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.

We claim: 
     
         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.