SYSTEMS AND METHODS FOR A SMART CABLE TENSIONING UNIT

Abstract

In some embodiments, the disclosure is directed to a cable tensioning unit. In some embodiments, the cable tensioning unit includes a hydraulic jack mounting on a unit housing. In some embodiments, the unit housing includes a control panel with one or more actuators configured to control one or more pulling functions. In some embodiments, the cable tensioning unit includes a controller and a controller interface that enables a user to set interlocks and/or enter pull information. In some embodiments, pull information includes one or more of bed number, bed length, strand size, strand number, target initial tension, target final tension, target final elongation, date, time, actual initial tension, and/or actual final tension. In some embodiments, the controller is configured to automatically save data during one or more transient operations. In some embodiments, the controller is configured to display if pull information is within a tolerance during a pull operation.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority and benefit of U.S. Provisional Application No. 63/417,702, filed Oct. 20, 2022, the contents of which are incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure is generally related to the field of prestressed concrete construction. Specifically, the system relates to a tensioning unit that simplifies and enhances the cable tensioning process for prestressed concrete applications according to some embodiments.

BACKGROUND

Prestressed concrete is a widely used construction method that relies on the application of tension to steel cables within concrete elements to enhance structural strength and durability. Achieving the desired level of cable tension is critical to the success and longevity of such structures. Existing tensioning methods often involve complex setups and labor-intensive processes, and current machines are difficult to position and transport. In addition, there is not currently an effective way to ensure consistent quality control.

SUMMARY

In some embodiments, the disclosure is directed to a tensioning unit comprising one or more of a unit housing, a jack, and a controller. In some embodiments, the tensioning unit includes a cable tensioning unit. The terms “cable” and “strand” are used interchangeably herein, and both terms are not limited to any particular structure, as the systems and methods described herein can be applied to various materials. In some embodiments, the jack includes one or more of a hydraulic jack, a linear actuator, a mechanical screw, and the like. A reference to hydraulic jack is interchangeable with any other type of jack when describing the metes and bounds of the system. In some embodiments, the hydraulic jack is removably coupled to a top portion of the unit housing. In some embodiments, the controller is configured to control, monitor, and/or record pull information.

In some embodiments, the hydraulic jack includes one or more position sensors configured to transmit piston position to the controller. In some embodiments, the hydraulic jack comprises a jack frame, a yoke, and a hydraulic cylinder comprising a piston rod and a cylinder tube. The term “yoke” and “bracket” are interchangeable when describing the metes and bounds of the system. In some embodiments, the hydraulic cylinder is configured to move the yoke along the jack frame via the piston rod. In some embodiments, the hydraulic jack further comprises a cable chuck. The term “chuck” and “clamp” are interchangeable when describing the metes and bounds of the system. In some embodiments, the cable chuck is configured to enable a cable to slide along an interior portion thereof. In some embodiments, the cable chuck includes a clamp release configured to be pushed to release a gripping force on the cable. In some embodiments, the yoke is configured to abut against a front portion the cable chuck. In some embodiments, the piston rod is configured to pull the yoke toward the cylinder tube which in turn pulls against the cable chuck applying tension to the cable.

In some embodiments, the controller further comprises a control panel. In some embodiments, the control panel includes one or more of a hydraulic actuator, a start button, a stop button, an initial tension actuator, a final tension actuator, an emergency stop, an auxiliary actuator, and a controller interface. In some embodiments, the auxiliary actuator includes one or more of a flood light control and a low oil level indication. In some embodiments, the controller further comprises a controller interface mounted to the unit housing. In some embodiments, the controller interface is configured to display real-time diagnostics. In some embodiments, the real-time diagnostics include one or more of cylinder position, fluid temperature, and hydraulic pressure.

In some embodiments, the controller is configured to monitor a cylinder position and/or a fluid pressure in real-time and display the cylinder position and/or the fluid pressure on the controller interface. In some embodiments, the controller interface is configured to enable a user to input pull information. In some embodiments, the pull information includes one or more of bed number, bed length, strand size, strand number, target initial tension, target final tension, target final elongation, date, time, actual initial tension, and/or actual final tension.

In some embodiments, the controller is configured to use a combination of the one or more position sensors and one or more fluid pressure sensors to generate at least a portion of the pull information for each strand pull. In some embodiments, the controller is configured to automatically load at least a portion of the pull information for a second strand after a first strand pull is complete. In some embodiments, the system is configured to automatically load information for the next strand after the current pull is complete. In some embodiments, the system is configured to repeat the automatic loading for each strand in a series of strands. In some embodiments, the controller is configured to automatically save data during one or more transient operations. In some embodiments, the controller is configured to display if pull information is within a tolerance during a pull operation. In some embodiments, the controller is configured to generated calibration reports. In some embodiments, the controller is configured to record, display, and/or update elongation corrections.

DRAWINGS DESCRIPTION

FIG. 1 shows a cable tensioning unit according to some embodiments.

FIG. 2 shows a first side interior view of the unit housing according to some embodiments.

FIG. 3 shows a second side interior view of the unit housing according to some embodiments.

FIG. 4 depicts elements of the hydraulic jack according to some embodiments.

FIG. 5 depicts one or more flood lights and one or more warning lights configured to adjustably attach to the unit according to some embodiments.

FIG. 6 illustrates a tensioner unit control panel according to some embodiments.

FIG. 7 shows data ports in the form of USB ports according to some embodiments.

FIG. 8 depicts a controller interface (HMI) according to some embodiments.

FIG. 9 shows a non-limiting example report output according to some embodiments.

FIG. 10 illustrates a computer system enabling or comprising the controller programs in accordance with some embodiments.

FIG. 11 shows an assembled hydraulic jack according to some embodiments.

FIG. 12 depicts hydraulic hose connections located on a rear of the hydraulic jack according to some embodiments.

FIG. 13 shows another view of the hydraulic hose connections of FIG. 12 according to some embodiments.

FIG. 14 illustrates a novel cone nose according to some embodiments.

FIG. 15 shows a close-up view of the strand guide according to some embodiments.

FIG. 16 illustrates an extend and retract button according to some embodiments.

DETAILED DESCRIPTION

In some embodiments, the system is directed to a novel solution that expedites a cable tensioning process. FIG. 1 shows a cable tensioning unit 100 according to some embodiments. In some embodiments, the tensioning unit comprises a hydraulic jack 101 and a unit housing 102.

FIG. 2 shows a first side interior view of the unit housing 102 according to some embodiments. In some embodiments, within the unit housing 102 resides one or more of a retractable power line reel 201, a hydraulic pump with electric motor 202, a hydraulic tank 203, and a cooling fan 204. Underneath the unit housing 102 one or more tires 205 (e.g., foam filled tires) are connected to the unit frame 206 in some embodiments, enabling the cable tensioning unit 100 to be easily transported. In some embodiments, a forward portion of the unit frame 206 extends away from the unit housing 102 adding stability to the cable tensioning unit 100. In some embodiments, a storage box 207 is situated on the forward portion of the unit frame, where various tools and supporting equipment can be stored. In some embodiments, the hydraulic jack 101 is removably coupled to the top of the unit housing 102.

FIG. 3 shows a second side interior view of the unit housing 102 according to some embodiments. In some embodiments, the unit housing 102 further includes a hydraulic line reel 301 for retracting one or more hydraulic lines. In some embodiments, the unit housing 102 encloses one or more hydraulic line couplings 302 configured to connect various hydraulic system components. In some embodiments, the unit housing 102 includes a controller 303, which may include various computer and/or network components described herein, as well as one or more power buses and electrical connections configured to deliver power to various components such as the electric motor 202, and fan 204.

FIG. 4 depicts elements of the hydraulic jack 101 according to some embodiments. In some embodiments, the hydraulic jack 101 comprises a jack frame 402 within which a piston rod 403 is connected to a cable chuck yoke 404. In some embodiments, the yoke 404 comprises a removable cable chuck 405 that can slide over the cable 406 to a desired position. In some embodiments, the yoke 404 includes a clamp release 407 configured to be pushed in to release a gripping force on the cable 406. In some embodiments, the piston rod 403 is configured to pull the yoke 404 toward a cylinder tube, which in turn pulls against the cable chuck 405 attached to the cable 406 applying tension to the cable. In some embodiments, external clamp chucking with 404, 405/407 allows for easier maintenance. In some embodiments, the same cable chucks 405/407 as used in precast production, allowing for ready access to parts. In some embodiments, the frame includes a cone shaped nose and/or one or more hoisting hooks to improvement placement between strands as well as improve handling as further described below.

In some embodiments, the tensioner unit includes horn and/or beacon lighting 500 for ‘in use’ operation. FIG. 5 depicts one or more flood lights 501 and one or more warning lights 502 configured to adjustably attach to the unit housing 102 according to some embodiments. In some embodiments, the tensioner unit 100 includes one or more electrical connections and one or more hydraulic connections configured to interface with a variety of tensioner components.

FIG. 6 illustrates a tensioner unit control panel 600 according to some embodiments. In some embodiments, the control panel 600 includes one or more of a hydraulic actuator 601, start button 602, stop button 603, initial tension actuator 604, final tension actuator 605, emergency stop 606, auxiliary actuator 607, and controller interface 608. In some embodiments, the auxiliary actuator 607 includes auxiliary lighting control. In some embodiments, the controller 303 is configured to monitor and/or record pull data for tracking and archiving purposes. In some embodiments, the data can be transferred through the wireless connection or through one or more data ports. FIG. 7 shows data ports in the form of USB ports according to some embodiments. In some embodiments, the control panel 600 includes an upload USB port 701 and/or a download USB port 702.

In some embodiments, manipulating the actuators is configured to update a position on the screen in real time. In some embodiments, manipulation of one or more actuators is configured to cause the controller 303 to execute one or more new strand elongation calculations based on the new actuator setting. In some embodiments, manipulation of one or more actuators is configured to cause the controller 303 to execute an adjustment of the hydraulic pressure and/or cable tension information simultaneously and/or in near real time. In some embodiments, manipulation of one or more actuators is configured to cause the controller 303 to execute one or more new force calculations. In some embodiments, manipulation of one or more actuators is configured to change the sequence of operations that assist with the auto-incrementation of the strand number to facilitate autonomous process flow of stressing. In some embodiments, manipulating the actuators can also affect the informational pop ups that can be seen when a strand is tensioned beyond the programmed targets.

FIG. 8 depicts a controller interface 608 (HMI) according to some embodiments. In some embodiments, the controller interface 608 includes an ergonomic and weatherproof control station equipped with rugged high-resolution screen (e.g., 7″). In some embodiments, the controller interface 608 is configured to display real-time diagnostics including one or more of cylinder position, fluid temperature, and hydraulic pressure. In some embodiments, the controller 303 comprises one or more wireless networks configured to enable a wireless connection to the controller interface 608 through a secure and reliable gateway. In some embodiments, the wireless connection is configured to enable remote operation of one or more of any electronically actuated components described herein.

In some embodiments, the controller 303 includes a programmable logic controller (PLC) to provide monitoring and control over the pulling operation. In some embodiments, the controller 303 is configured to execute one or more programmed intelligent features for ease of use and data retention. In some embodiments, the programs include instructions to monitor cylinder position and/or fluid pressure in real-time and display that information on the controller interface 608. In some embodiments, the controller 303 is also configured to save and/or export data for the customer's record. Example programmable instructions include elongation tolerances to accommodate different testing standards according to some embodiments.

In some embodiments, the hydraulic jack includes one or more position sensors (e.g., LVDT sensor) configured to transmit piston position to the controller 303. In some embodiments, the controller 303 is configured to store calibration data points for a plurality (e.g., at least 5) of different cylinder stroke sizes. In some embodiments, the tensioner unit is configured to support multiple strand sizes via a manually operated switch to activate different pop-off relief valves. In some embodiments, the controller 303 is configured to automatically control the fan to regulate hydraulic fluid temperature. In some embodiments, the controller interface 608 is configured to enable a user to set a hydraulic fluid temperature range.

In some embodiments, the controller 303 is configured to use a combination of the position sensor and the fluid pressure sensor to generate accurate pull information for each strand pull. In some embodiments, the controller 303 is configured to receive data from the position sensor and convert the data into strand elongation. In some embodiments, the controller 303 is configured to receive data from the fluid pressure sensor and convert the data into a pull force. In some embodiments, pull information, which includes “target” data, can be loaded wirelessly and/or via one or more data ports before the operation to avoid manual input. In some embodiments, the target data includes, but is not limited to, one or more of bed number, bed length, strand size, strand number, initial tension (target), final tension (target), final elongation (target). In some embodiments, the controller interface 608 is configured to display and/or enable settings for one or more pull information and/or target data fields. In some embodiments, the tensioner unit includes one or more environment sensors (e.g., temperature, humidity, etc.). In some embodiments, the interface is configured to enable a user to directly input environmental conditions into the controller 303 for analysis.

In some embodiments, actual pull information includes, but is not limited to, date, time, initial tension (actual), elongation (actual), and/or final tension (actual). In some embodiments, after each final pull, information for the next strand is automatically loaded by the controller 303. In some embodiments, the interface is configured to display live data (e.g., cylinder position and fluid pressure) even when the system is not under pressure.

In some embodiments, data is automatically saved during the strand pulling process in a plurality of instances. In some embodiments, the controller 303 is configured to automatically save data during one or more transient operations (e.g., switching from initial to final pressure settings to automatically save the initial pull data) to avoid operator error. In some embodiments, colored indicators on the HMI are configured to inform the operator of pull status (e.g., green when the strand has been pulled within the acceptable tolerance level, and red if the strand has been pulled outside the tolerance level).

In some embodiments, program instructions are configured to enable a user to input and/or track identification information (e.g., employee ID). In some embodiments, program instructions are configured to execute over-pressure warnings. In some embodiments, the interface is configured to display data log capacity and/or display a message when data log capacity falls below a pre-defined limit. In some embodiments, program instructions are configured to display elongation percentage and/or tension percentage on the interface, where the program instructions are configured to automatically shut down the unit if one or more values are exceeded.

FIG. 9 shows a non-limiting example report output 900 according to some embodiments. In some embodiments, various reports can be outputted from the controller 303, with further non-limiting examples including job number, strand manufacture, ultimate breaking strength of the strand and/or 80% of the ultimate breaking strength in addition to any pull information described herein. In some embodiments, the controller 303 is configured to generate a calibration report for one or more calibrations. In some embodiments, the report includes one or more types of jack, date of calibration, name of calibration, range of calibration, and a graph displaying readings vs. range. In some embodiments, the controller 303 is configured to record, display, and/or update elongation corrections. Elongation corrections include chuck seating which includes dead end, live end, splice, and thermal effects, as well as bed shorting and/or abutment rotation/movement according to some embodiments. In some embodiments, the system is configured to detect whether a pull is within 5% of error of pull and/or error of elongation (PCI specification).

In some embodiments, the controller 303 is configured to monitor one or more settings in the profile of the pull (i.e., actively pulling a strand) within a given tolerance. In some embodiments, the controller 303 is configured to display troubleshooting messages. As a non-limiting example, in some embodiments the controller 303 is configured to display a warning message indicating excess friction or wrong strand if the if the tensioning is moving slower or faster than preset tolerances. In some embodiments, the tensioner unit includes one or more locks and/or passwords to prevent unauthorized use.

In some embodiments, the tensioner unit 100 is configured to interface with any feedback enabled stressing equipment (e.g., hydraulic actuators or linear actuators) by updating the program instructions. In some embodiments, the tensioner unit is configured for pre-tensioning and/or post-tensioning of single strand items. In some embodiments, the tensioning unit is configured to connect to multiple strands, where the controller 303 is configured to provide feedback on structure movement and/or individual strand status. While described herein as being used with cables, the system is not limited to cables and can be configured to include pull information for any object.

FIG. 10 illustrates a computer system 1010 enabling or comprising the controller 303 in accordance with some embodiments. In some embodiments, the computer system 1010 is configured to operate and/or process computer-executable code of one or more software modules of the controller of the aforementioned system and method. Further, in some embodiments, the computer system 1010 is configured to operate and/or display information within one or more graphical user interfaces (e.g., HMIs) integrated with or coupled to the system.

In some embodiments, the computer system 1010 comprises one or more processors 1032. In some embodiments, at least one processor 1032 resides in, or is coupled to, one or more servers. In some embodiments, the computer system 1010 includes a network interface 1035a and an application interface 1035b coupled to the least one processor 1032 capable of processing at least one operating system 1034. Further, in some embodiments, the interfaces 1035a, 1035b coupled to at least one processor 1032 are configured to process one or more of the software modules (e.g., such as enterprise applications 1038). In some embodiments, the software application modules 1038 includes server-based software. In some embodiments, the software application modules 1038 are configured to host at least one user account and/or at least one client account, and/or are configured to operate to transfer data between one or more of these accounts using one or more processors 1032.

With the above embodiments in mind, it is understood that the system is configured to execute various computer-implemented program steps involving data stored on one or more non-transitory computer media according to some embodiments. In some embodiments, the above-described databases and models described throughout this disclosure are configured to store analytical models and other data on non-transitory computer-readable storage media within the computer system 1010 and on computer-readable storage media coupled to the computer system 1010 according to some embodiments. In addition, in some embodiments, the above-described applications of the system are stored on computer-readable storage media within the computer system 1010 and on computer-readable storage media coupled to the computer system 1010. In some embodiments, these operations are those requiring physical manipulation of structures including electrons, electrical charges, transistors, amplifiers, receivers, transmitters, and/or any conventional computer hardware in order to transform an electrical input into a different output. In some embodiments, these structures include one or more of electrical, electromagnetic, magnetic, optical, and/or magneto-optical signals capable of being stored, transferred, combined, compared and otherwise manipulated. In some embodiments, the computer system 1010 comprises at least one computer readable medium 1036 coupled to at least one of at least one data source 1037a, at least one data storage 1037b, and/or at least one input/output 1037c. In some embodiments, the computer system 1010 is embodied as computer readable code on a computer readable medium 1036. In some embodiments, the computer readable medium 1036 includes any data storage that stores data, which is configured to thereafter be read by a computer (such as computer 1040). In some embodiments, the non-transitory computer readable medium 1036 includes any physical or material medium that is used to tangibly store the desired information, steps, and/or instructions and which is configured to be accessed by a computer 1040 or processor 1032. In some embodiments, the non-transitory computer readable medium 1036 includes hard drives, network attached storage (NAS), read-only memory, random-access memory, FLASH-based memory, CD-ROMs, CD-Rs, CD-RWs, DVDs, magnetic tapes, and/or other optical and non-optical data storage. In some embodiments, various other forms of computer-readable media 1036 are configured to transmit or carry instructions to one or more remote computers 1040 and/or at least one user 1031, including a router, private or public network, or other transmission or channel, both wired and wireless. In some embodiments, the software application modules 1038 are configured to send and receive data from a database (e.g., from a computer readable medium 1036 including data sources 1037a and data storage 1037b that comprises a database), and data is configured to be received by the software application modules 1038 from at least one other source. In some embodiments, at least one of the software application modules 1038 are configured to be implemented by the computer system 1010 to output data to at least one user 1031 via at least one graphical user interface rendered on at least one digital display.

In some embodiments, the one or more non-transitory computer readable 1036 media are distributed over a conventional computer network via the network interface 1035a where some embodiments stored the non-transitory computer readable media are stored and executed in a distributed fashion. For example, in some embodiments, one or more components of the computer system 1010 are configured to send and/or receive data through a local area network (“LAN”) 1039a and/or an internet coupled network 1039b (e.g., such as a wireless internet). In some embodiments, the networks 1039a, 1039b include one or more wide area networks (“WAN”), direct connections (e.g., through a universal serial bus port), or other forms of computer-readable media 1036, and/or any combination thereof.

In some embodiments, components of the networks 1039a, 1039b include any number of personal computers 1040 which include for example desktop computers, laptop computers, and/or any fixed, generally non-mobile internet appliances coupled through the LAN 1039a. For example, some embodiments include one or more personal computers 1040, databases 1041, and/or servers 1042 coupled through the LAN 1039a that are configured for use by any type of user including an administrator. Some embodiments include one or more personal computers 1040 coupled through network 1039b. In some embodiments, one or more components of the computer system 1010 are configured to send or receive data through an internet network (e.g., such as network 1039b). For example, some embodiments include at least one user 1031a, 1031b, coupled wirelessly and accessing one or more software modules of the system including at least one enterprise application 1038 via an input and output (“I/O”) 1037c. In some embodiments, the computer system 1010 is configured to enable at least one user 1031a, 1031b, to be coupled to access enterprise applications 1038 via an I/O 1037c through LAN 1039a. In some embodiments, the user 1031 includes a user 1031a coupled to the computer system 1010 using a desktop computer, and/or laptop computers, or any fixed, generally non-mobile internet appliances coupled through the internet 1039b. In some embodiments, the user includes a mobile user 1031b coupled to the computer system 1010. In some embodiments, the user 1031b connects using any mobile computing 1031c to wireless coupled to the computer system 1010, including, but not limited to, one or more personal digital assistants, at least one cellular phone, at least one mobile phone, at least one smart phone, at least one pager, at least one digital tablet, and/or at least one fixed or mobile internet appliances.

FIG. 11 shows an assembled hydraulic jack 101 according to some embodiments. In some embodiments, the hydraulic jack 101 includes a cone shaped nose 1101 and/or one or more hoisting hooks 1102 to improvement placement between strands as well as to improve handling.

FIG. 12 depicts hydraulic hose connections 1201 located on a rear of the hydraulic jack 101 according to some embodiments. FIG. 13 shows another view of the hydraulic hose connections 1102 of FIG. 12 according to some embodiments.

FIG. 14 illustrates a novel cone nose 1301 according to some embodiments. The term “cone” and “tapered” may be interchanged when describing the metes and bounds of the system. In some embodiments, the cone nose 1301 includes a tapered end 1302. In some embodiments, the tapered end 1302 includes a removable strand guide 1303 configured to fit to various strand/cable sizes and/or configured to be a part to protect the jack frame 402 from damage. In some embodiments, the strand guide 1303 includes an elongated slot 1304 configured to enable a cable to fit therethrough. In some embodiments, the strand guide 1303 includes a tapered (e.g., cone) shape. FIG. 15 shows a close-up view of the strand guide 1303 according to some embodiments.

In some embodiments, the tensioner unit 100 includes remote extend and retract buttons 1601 located proximate one or more hydraulic cylinder on the hydraulic jack 101. FIG. 16 illustrates an extend and retract button 1601 configured to enable the hydraulic cylinder to be actuated by a user guiding the hydraulic jack against an abutment according to some embodiments.

The disclosure describes the specifics of how a machine including one or more computers comprising one or more processors and one or more non-transitory computer readable media implement the system and its improvements over the prior art. The instructions executed by the machine cannot be performed in the human mind or derived by a human using a pen and paper but require the machine to convert process input data to useful output data. Moreover, the claims presented herein do not attempt to tie-up a judicial exception with known conventional steps implemented by a general-purpose computer; nor do they attempt to tie-up a judicial exception by simply linking it to a technological field. Indeed, the systems and methods described herein were unknown and/or not present in the public domain at the time of filing, and they provide technologic improvements and advantages not known in the prior art. Furthermore, the system includes unconventional steps that confine the claims to a useful application.

It is understood that the system is not limited in its application to the details of construction and the arrangement of components set forth in the previous description or illustrated in the drawings. The system and methods disclosed herein fall within the scope of numerous embodiments. The previous discussion is presented to enable a person skilled in the art to make and use embodiments of the system. Any portion of the structures and/or principles included in some embodiments can be applied to any and/or all embodiments: it is understood that features from some embodiments presented herein are combinable with other features according to some other embodiments. Thus, some embodiments of the system are not intended to be limited to what is illustrated but are to be accorded the widest scope consistent with all principles and features disclosed herein.

Some embodiments of the system are presented with specific values and/or setpoints. These values and setpoints are not intended to be limiting and are merely examples of a higher configuration versus a lower configuration and are intended as an aid for those of ordinary skill to make and use the system.

Any text in the drawings is part of the system's disclosure and is understood to be readily incorporable into any description of the metes and bounds of the system. Any functional language in the drawings is a reference to the system being configured to perform the recited function, and structures shown or described in the drawings are to be considered as the system comprising the structures recited therein. Any figure depicting a content for display on a graphical user interface is a disclosure of the system configured to generate the graphical user interface and configured to display the contents of the graphical user interface. It is understood that defining the metes and bounds of the system using a description of images in the drawing does not need a corresponding text description in the written specification to fall with the scope of the disclosure.

Furthermore, acting as Applicant's own lexicographer, Applicant imparts the explicit meaning and/or disavow of claim scope to the following terms:

Applicant defines any use of “and/or” such as, for example, “A and/or B,” or “at least one of A and/or B” to mean element A alone, element B alone, or elements A and B together. In addition, a recitation of “at least one of A, B, and C,” a recitation of “at least one of A, B, or C,” or a recitation of “at least one of A, B, or C or any combination thereof” are each defined to mean element A alone, element B alone, element C alone, or any combination of elements A, B and C, such as AB, AC, BC, or ABC, for example.

“Substantially” and “approximately” when used in conjunction with a value encompass a difference of 5% or less of the same unit and/or scale of that being measured.

“Simultaneously” as used herein includes lag and/or latency times associated with a conventional and/or proprietary computer, such as processors and/or networks described herein attempting to process multiple types of data at the same time. “Simultaneously” also includes the time it takes for digital signals to transfer from one physical location to another, be it over a wireless and/or wired network, and/or within processor circuitry.

As used herein, “can” or “may” or derivations there of (e.g., the system display can show X) are used for descriptive purposes only and is understood to be synonymous and/or interchangeable with “configured to” (e.g., the computer is configured to execute instructions X) when defining the metes and bounds of the system. The phrase “configured to” also denotes the step of configuring a structure or computer to execute a function according to some embodiments.

In addition, the term “configured to” means that the limitations recited in the specification and/or the claims must be arranged in such a way to perform the recited function: “configured to” excludes structures in the art that are “capable of” being modified to perform the recited function but the disclosures associated with the art have no explicit teachings to do so. For example, a recitation of a “container configured to receive a fluid from structure X at an upper portion and deliver fluid from a lower portion to structure Y” is limited to systems where structure X, structure Y, and the container are all disclosed as arranged to perform the recited function. The recitation “configured to” excludes elements that may be “capable of” performing the recited function simply by virtue of their construction but associated disclosures (or lack thereof) provide no teachings to make such a modification to meet the functional limitations between all structures recited. Another example is “a computer system configured to or programmed to execute a series of instructions X, Y, and Z.” In this example, the instructions must be present on a non-transitory computer readable medium such that the computer system is “configured to” and/or “programmed to” execute the recited instructions: “configure to” and/or “programmed to” excludes art teaching computer systems with non-transitory computer readable media merely “capable of” having the recited instructions stored thereon but have no teachings of the instructions X, Y, and Z programmed and stored thereon. The recitation “configured to” can also be interpreted as synonymous with operatively connected when used in conjunction with physical structures.

It is understood that the phraseology and terminology used herein is for description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

The previous detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict some embodiments and are not intended to limit the scope of embodiments of the system.

Any of the operations described herein that form part of the system are useful machine operations. The system also relates to a device or an apparatus for performing these operations. All flowcharts presented herein represent computer implemented steps and/or are visual representations of algorithms implemented by the system. The apparatus can be specially constructed for the required purpose, such as a special purpose computer. When defined as a special purpose computer, the computer can also perform other processing, program execution or routines that are not part of the special purpose, while still being capable of operating for the special purpose. Alternatively, the operations can be processed by a general-purpose computer selectively activated or configured by one or more computer programs stored in the computer memory, cache, or obtained over a network. When data is obtained over a network the data can be processed by other computers on the network, e.g., a cloud of computing resources.

The embodiments of the system can also be defined as a machine that transforms data from one state to another state. The data can represent an article, which can be represented as an electronic signal and electronically manipulate data. The transformed data can, in some cases, be visually depicted on a display, representing the physical object that results from the transformation of data. The transformed data can be saved to storage generally, or in particular formats that enable the construction or depiction of a physical and tangible object. In some embodiments, the manipulation can be performed by a processor. In such an example, the processor thus transforms the data from one thing to another. Still further, some embodiments include methods can be processed by one or more machines or processors that can be connected over a network. Each machine can transform data from one state or thing to another, and can also process data, save data to storage, transmit data over a network, display the result, or communicate the result to another machine. Computer-readable storage media, as used herein, refers to physical or tangible storage (as opposed to signals) and includes without limitation volatile and non-volatile, removable and non-removable storage media implemented in any method or technology for the tangible storage of information such as computer-readable instructions, data structures, program modules or other data.

Although method operations are presented in a specific order according to some embodiments, the execution of those steps do not necessarily occur in the order listed unless explicitly specified. Also, other housekeeping operations can be performed in between operations, operations can be adjusted so that they occur at slightly different times, and/or operations can be distributed in a system which allows the occurrence of the processing operations at various intervals associated with the processing, as long as the processing of the overlay operations are performed in the desired way and result in the desired system output.

It will be appreciated by those skilled in the art that while the system has been described above in connection with particular embodiments and examples, the system is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the system are set forth in the following claims.

Claims

1. A cable tensioning unit comprising:

a unit housing,

a hydraulic jack, and

a controller;

where the hydraulic jack is removably coupled to a top portion of the unit housing; and

wherein the controller is configured to control, monitor, and/or record pull information.

2. The cable tensioning unit of claim 1,

wherein the hydraulic jack includes one or more position sensors configured to transmit piston position to the controller.

3. The cable tensioning unit of claim 1,

wherein the hydraulic jack comprises: a jack frame, a piston rod, a cylinder tube, and a yoke;

wherein the piston rod is configured to move the yoke along the jack frame.

4. The cable tensioning unit of claim 3,

further comprising a cable chuck;

wherein the cable chuck is configured to enable a cable to slide along an interior portion thereof; and

wherein the cable chuck includes a clamp release configured to be pushed to release a gripping force on the cable.

5. The cable tensioning unit of claim 4,

wherein the yoke is configured to abut against a front portion the cable chuck; and

wherein the piston rod is configured to pull the yoke toward the cylinder tube which pulls the cable chuck against the yoke applying tension to the cable.

6. The cable tensioning unit of claim 1,

wherein the controller further comprises a control panel.

7. The cable tensioning unit of claim 6,

wherein the control panel includes a hydraulic actuator, a start button, a stop button, an initial tension actuator, a final tension actuator, an emergency stop, an auxiliary actuator, and a controller interface.

8. The cable tensioning unit of claim 1,

wherein the controller further comprises a controller interface mounted to the unit housing; and

wherein the controller interface is configured to display real-time diagnostics.

9. The cable tensioning unit of claim 8,

wherein the real-time diagnostics include one or more of cylinder position, fluid temperature, and hydraulic pressure.

10. The cable tensioning unit of claim 8,

wherein the controller is configured to monitor a cylinder position and/or a fluid pressure in real-time and display the cylinder position and/or the fluid pressure on the controller interface.

11. The cable tensioning unit of claim 8,

wherein the controller interface is configured to enable a user to input pull information.

12. The cable tensioning unit of claim 11,

wherein the pull information includes one or more of bed number, bed length, strand size, strand number, target initial tension, target final tension, target final elongation, date, time, actual initial tension, and/or actual final tension.

13. The cable tensioning unit of claim 2,

wherein the controller is configured to use a combination of the one or more position sensors and one or more fluid pressure sensors to generate at least a portion of the pull information for each strand pull.

14. The cable tensioning unit of claim 13,

wherein the controller is configured to automatically load at least a portion of the pull information for a second strand after a first strand pull is complete.

15. The cable tensioning unit of claim 1,

wherein the controller is configured to automatically save data during one or more transient operations.

16. The cable tensioning unit of claim 1,

wherein the controller is configured to display if at least a portion of the pull information is within a tolerance during a pull operation.

17. The cable tensioning unit of claim 1,

wherein the controller is configured to generated calibration reports.

18. The cable tensioning unit of claim 1,

wherein the controller is configured to record, display, and/or update elongation corrections.