Patent ID: 12199415

DETAILED DESCRIPTION

Examples of the present disclosure can include a line pulling assembly with an engagement assembly capable of improving the reliability of the engagement between a line pulling drum and a motor with minimal effort from an operator and a level wind head capable of improving reliability in pulling two or more lines by utilizing well placed side rollers, sheaves, and actuated via a hydraulic arm to ensure alignment with respect to line previously wound on a drum.

For ease of explanation, the system is discussed below with reference to stringing and supporting power and communications lines. One of skill in the art will recognize, however, that the system is not so limited. Indeed, the system could be used in any number of industries where ropes, support cables (e.g., for ski lifts), communications cables, wires, and other similar products need to be efficiently installed and supported. Thus, the description below is intended to be illustrative and not limiting.

It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named. In other words, the terms “a,” “an,” and “the” do not denote a limitation of quantity, but rather denote the presence of “at least one” of the referenced item.

As used herein, the term “and/or” may mean “and,” it may mean “or,” it may mean “exclusive-or,” it may mean “one,” it may mean “some, but not all,” it may mean “neither,” and/or it may mean “both.” The term “or” is intended to mean an inclusive “or.”

Also, in describing the exemplary embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. It is to be understood that examples of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description.

Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, other exemplary embodiments include from the one particular value and/or to the other particular value. Further, the term “about” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within an acceptable standard deviation, per the practice in the art. Alternatively, “about” can mean a range of up to ±20%, preferably up to ±10%, more preferably up to ±5%, and more preferably still up to ±1% of a given value. Alternatively, the term can mean within an order of magnitude, preferably within 2-fold, of a value. Where particular values are described in the application and claims, unless otherwise stated, the term “about” is implicit and in this context means within an acceptable error range for the particular value.

Throughout this disclosure, various aspects of the disclosure can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, and 6. This applies regardless of the breadth of the range.

By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.

Throughout this description, various components may be identified having specific values or parameters, however, these items are provided as exemplary embodiments. Indeed, the exemplary embodiments do not limit the various aspects and concepts of the present disclosure as many comparable parameters, sizes, ranges, and/or values may be implemented. The terms “first,” “second,” and the like, “primary,” “secondary,” and the like, do not denote an order, quantity, or importance, but rather are used to distinguish one element from another.

It is noted that terms like “specifically,” “preferably,” “typically,” “generally,” and “often” are not utilized herein to limit the scope of the claimed disclosure or to imply that certain features are critical, essential, or even important to the structure or function of the claimed disclosure. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure. It is also noted that terms like “substantially” and “about” are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation.

It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional components than those expressly identified.

The materials and/or components described hereinafter as making up the various elements of the present disclosure are intended to be illustrative and not restrictive. Many suitable materials and/or components that would perform the same or a similar function as the materials and/or components described herein are intended to be embraced within the scope of the disclosure. Such other materials and/or components not described herein can include, but are not limited to, materials and/or components that are developed after the time of the development of the disclosure, for example. Any dimensions listed in the various drawings are for illustrative purposes only and are not intended to be limiting. Other dimensions and proportions are contemplated and intended to be included within the scope of the disclosure.

Turning now to the drawings in which like references represent like elements,FIG.1A-Cillustrate an improved line pulling system100that can comprise one or more line pulling drums110(e.g., two or four line pulling drums110), a hydraulic system120, and an operator station130. The line pulling system100can further comprise a chassis140to support some or all of the components discussed herein, and the line pulling system100can also have a motor150to power some, or all, of the components discussed herein. In some examples, the motor150can be configured to cause the line pulling drum110to be rotated in a first direction to receive the line and in a second direction to facilitate removal of the line from the one or more line pulling drums110.

As shown, each line pulling drum110can be mounted on a first end160of the chassis140and be configured to receive the line. The line pulling drum110can have a driven element (not shown) to transfer power and/or torque from the motor150to the line pulling drum110. In some examples, the driven element can be mounted in a central position on the line pulling drum. The motor150can have complementary one or more driving elements (not shown), shaped to interface with one or more driven elements, and one or more coupling rings187(shown and discussed in more detail below, with reference toFIGS.2D,2F,2H,2I) to connect the one or more driving elements to the one or more driven elements. The one or more coupling rings187can be fitted around the one or more driving elements. In some examples, the one or more coupling rings187can have a first uncoupled state in which the one or more coupling rings187are not in contact with the one or more line pulling drums110and a second coupled state in which the one or more coupling rings187is in contact with the one or more driven elements, coupling the motor150to the one or more line pulling drums110.

As shown, the operator station130of the line pulling system100may include a control console400(described in more detail below with reference toFIG.4) located at the second end170of the line pulling system100and fastened to a platform142of the chassis140. The control console400may include one or more joysticks152for controlling the motor's150engagement of each line pulling drum110.

Also as shown, the line pulling system100may also include one or more level wind heads148connected to the chassis140and respective hydraulic arms149. As will be described more fully with respect toFIGS.3A,3B, and3C, each level wind head148is configured to guide two or more lines to wind or unwind from two or more line pulling drums110.

As shown inFIGS.2A-2Kline pulling system100may also include one or more engagement assemblies180located near the first end160of the chassis140. The engagement assemblies may include a portion of the engagement cable154running from an engagement lever152in the control panel400. The one or more engagement assemblies180may include a support member182that may be approximately U-shaped and connected to the engagement cable via an engagement cable assembly184. The support member182may include a first hinge mating piece183at approximately the center of an internal bottom portion of the support member182. The first hinge mating piece183may be configured to receive and rotationally mate with a corresponding mating piece of a hinged linkage186at a joint181. The hinged linkage186may be L-shaped and connected with the first hinge mating piece183at an exterior corner of the L at a first end of the hinged linkage186. As shown inFIGS.2H and2I, the hinged linkage186may be connected to the engagement cable154at a second end (e.g., the top of the L) opposite the first end. The hinged linkage186may also be rotatably connected with a first end of an engagement arm190at the second end of the hinged linkage186at a joint185. The engagement arm190may be rotatably connected to a coupling ring187via an alignment arm189extending from the coupling ring187to align approximately vertically over an approximate center of the first hinge mating piece183but off center the joined ends of the hinged linkage186and the engagement arm190.

As shown inFIGS.2H and2I, depending on the position of a corresponding engagement lever152(see e.g.,FIG.2A), the engagement cable154may be pushed or pulled in the movement of a corresponding engagement lever152. For example, as shown inFIG.2H, an operator may move an engagement lever152to the up position which may push a corresponding engagement cable154causing the connected hinged linkage186and the engagement arm190to move into the disengaged position thereby causing the coupling ring187, connected to the engagement arm190, to disengage from the corresponding core of a drum110. When the system is in the disengaged position, the hydraulic system is unable to transfer power to rotate the drum110. Put another way, the first end of the engagement arm190and the first end of the hinged linkage186may be positioned off center the coupling ring187proximate a first end of the line pulling system160when in the disengaged position. For example, as shown inFIG.2I, an operator may move an engagement lever152to the down position which may pull a corresponding engagement cable154thereby causing the connected hinged linkage186and engagement arm190to move into the engaged position thereby causing the coupling ring187, connected to the engagement arm190, to engage from the corresponding core of a drum110. Put another way, the first end of the engagement arm190and the second end of the hinged linkage186may be off centered with the coupling ring187proximate the second end170when in the engaged position. When the system is in the engaged position, the hydraulic system is able to transfer power to rotate the drum110

As shown inFIGS.2E,2F,2H,2I, and2K, the one or more engagement assemblies180may include one or more support arms188rotatably coupled to sides of the support member182and a coupling ring187.FIG.2Kshows the coupling ring187may include a plurality of protrusions192configured to engage with corresponding receptacles (not shown) of the core of the drum110. The protrusions192may be positioned radially about the coupling ring187. The protrusions192can have a variety of shapes so long as the protrusions comprise a portion of material raised and extended outward from the coupling ring187. For example, the protrusions192can be any shape such as involute splines, a polygon of any number of sides, or smooth shapes such as an oval. The size of the protrusions192can depend on the torque requirements and the spatial constraints of the containing assembly. In general, a smaller size can be better for manufacturing cost, while a larger size is better for torque transfer. Alternatively, the one or more coupling rings187may include receptacles instead of protrusions which correspond with protrusions (not shown) on the core of the drums110.

The core of the drum110can comprise receptacles that correspond to the protrusions192. In such a manner, the coupling ring187can slide within the core of the drum110. The receptacles can interact with the protrusions192and the protrusions192simultaneously so that the coupling ring187and the core of the drum110are attached. Therefore, when the line pulling drum110is under tension, the tensioning force can be transferred through the coupling ring187such that the coupling ring187and the core of the drum110are locked together or otherwise in mechanical communication with each other.

The receptacles can be any shape that allows the line pulling drum110(and therefore the coupling ring187) to be in an orientation that is rotated some amount in the direction of torque while engaged and requires that the line pulling drum110be rotated some amount in the opposite direction of torque to disengage. The receptacles, for example, can include a cutaway portion that can be recessed and configured to contact the coupling ring187when the coupling ring187is engaged with the core of the drum110. The cutaway portion can have a ridge that can contact the coupling ring187and prevent the coupling ring187from moving to an uncoupled position when force is applied via the coupling ring187or when under tension and applying force. In such a manner, the receptacles can create a locking effect. As will be appreciated, the ratio between the rotational displacement and linear displacement to disengage can affect the force required to disengage while the line pulling drum110is subjected to a given torque.

Referring back toFIG.1A-1C, the hydraulic system120can also be mounted on the chassis140. The hydraulic system120can include various lines and hoses to transfer hydraulic fluid throughout the line pulling system100. The hydraulic system120can also include other components designed to control hydraulic fluid, such as pistons, valves, metering devices, and the like. In some examples, the hydraulic system120can include a manifold (not shown). The manifold can be configured to fluidly communicate with two or more hydraulic lines (not shown) from the hydraulic system and to conduct heat between the two or more hydraulic lines as a heat exchanger. As will be appreciated, however, the manifold is not limited simply to two hydraulic lines.

The operator station130can be mounted on the chassis140. The operator station130can have a front safety screen134between the operator station130and the one or more line pulling drums110. To further improve the safety of the operator station130, the operator station can be mounted on the chassis140on a second end170opposite the first end160where the one or more line pulling drums110are mounted. The operator station130can further comprise a control panel400(shown and described in greater detail with respect toFIG.4) configured to communicate with the motor150and/or other components of the line pulling system100.

As shown inFIGS.1A-1C, the front safety screen134can be curved to increase the protective surface area and to increase the deflection of forces or objects that happen to strike the front safety screen134. Additionally, the curvature of the front safety screen134can be concentric or nearly concentric with the operator's point of view so that the line of sight of the operator can always be perpendicular (or close to perpendicular) to the safety screen. In such a manner, the operator can have a minimally obstructed view through the safety screen. The front safety screen134can further comprise a mesh (shown), window, grating, holes, or other suitable design such that the one or more line pulling drums110(or other components attached to the chassis140) are visible through the front safety screen134. The visual designs (or apertures of the mesh, or grating, etc.) can be sufficiently small in size such that a loose line (or other projectile) is prevented from crossing into the operator station130through the front safety screen134, while an operator is still able to see out of the front safety screen134. For instance, if a metal grating is used, the spaces between the grating can be small enough to prevent a loose line or other debris from entering the operator station130while still remaining large enough to ensure the other components attached to the chassis140are visible. Alternatively, the front safety screen134can comprise a transparent material, rather than holes or other openings. For example, the front safety screen134can comprise a transparent window made from an acrylic or another transparent plastic material.

The front safety screen134may additionally have sufficient strength such that the front safety screen is able to withstand forces induced from striking (i.e., from a snapped and/or loose line, with a baseball bat, or crowbar), prying, tearing, cutting (i.e., with a saw), and/or wearing (i.e., with a Dremel or sander). In some examples, the front safety screen134can have sufficient strength to withstand forces from flying objects such as rope, conductor, swivels, and grips caused by a line breaking or some portion of a supporting structure breaking.

The front safety screen134can also have cutouts or apertures of a specific shape when the front safety screen134employs a mesh (as shown). For example, the front safety screen134can comprise hexagonal cutouts or apertures. The hexagonal cutouts can break up horizontal and vertical lines so that an operator can better distinguish objects outside the safety screen134. It is understood that other shapes and patterns of cutouts can be used to create the front safety screen134and distinguish the lines of the front safety screen134from other lines outside of the front safety screen134.

Referring toFIGS.1C and3A-3C, the line pulling system100may include one or more level wind heads148configured to guide two or more lines302on or off drums110. The one or more level wind heads148can also be attached to the hydraulic system120and/or in communication with the control panel400. The one or more level wind heads148can be configured to move laterally with respect to the line pulling drum110by one or more level wind hydraulic arms149to ensure that any lines being pulled will be evenly distributed around the line pulling drum110. The one or more level wind heads148can have two or more windows through which two lines302can pass on its way to the line pulling drum110. The windows can ensure that the line is retained by the one or more level wind heads148, and the window can have rollers or other friction-reducing devices to ensure that the line can pass smoothly through the window. In some examples, the one or more level wind heads148can also be powered by the hydraulic system120and moved via hydraulic arm149.

The one or more level wind heads148may define the two or more window with three or more spaced apart rotating sheaves308. For example, the space between the bottom and middle sheaves308may define a first window for a first line302to guide to a first drum110and the space between the middle and top sheaves308may define a second window for a second line302to a second drum110located behind the first drum110. The one or more level wind heads148may also include one or more sets of side rollers306configured to prevent lines302from moving outside of the windows in the approximately horizontal direction. The one or more side rollers306may be approximately parallel with a shaft304of the level wind head148and may be attached to a top brace312and a bottom brace310. Four side rollers306may be used to prevent lines302from moving off of the sheaves308. Each sheave308may include a curved surface around a circumference of the sheave308configures to partially surround a portion of a corresponding line302.

As is apparent, using level wind head148, operators may choose to pull more than line at a time, dramatically reducing time in operation on the job. The level wind head148is hydraulically synchronized with the drum110while the operator may be safely positioned behind safety screen134. The level wind head148allows operators to be able to properly lay rope in a uniform manner back onto the drum110eliminating the possibility during the pulling operation for the ropes to become crossed. Using the control panel400, the operator can activate one of three modes; curb or street side level wind arms or synchronize both. When two level wind heads148are synchronized, they move at the same rate from an inner position to an outer position or an outer position to an inner position. Internal valves of the hydraulic system120maintain synchronous motion between for the two level wind heads148.

As shown inFIG.4, the control panel400can have one or more controls410connected to one or more components of the line pulling system100. The one or more controls410can also be in electrical communication with one another and/or the other components of the line pulling system100. For example, the one or more controls410can include an on/off switch for the hydraulic system120. In some examples, the one or more controls410can also be mechanically coupled to each other and/or the components of the line pulling system100. As shown inFIG.4, the one or more controls810can include one or more joysticks420for controlling the line pulling drum110and/or level wind head148(described below). The joysticks420can be mechanically coupled (e.g., via cables, lines, pulleys, and the like) to the hydraulic system120, one or more line pulling drums110, and the like. In order to increase user comfort, the control panel132can include one or more hand rests430disposed proximal to any of the one or more controls410, as shown inFIG.4.

As shown inFIG.4, the hand rest430can be configured in a curved shape to partially or substantially surround any of the one or more controls410, such as joystick420. The hand rest430can have one or more attachment points to fasten the hand rest430to the control panel400. The attachment points can ensure that the hand rest430remains in place even after enduring a long life of use and wear-and-tear.

The hand rest430can also allow an operator to use the joystick420(or any other controls from the one or more controls410) for longer periods of time and with greater precision. Having the hand rest430for control can enable an operator to stabilize their arm and utilize their grip, rather than arm and shoulder muscles, to actuate the controls. The hand rest430can also allow an operator to make more accurate movements.

Referring again toFIG.1A-1C, the chassis140can be any form of frame, subframe, trailer, platform, and the like capable of supporting one or more components of the line pulling system100. The chassis140can have a platform142to allow an operator to walk or move between the various components of the line pulling system100. The chassis140can also be mounted on top of wheels144to allow the line pulling system100to be moveable. Any number of wheels can be used, such as two (e.g., if the chassis is a trailer), three, four, or more. In some examples, if the chassis140has only two wheels144(or multiple wheels on a single axle) or less and requires additional support, the chassis140can include a hitch146to attach the chassis140to a truck, car, trailer mount, jack stand, or other device that can provide stabilization to the chassis140.

The motor150can be any suitable motor to power one or more components of the line pulling system100(such as the one or more line pulling drums110), and the motor150can be powered by the hydraulic system120. The motor150can be any motor suitable to transfer power from the hydraulic system120to the line pulling drum110. The hydraulic system120can be powered by an engine, such as a diesel motor. Other types of engines can be used, such as gasoline, electric, hybrid, and the like. The engine can include various lines and connections to allow the engine to power the various components of the line pulling system100, including the hydraulic system120. The engine can also be connected to a fuel tank, or other energy storage device (e.g., a battery), to provide power to the engine.

The motor150can be mounted on the chassis140proximal to the line pulling drum110and/or the hydraulic system120, such as on the platform142. The engine, powering the hydraulic system120, can be external to the chassis140, such as a portable generator. In some examples, if the engine is external to the chassis140, the chassis140can have mounting points to store the engine when not in use.

While several possible examples are disclosed above, examples of the present disclosure are not so limited. For instance, while the system is discussed above with reference to suspending power or communications lines, the system could also be used in many other industries such as transportation (e.g., towing, cables cars, street cars, and trains); rope for climbing, rigging, and boundaries; and virtually any other types of lines that need to be strung and/or suspended. In addition, while various features are disclosed, other designs could be used. Such changes are intended to be embraced within the scope of this disclosure. The presently disclosed examples, therefore, are considered in all respects to be illustrative and not restrictive.