteries are secured in an undercarriage formed of channel  210  which is obscured from view in  FIG. 2  by battery skirt  202 . Chain guard  203  protects a person from entanglement with a chain (not shown) which operates between a small sprocket (not shown) having  19  teeth per revolution and a large sprocket (not shown) having  84  teeth per revolution. Reel  205  upon which conductor or rope is wound and reel shaft  204  are viewed well in  FIG. 2 . An outer frame  206  supports the operator and his or her chair as well as the control panel. The main frame  207  supports the batteries, the electric motor, the chain and the conductor/rope reel. Wheel covering/wheel guard  203  is illustrated over wheels/tires. The outer and main frames  206  are covered with metal plates enabling limited mobility of the operator around the machine. 
       FIG. 2A  is a view  200 A taken along the cross-sectional lines  2 A- 2 A of  FIG. 2 . Batteries  220  are illustrated residing in channels  210 . Channels  210  include upwardly extending portions  220 A. Motor controller  240 A is illustrated in  FIGS. 2A and 2C .  FIG. 2B  is a top view  200 B of the conductor  230  stringing puller-tensioner of the instant invention. Flooring-battery covering  231 ,  231 A,  231 B and  231 C are metal plates which are attached to the frame  206 ,  207  with screws or other attachment means as shown in  FIG. 2B . Battery hatch  211 B allows access to battery  319  which supplies start-up control power to the 12 volt dc circuit illustrated in  FIG. 3A . The flooring-battery coverings reside over the batteries and enable limited movement by the operator or maintenance personnel on the device. The batteries  220  are held in place by tie-downs  220 B as illustrated in  FIG. 2B . 
     The batteries may be replaced periodically for maintenance, repair or substitution of a fresh fully charged battery. Alternatively, an auxiliary trailer having thirty (30) fully charged 12 volt dc batteries may be placed in proximity to the conductor puller-tensioner as a supplemental energy source for longer pulls. The auxiliary batteries may be coupled by using a socket and plug interconnection  320 . Reference numeral  320  diagrammatically illustrates the socket and plug and includes necessary electrical interconnection and extensions to the supplemental energy source. 
       FIG. 3  is a schematic ladder diagram  300  of the nominal 180 volt dc circuit which includes batteries  220 , resistor bank  316 , alternating current motor  240 , and DMOC motor controller  240 A. As for the resistor bank, it is a customized grouping of 15 individual resistors from Milwaukee Resistor&#39;s Edge Power product line. Five (5) 2.75 ohms resistors are in parallel with each other and form a set. Each individual resistor has a resistance of 2.75 ohms. Each set of resistors has a resistance of 0.55 ohms and then three sets of the resistors are series with each other for a total resistance of 1.65 ohms. 
     In  FIG. 3 , the batteries  220  are illustrated as being connected in series. The power required by the three phase alternating current motor  240  is approximately 27.767 Hp (20.7 Kw) and the required torque is approximately 70,000 in-lbs. The reel sprocket (not shown) includes 84 teeth per revolution and the motor sprocket (not shown) includes 19 teeth per revolution. The sprockets reside within the chain guard  203  and are not visible. The reduction of the gearbox is 15.3:1 and the total reduction is 67.642 which yields a torque requirement of 1,034. 8 in-lbs (116.9 N-m). The required reel speed is 25 rpm which yields a required motor speed of 1691 rpm. Different speeds, torques and gear reductions may be used as will be recognized by those skilled in the art without departing from the spirit and scope of the invention as set forth herein. 
     Still referring to  FIG. 2B , conductor  230  is illustrated wound on reel  205 . Level winds  310 B,  310 C are illustrated in  FIG. 3A  which are responsible for winding and unwinding the rope or conductor onto and off-of reel  205  in an orderly fashion for efficient storage and payout. Adapter  241 , multi-disc brake  242  and gearbox (gear reducer)  243  are illustrated in  FIG. 2B . 
       FIG. 2C  is a cross-sectional view  200 C of the conductor stringing puller-tensioner of the instant invention taken along the lines  2 C- 2 C of  FIG. 2B  with the reel and the three phase alternating current motor removed.  FIG. 2C  illustrates the batteries  220  and their placement in the channel  210  and the upwardly extending portion  220 A of the channel  FIG. 2D  is a rear view  200 D of the conductor stringing puller-tensioner of the instant invention. 
       FIG. 2E  is a sectional view  200 E taken along the lines of  2 E- 2 E of  FIG. 2B  illustrating the battery securement. Tie down rod  252  which may be partially threaded rod or it may be threaded along its entirely length. Rod  252  is connected to the lower plate  254  which traverse channels  210 . Nut  256  threads onto the tie down rod  252  and applies pressure to upper plate  220 B against the batteries  220 . Reference numeral  258  is the side wall of the battery enclosure.  FIG. 2F  is a sectional view  200 F taken along the lines of  2 F- 2 F of  FIG. 2B  illustrating the battery securement. 
       FIG. 2G  is a perspective view  200 G of a battery  220  and terminals  261 ,  262 .  FIG. 2H  is an enlargement  200 H of a portion of  FIG. 2G  illustrating a threaded screw  265  in the negative most terminal  262 . Reference numeral  263  indicates the female threads within post/terminal  262 . Thermocouple  264  may be affixed into engagement with the terminal  262  to monitor the temperature of the battery. 
     Referring to  FIG. 3 , a schematic ladder diagram  300  of the nominal 180 volt dc power system is illustrated. The voltage is referred to as nominal, meaning ordinary or expected. However the voltage across the battery strings arranged in parallel with each other varies. Specifically, in the tensioning mode, if the voltage exceeds 198 volts dc, then the 20 kW resistor bank  316  dissipates some of the energy according to the width of a pulse width modulation control signal applied to a relay, solid state switching device, or an insulated gate bipolar transistor  349 . Insulated gate bipolar transistors function as a switch applying current to the resistor bank. Alternatively, contacts of CR  5  may be used to control the application of the regenerated energy from the alternating current motor  240 /DMOC controller/processor  240 A to the resistor bank. 
     Alternatively, an ultra-capacitor  391  may be used in parallel with the string of batteries as illustrated on  FIG. 3D .  FIG. 3D  and  FIG. 3  illustrate the same components only  FIG. 3D  includes the ultra-capacitor capable of storing a large amount of charge. Ultra-capacitors or electrochemical double layer capacitors (EDLC), are electrochemical capacitors that have an unusually high energy density when compared to common capacitors, typically on the order of thousands of times greater than a high-capacity electrolytic capacitor. Ultra-capacitors store several are capable of storing many farads and some large commercial ultra-capacitors have capacities of thousands of farads. 
     The three phase alternating current motor  240  (Azure Dynamics Inc. Model no. AC55) and the DMOC motor controller  240 A are supplied by Azure Dynamics Inc. of Woburn, Mass. as a motor/controller package. The three phase alternating current motor is rated for 34 kW continuous power, 240 N-m peak torque, and 8,000 rpm maximum speed. Other electric motor-motor controller packages may be used as those skilled in the art will readily recognize for different loads and machine characteristics. 
     Referring to  FIG. 3 , the high voltage power source is comprised of thirty (30) deep cycle twelve (12) volt batteries  220  that are rated at 150 amp-hours each. Fifteen (15), twelve (12) volt dc batteries  220  are wired in series to form the nominal 180 volt dc circuit. Two of the fifteen (15), twelve (12) volt battery strings are wired in parallel resulting in a 180 volt pack with a 300 amp-hour capacity. Trojan T-1275 Plus, 12 volt dc, lead acid deep cycle batteries with 150 amp-hour capacity are the preferred batteries  220 . The batteries may be charged in the tension mode as explained herein or they may be charged overnight or when the puller-tensioner is not in operation by employing charger  305 . Charger  305  is a Nivan Charger having an input source voltage of 230 volts AC and can draw 30 Amps. Charger  305  outputs 180 volts DC. At a voltage of 180 volts dc, the maximum current draw will be about 115 amps to supply a motor load of 20.7 kW. The maximum current draw will only be reached close to the end of a conductor stringing operation. 
     Voltage across the battery strings is monitored  370 ,  371  by a voltage transducer illustrated in  FIG. 3B .  FIG. 3B  is a schematic  300 B illustrating: a processor module  306 , rocker switches  311 , joystick  311 A, voltage transducer  307  monitoring the 180 volt dc power system and the temperature transducer  307 A monitoring the battery temperature. Processor  306 ,  306 A,  306 B, and the DMOC motor controller  240 A use CAN program parameters for communication and processing. The voltage transducer  307  monitors the voltage  370 ,  371  on terminals  323 ,  323 A and outputs (from terminal  326 ) a signal  338 A which is input into and communicates with terminal  338  of processor  306 . Processors  306 ,  306 A, and  306 B are an IQAN Parker Hannifin MD-3 processor. Processor  306  includes terminal  339  which communicates with terminal  339 A of module  306 A. Expansion module  306 B includes terminals  359 ,  360  which communicate with terminals  357 ,  358  of module  306 A. 
     Voltage monitoring across the battery strings is important as the voltage may increase during tensioning mode and the batteries are limited as to how much energy or charge them may accept per unit time and contain. The voltage transducer requires a 24 volt dc supply which is supplied at pins  324 ,  312  of the transducer. Voltage converter  321  is powered from the 12 volt dc logic circuit illustrated in  FIG. 3A  and steps up the voltage to 24 volts dc for application to the voltage transducer  307  and the temperature transducer  307 A. 
     At a voltage of 198 volts dc as monitored across the nominal 180 volt dc power supply circuit, the processor begins to modulate the amount of energy applied to the batteries and directs the energy to the resistor bank  316 . At 198 volts DC the processor enables relay CR 4  (SWITCH  349 ) which is output from terminal  346  of processor module  306 B. Engineering units of volts dc across the battery string are converted by a CAN program into counts for use within the CAN program. Energization of relay CR  4  closes contact CR 4  which then allows current to flow in the circuit and then applies power to energize relay CR 5 . Upon energization of relay CR 5 , contacts CR 5  in series with resistor bank  316  enables application of current for the dissipation of energy in the resistor bank  316 . 
       FIG. 3C  illustrates  300 C operation of the resistor bank pulse width modulation control signal. Specifically, reference numeral  349 E illustrates the battery voltage. Reference numeral  349 D indicates the resistor power dissipation in Watts. Reference numeral  349 C illustrates the pulse width that corresponds to a particular voltage in the range of 198 volts to 215 volts dc. Reference numeral  198  illustrates that when the voltage across the battery strings reaches 198 volts dc, a resistor pulse width modulation signal is applied to CR 4  (or other switching device) which controls relay contacts CR 5  in series with the resistor ban. The pulse width modulation signal begins at 198 volts dc and increases linearly such that when 215 volts dc is reached the application of current to the resistor bank is constant, specifically, current is applied 100% of the time and 20 kW is dissipated in the resistor bank. The resistor bank dissipates 20 kW and is comprised of sets of resistors which have a total resistance of 1.65 ohms. Specifically there are three sets of resistors in series with each set having five 2.75 ohm resistors arranged in parallel. 
     The invention includes a battery charging algorithm. Checks and balances are used during tensioning for a safe battery pack charge. Voltage, current, and temperature are all used in the program to control it. Generally, charging current of a battery system is equal to Current/10, where Current is the 20 hr capacity of the system. Each battery string employs batteries having a 150 Amp-hour capacity. System capacity is 300 Amp-hours because two battery strings are used so charging current is nominally 30 amps. 
     Current is not measured directly and externally to the DMOC motor controller  240 A. Current is calculated from the power generated from tensioning. We have inputs for speed and torque from the DMOC motor controller  240 A, so horsepower is calculated from the formula Horsepower=(ft-lbs*rpm)/5252. Horsepower is then converted Watts as 746 Watts is approximately equal to 1 horsepower. Current in Amps is equal to Watts/Volts. The program uses torque, speed, voltage, current and temperature for use in operating the resistor bank and charging the batteries. 
     The program uses these values to decide if, and how much to pulse the resistors. If the charge rate is below 30 amps, and if the voltage is below 198 VDC, and if the temperature is below 118 degrees F., then the resistors are not used, or pulsed at zero percent. 
     There are three calculations made to determine the pulse rate of the resistors. They are all a percentage of the total resistive power. The program picks the largest value to use as the actual PWM percentage employed. 
     Formula 1: Current based pulse width modulation percentage. 
     A charge current of 30 amps is the nominal charging current. Potential resistive power of the resistor bank is determined by squaring the voltage and dividing by the resistance. Resistance of the resistor bank is a constant 1.65 ohms as explained elsewhere herein. Voltage of the 180 volt circuit is not constant and is changing depending on operational conditions and, as such, the potential power is also changing. Power is calculated from the tensioning. Power in the batteries is 30 amps multiplied by the instantaneous voltage and may range from 5.4 kW to 6 kW, more or less. Power supplied to the batteries is subtracted power from the power determined and generated by the tension and what remains, for example, the difference is the power dissipated in the resistor bank. Power to be dissipated in the resistor bank is divided by the potential resistive power and is multiplied by 100 to get a pulse width modulation percentage. This is the PWM percentage determined using a current analysis. 
     Formula 2: Voltage based pulse width modulation percentage. 
     The calculation for voltage is much simpler than the calculation for current. The battery voltage should not exceed 217 volt dc but needs to be above 190.5 volts dc to charge the batteries. A linear calculation between 198 and 215 volts dc is used to determine a linear pulse width modulation percentage. In other words, the pulse width varies between 0 and 100 percent as the voltage varies between 198 and 215 volts dc. Consequently, this is the formula that is used most often by the program because even if the charge rate is below 30 amps the voltage increases. 
     Formula 3: Temperature based pulse width modulation percentage. 
     The temperature of the batteries does not exceed 120 degrees F. When the temperature reaches 118 degrees F., we equal the tension power and resistive power so that there is no charge or discharge in the batteries and the resistors handle all of the current. 
     Again, these three formulas all calculate a percentage. The greatest percentage is the one that the program uses. 
     Battery temperature is monitored by the battery transducer  307 A. Engineering units of degrees Fahrenheit are converted into counts for use in the CAN program. The temperature transducer circuit is supplied by the voltage converter  321  with 24 volts dc across terminals  313 ,  329 . A thermocouple input  315 A is applied across terminals  314  and  315  of the temperature transducer. The temperature transducer  307 A outputs a signal  318 A on pin  318  which communicates with pin  330  on processor  306 . If battery temperature exceeds 120° F. then the machine is shut down and relay contacts CR 2  and CR 3  in the 180 volt circuit open. Relay contacts CR 2  and CR 3  open as the output of pin  348  goes to zero and disables relay CR 6 . With relay CR 6  de-energized, contacts CR 6 , CR 6  open de-energizing relay contacts CR 2 , CR 3  which result in the isolation of the battery strings  220  from electric motor  240 /motor controller  240 A and from the dc-dc converter  317 . 
     The 12 volt dc control circuit is supplied by the output  374 ,  375  of the 180 vdc-12 vdc converter  317  illustrated in  FIG. 3 . Converter outputs  374 ,  375  are also viewed in the upper portion of  FIG. 3A . Referring to  FIG. 3A , voltage isolating converter  309  supplies 12 volts dc from unnumbered terminals and communication points  382 ,  383  to battery meter  301  ( FIG. 3 ) as indicated by communication points  382 ,  383  which in turn communicate with pins  361 ,  365  of the battery meter. The battery meter includes a shunt  351  which provides an input to pins  362 ,  363  of the battery meter. Prescaler  301 A is also used in connection with the battery meter and communicates with terminals  361  and  364  respectively. 
     Referring to  FIG. 3 , alternating current three phase motor  240  and DMOC controller  240 A are illustrated. Reference numerals A, B, C indicate the three phase inputs to the windings of the motor. Twelve (12) volts dc are applied across terminals  369 ,  350  of the DMOC through communication with the 12 volt dc supply  374 ,  375  from the 180 volt dc-12 volt dc converter  317 . A CAN control message is applied to pins  366 ,  367  of the DMOC motor controller  240 A. The CAN control message comes from processor  306  pins  355 ,  356  of the IQAN MD-3 processor  306  and is interconnected  378 ,  379  to the DMOC controller  240 A. Similarly status messages are communicated from the DMOC motor controller  240 A back to the processor  306 . The DMOC controller  240 A applies an algorithm which depends on the operational mode of the processor, for instance, whether the processor is in the tension mode or pulling mode. Further, processor  306  and its modules  306 A,  306 B are in communication with an interface  406  illustrated in  FIG. 4 . Voltage, temperature, speed, torque as well as other parameters are displayed on the graphical interface  406 . 
     In the pulling mode, lower torque and upper torque are set by the operator. Speed is also operator controlled in a range of plus and minus 0 to 100% with a dead band of +/−10%, but is limited by the values input for lower and upper torque. The speed regulator is active within the window given by the lower and upper torque limit. The speed set-point as well as the toque limits are transmitted over CAN and may be modified by the DMOC at a rate of 20 hz. If the speed set value can be reached within the torque limits then speed regulation as commanded by the operator speed input is achieved. If the limits are too restrictive, for example, the lower torque and the upper torque are too close together, then the drive becomes essentially torque controlled. 
     In the tension mode, lower torque is set equal to upper torque and the tensioner acts as a classical torque resistance or tensioner. 
     Referring to  FIG. 3B , rocker switch  311  communicates with pins  331 ,  332  of processor  306 . Joystick  311 A includes right (increase) and left (decrease) torque pushbuttons. Depressing the right button  407 B communicates a torque increase signal to pin  332  of processor  306 . See  FIG. 4  for an illustration of the torque push button  407 A,  407 B. Depressing the left button  407 A communicates a torque decrease signal to pin  331  of processor  306 . Source voltage is applied to pin  335  and ground is applied to pin  334 . The speed signal input, directionally indicated as plus-minus 100% is applied to pin  333  of the processor  306 . Speed input is controlled by the Joystick single axis forward and reverse movement as indicated in  FIG. 4 . A USB port communicates with pins  336 ,  337 . The torque inputs to processor  306  are digital inputs and the joystick speed on pin  333 , the battery bus voltage on pin  338  and the battery temperature on pin  330  are analog inputs. Torque and speed inputs are user controlled while operating the puller-tensioner. 
       FIG. 3A  is a schematic ladder diagram  300 A of the 12 volt dc circuit which includes the modules of the processor  306 A,  306 B, relays CR 1 , CR 4 , CR 5 , CR 2 , CR 3 , level wind actuator motors  310 ,  310 A and switch  349 . Battery  319  supplies energy for the control logic set forth in  FIG. 3A  before the puller-tensioner is started. A DC-DC converter  317  keeps the 12 volt dc battery  319  charged via interconnection points  374 ,  375  of the converter  317  and interconnection points  380 ,  381  of the 180 volt dc circuit. Key switch  302  energizes relay CR 1  which is a permissive to application of power to the isolating DC-DC converter for the battery meter  301 , the level wind actuators  310 ,  310 A and the processor  306 ,  306 A,  306 B. Switch  302  is also viewed on  FIG. 4  and is labeled system enable. 
     Processor module  306 A is powered by the 12 volt dc bus at terminals  352 ,  354  as illustrated in  FIG. 3A  and socket relay indicates that the processor is active. Similarly processor module  306 B is supplied with power at pins  340 ,  345 . RS 232 communication is accomplished at terminals  343 ,  344  of module  306 B. An address tag is communicated at terminals  341 ,  342  of module  306 B. Processor  306 B drives the brake disable relay which controls the electric brake  242  contained within the electric motor-electric motor brake housing. Electric brake  242  is applied when the electric motor  240  is commanded to shutdown when the battery temperature exceeds 120° F. 
     Still referring to  FIG. 3A , control relays CR 2  and CR 3  are enabled when relay CR 6  is energized closing contacts CR 6 , CR 6 . Control relay CR 6  is energized when the joystick  311 A is centered or it is within its dead band zone (plus-minus 10% of being centered) and the holding electric brake  242  is off. When CR 6  is energized two sets of contacts CR 6  are enabled which, in turn, enable CR 2  and CR 3  which then energizes the 180 volt dc circuit upon the closure of contacts CR 2 , CR 3  as illustrated in  FIG. 3 . 
       FIG. 4  is an illustration  400  of the control panel  408 . Control panel  408  is viewed by the operator and informs the operator as to several important parameters. First, key  302  enables the system. Battery meter  301  indicates the voltage across the battery strings. Brake pressure  404  is the pressure applied by the brake within the motor-brake assembly. The electric brake can be manually applied by the operator through toggle brake arm  405 . The direction  403  of the level wind is controllable as is viewed in  FIG. 4 . Joystick  311 A and torque increase  407 B and torque decrease  407 A buttons are illustrated. Indicia  420  instructing the operator as to operation of the joystick (payout and pull-in) and the torque inputs is applied to the control panel  408 . 
     Master control interface  406  is illustrated in  FIG. 4  having a display screen for conveying information to the operator. F 1 , designated by reference numeral  430 , is depressed to enter the puller mode. F 2 , designated by reference numeral  431 , is depressed to enter the tensioning mode. Button F 3 , designated by reference numeral  432 , is depressed to enter the diagnostic mode. 
     In the pulling mode, input and actual speed and torque are displayed. Battery temperature and voltage are also displayed. The operator may also reset the torque by depressing one of the arrow buttons on the controller (processor) interface  406 . The controller temperature is also indicated. 
     In the tension mode, input and actual speed and torque are displayed. Battery temperature and voltage are also displayed. Also, in the tension mode the percentage of the pulse width modulation being applied is also displayed. A green light is displayed on the processor screen indicating that the controller is operating in the tension mode. The controller temperature is also indicated. 
     In the diagnostic mode the input and output speed and torque are displayed in parametric indications of the CAN program. 
       FIG. 5  is a schematic diagram  500  of the master start sequence of the conductor stringing puller-tensioner. Reference numeral  501  indicates the master start sequence. The first query  502  is whether the joystick lever is centered. If the joystick lever is not centered, the operator must center it to enable the 180 volt dc circuit. So, in other words, the joystick must be centered plus or minus 10% as previously indicated as a permissive to starting the puller-tensioner. Next, the holding brake must be off and a query  503  in this regard is represented in the flow chart. If the brake is off then the 180 volt dc circuit can be enabled by energizing control relays CR 6 , CR 2 , and CR 3 . If the holding brake is not off, it must be positioned in the off position. To enable the 180 volt dc circuit, relays CR 6 , CR 2  and CR 3  are energized. Therefore, the CAN program requires the joystick to be centered +/−10% and the motor brake  242  must be off. 
       FIG. 5A  is a schematic diagram  500 A of the motor control  505  for the puller mode and the tension mode of the conductor stringing puller-tensioner. If the machine was automatically shutdown  506  then the input speed is automatically set to zero  507 . If the machine was not automatically shut down then the input speed and direction is determined  508  by the operator positioning the joystick lever. Upper and lower torque is then determined and set by the operator by pressing right  407 B or left  407 A joystick buttons  509 . 
     If the machine is in the puller mode  510  then a query  511  is present as to whether or not the torque reset button has been pressed. If the torque reset button has not been pressed then the lower torque is set to zero  515  and the upper torque remains as set in step  509 . If the torque reset button has been pressed then the reset is confirmed  512 ,  513  through messages displayed on the interface  406  and the upper torque is set to zero  514  and the lower torque is also zero  515 . For this condition, where the pulling mode is active and the reset button is pressed the upper and lower torque are both set to zero. If the torque button has not been depressed then in the pulling mode the motor is operating with an upper torque set by the operator and a lower torque set at zero. 
     Still referring to  FIG. 5A , in tension mode, the lower and upper torque are equal  516  and determined by the upper torque setting  509 . 
     Still referring to  FIG. 5A , next, regardless of tension or pulling mode, the input speed, upper torque, and lower torque values are converted into CAN program parameters  517  and transmitted to the motor controller via the CAN bus  518 . The input speed and upper torque values are mathematically processed  519  for display  520  as input values on the interface  406 . The processor receives actual speed and torque values  521  from the DMOC motor controller  240 A and mathematically processes them  522  and displays them as actual values  522 ,  523 . 
       FIG. 5B  is a schematic diagram  500 B of the energy control and management system in the tension mode  524  resulting from depressing the tension function key  525 . In the tension mode the joystick lever must be pushed back to plus or minus 10% and the tension mode green lamp is displayed  527 . Battery temperature from the controller is received by the processor via the CAN bus  528  and is mathematically processed  529  for display in engineering units of volts dc  530 . The resistor bank pulse width modulation duty cycle is calculated  531  depending on the voltage. The resistor bank is enable by the pulse width duty cycle as dictated by CR  5   532 . The pulse width modulation duty cycle as a percentage is displayed  533  on the graphical interface. Battery temperature is measured  534  and mathematically processed  535  and displayed  536  in engineering units. If the battery temperature is greater than 120° F. then the holding brake is applied  538  and the machine is shut down  539 . If the temperature is less than 120° F. then the temperature is processed for display in engineering units  528 ,  529  and the steps are repeated. 
     The input for speed is an analog signal originating from a bi-directional, single-axis joystick on the control panel. The signal that it sends is a voltage ranging from 500-4500 mV when the joystick is in its full back or full forward position, respectively. This voltage signal is received by the Parker IQAN MD3 control module/processor  306  and is represented by the voltage-in channel (pin  333 ) labeled Joystick. In this channel the voltage signal is converted to a percentage that ranges from −100 to 100. This value is converted into CAN program parameters. First, a dead zone is created by specifying that between −10% and +10% the value will be zero. Second, the range is converted to the CAN parameters needed by the Azure Dynamics, Inc. motor controller  240 A. This CAN parameter value is  670  for max speed. 
     The inputs for torque are the two buttons  407 A,  407 B on the top of the joystick  311 A. Each button inputs to channel (pins  331 ,  332 ) on processor  306 . The right button  407 B is connected to pin  332  to raise torque and the left button is connected to pin  331  to lower torque. An event-counter counts the amount of times the user presses the joystick buttons, adding when the right button  407 B is pressed and subtracting when the left button  407 A is pressed. The user reaches maximum torque after 100 clicks of the right button. The value for maximum torque in CAN parametric form is 1146.88. To reach this value in 100 clicks, each count of the Joystick is multiplied by 11.4688. This value is sent to the parameter-out channel and is the upper torque limit. The parameter-out channel, lower torque limit is either zero, as is the case when pulling, or is equal to the upper torque limit, as is the case when tensioning. 
     Three parameter-out channels, speed control, upper torque limit, and lower torque limit, are attached to the generic frame out channel, control message. The control message is sent to the Azure Dynamics Inc. motor controller  240 A where it interprets the inputs and regulates the motor speed and torque accordingly. The motor controller  240 A communicates status messages back to the processor  306  for processing and display on display  406 . 
     The algorithms implemented by the processor described herein are set forth by way of example only. It is specifically contemplated that different algorithms may be used for the control of, for example, the electric motor(s), tension, speed, torque and safety and other parameters without departing from the spirit and scope of the claimed invention. 
     REFERENCE NUMERALS 
     
         
         A, B, C—motor phases 
         F 1 —puller function key 
         F 2 —tension function key 
         F 3 —diagnostic function key 
         CR 1 —actuator relay and relay contacts 
         CR 2 —180 Vdc relay and relay contacts 
         CR 3 —180 Vdc relay and relay contacts 
         CR 5 —resistor bank relay and relay contacts 
           100 —prior art schematic of conductor stringing process 
           101 —pole 
           102 —insulator 
           103 —stringer attachment 
           104 —puller 
           105 —tensioner 
           200 —side view of puller-tensioner 
           200 A—cross-sectional view taken along the lines  2 A- 2 A of  FIG. 2   
           200 B—top view of puller-tensioner 
           200 C—cross-sectional view taken along the lines  2 C- 2 C of  FIG. 2   
           200 D—rear view of the puller-tensioner 
           200 E—sectional view taken along the lines of  2 E- 2 E of  FIG. 2B . 
           200 E—sectional view taken along the lines of  2 F- 2 F of  FIG. 2B . 
           200 G—perspective view of battery and terminals 
           200 H—enlargement of a portion of  FIG. 2G   
           201 —resistor bank cabinet 
           202 —battery skirt 
           203 —chain guard 
           204 —reel shaft 
           205 —reel 
           206 —frame (frontal portion) 
           207 —main frame 
           208 —wheel covering/wheel guard 
           210 —channel forming battery supports 
           211 —control panel 
           211 A—control box housing 
           211 B—battery hatch 
           212 —joystick 
           213 —protective screen 
           220 —battery 
           220 A—upwardly extending portion of channel 
           220 B—battery upper plate for tie down 
           230 —conductor 
           231 ,  231 A,  231 B,  231 C—flooring/battery cover 
           240 —three phase electric motor 
           240 A—DMOC motor controller 
           241 —adapter 
           242 —multi-disc brake 
           243 —gearbox 
           252 —tie down rod which may be partially threaded 
           256 —nut which threads onto the tie down rod 
           254 —lower plate affixed to and traverses channels 
           258 —side wall of battery enclosure 
           261 ,  262 —battery terminals  261 ,  262 . 
           263 —female threads within terminal  262   
           264 —thermocouple  264  affixed into engagement with the terminal  262   
           300 —180 volt ladder diagram 
           300 A—12 volt ladder diagram 
           300 B—joystick, temperature and voltage transducer 
           300 C—pulse width modulation schematic 
           301 —battery meter 
           301 A—prescaler 
           302 —keyed switch 
           305 —charger 
           306 —processor, Parker Hannifin, IQAN MD3-C1 
           306 A—IQAN module 
           306 B—IQAN Expansion Module 
           307 —voltage transducer 
           307 A—temperature transducer 
           308 —180 volt battery 
           309 —isolating converter for battery monitor 
           310 ,  310 A—level wind actuator motors 
           311 —torque rocker switch inputting to IQAN MD3-C2 
           311 A—joystick 
           312 —negative (−) 24 volts dc 
           313 —positive (+) 24 volt dc supply to voltage transducer 
           314 —thermocouple attached to first negative battery terminal 
           315 —thermocouple attached to second negative battery terminal 
           315 A—thermocouple 
           316 —resistor bank 
           317 —180 volt dc−12 volt dc+converter 
           318 —output terminal of temperature transducer 
           318 A—output (volts dc) to processor representing battery temperature 
           319 —12 volt battery 
           320 —battery interconnection with motor circuit, resistor bank and meter 
           321 —voltage converter 12/24 volt dc 
           323 —positive (+) 180 volt dc supply 
           323 A—negative (−) 180 volt dc supply 
           324 —positive (+) 24 volts dc 
           325 —socket relay 
           326 —output (volts dc) to processor representing voltage temperature 
           329 —negative (−) 24 volt dc supply to voltage transducer 
           330 —battery temperature input terminal 
           331 —lower torque pushbutton terminal 
           332 —raise torque pushbutton terminal 
           333 —ground 
           334 —common 
           335 —source voltage joystick (positive 12 volt dc) 
           336 —USB 
           337 —USB 
           338 —180 volt dc bus voltage measurement/input 
           338 A—voltage transducer 
           339 ,  339 A—communication between IQAN MD3-C1 and IQAN MD3-C2 
           340 —positive (+) 12 volt dc 
           341 —address tag 
           342 —address tag 
           343 —RS 232 communication terminal 
           344 —RS 232 communication terminal 
           345 —negative (−) 12 volt dc supply 
           346 —digital output enabling CR 5   
           347 —digital output enabling brake 
           348 —digital output enabling 180 volt dc power to motor/DMOC 
           349 —Switch, i.e., Relay, IGBT (Insulated Gate Bipolar Transistor), or other solid state device 
           349 C—pulse width modulation signal 
           349 D—resistor power dissipation in % and Watts 
           349 E—measured battery voltage, volt dc 
           349 G—198 volts dc 
           350 —negative (−) input terminal 
           351 —shunt 
           352 —positive (+) 12 volt dc voltage input to IQAN MD3-C1 processor 
           353 —socket relay terminal on IQAN MD3-C1 
           354 —negative (−) 12 volt dc voltage input to IQAN MD3-C1 
           355 —communication terminal to DMOC motor controller 
           356 —communication terminal to DMOC motor controller 
           357 —communication terminal to IQAN XA2 
           358 —communication terminal to IQAN XA2 
           359 —communication terminal to IQAN MDC3-C1 
           360 —communication terminal to IQAN MDC3-C1 
           361 —negative (−) 12 volt dc terminal to battery meter and prescaler 
           362 —shunt terminal connection 
           363 —shunt terminal connection 
           364 —prescaler connection 
           365 —positive (+) 12 volt dc terminal to battery meter and prescaler 
           366 —CAN communication 
           367 —CAN communication 
           368 —ground 
           369 —positive (+) 12 volt dc terminal 
           370 ,  371 —voltage transducer power supply 
           374 ,  375 —12 volt dc output of converter 
           378 ,  379 —CAN communication 
           382 ,  383 —12 volt dc supply to battery monitor 
           391 —battery 
           391 A—ultra-capacitor 
           400 —control panel 
           402 —key/switch 
           403 —level wind control 
           404 —brake pressure indicator 
           405 —brake control 
           406 —master control interface 
           407 A—torque control decrease 
           407 B—torque control increase 
           420 —directional indication 
           430 —puller mode push button, F 1   
           431 —tension mode push button, F 2   
           432 —diagnostic push button, F 3   
           500 —180 volt dc control schematic flow chart 
           500 A—motor control schematic flow chart 
           500 B—tension mode schematic flow chart 
           501 —master start 
           502 —joystick lever centered? 
           503 —holding brake off? 
           504 —enable 180 volt dc circuit, energize CR 6 , CR 2  and CR 3   
           505 —motor control 
           506 —puller/tensioner automatically shutdown 
           507 —input speed=0 if machine was automatically shutdown 
           508 —input speed and direction (pay-out or pull-in) joystick controlled 
           509 —upper torque set by depressing right button (increase) or left button (decrease) 
           510 —tension mode? 
           511 —torque reset button pressed? 
           512 —display confirmation message of torque reset? 
           513 —user confirmation of torque reset? 
           514 —reset upper torque to zero 
           515 —lower torque equals zero 
           516 —lower torque equals upper torque in tension mode 
           517 —conversion of speed and upper and lower torque to motor controller 
           518 —transmit converted values to DMOC motor controller using CAN Bus 
           519 —mathematically process input and upper torque values for display 
           520 —display input speed and torque values 
           521 —receive actual speed and torque values from DMOC motor controller using CAN Bus 
           522 —mathematically process actual speed and torque values for display 
           523 —display actual speed and torque values 
           524 —tension mode 
           525 —tension function key F 2  pressed? 
           526 —joystick lever pulled back? 
           527 —enter tension mode, display green lamp 
           528 —receive battery voltage from DMOC motor controller via CAN Bus 
           529 —mathematically process battery voltage for display 
           530 —display batter voltage 
           531 —calculate resistor bank PWM duty cycle 
           532 —enable resistor bank, energize CR 5   
           533 —display PWM duty cycle as a % 
           534 —measure batter temperature 
           535 —mathematically process battery temperature for display 
           536 —display battery temperature 
           537 —is battery temperature greater than 120 degrees Fahrenheit? 
           538 —apply holding brake 
           539 —shut machine down 
       
    
     Those skilled in the art will recognize that the invention has been set forth by way of examples. As such, changes may be made to the invention has described and disclosed herein without departing from the spirit and the scope of the invention as claimed hereinbelow.

Technology Classification (CPC): 7