Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION:
INTELLIGENT FIBER ROPE TERMINATION, MODULE, AND NETWORKING
TECHNOLOGIES
CROSS-REFERENCES TO RELATED APPLICATIONS
This non-provisional patent application is a continuation-in-part of U.S.
Patent
Application Serial Number 15/445,306 and claims the benefit, pursuant to 37
C.F.R. section
1.53(c), of an earlier-filed provisional patent application assigned serial
number 62/686,210.
The parent application listed the same inventors and remains pending as of the
time of this
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
Not Applicable.
MICROFICHE APPENDIX
Not Applicable member
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DESCRIPTION
Title of the Invention: Intelligent Fiber Rope Termination, Module, and
Networking
Technologies
1. Technical Field.
This invention relates to the field of tensile strength members. More
specifically, the
invention comprises an intelligent cable module that can be placed in any
desired position
along a rope or cable. The module preferably includes an instrument package
useful for
things such as position monitoring and load monitoring, as well as other
components that are
connected to the instrument package.
2. Background Art.
In this disclosure the terms "rope" and "cable" are used interchangeably. Both
are
examples of a "tensile strength member," meaning a component that readily
transmits tensile
forces but not compressive forces. Tensile strength members must generally be
connected to
other components in order to be useful. A flexible cable provides a good
example. Most
cables include some type of end-fitting configured to transmit a load. For
example, a cable
used in a hoist generally includes a lifting hook on its free end. This
lifting hook may be
rigged to a load. The assembly of an end-fitting and the portion of the cable
to which it is
attached is commonly called a "termination." A termination is a useful point
for the addition
of the inventive intelligent cable module, though such a module can be added
at other points
as well.
The present invention has application to many fields where cables are used. A
non-
exhaustive listing of applicable fields includes offshore lifting, ship
mooring, drag line cranes
(in both fixed and moveable rigging), power shovels (in both fixed and
moveable rigging),
civil structure tendons (suspension bridges and the like), and floating
structure moorings
(such as offshore oil rigs)
Most high-strength cables are presently made of steel. The cable is a wound or
braided assembly of individual steel wire. An end fitting (such as a lifting
hook) is often
attached to the steel cable by placing a length of the cable within a cavity
running through a
portion of the end fitting. The wires within the end fitting are splayed apart
and a potting
compound is then used to lock the wires within the fitting. The term "potting
compound"
means any substance which transitions from a liquid to a solid over time.
Examples include
molten lead, thermoplastics, and UV-cure or thermoset resins (such as two-part
polyesters or
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epoxies). Other examples include plasters, ceramics, and cements. The term
"solid" is by no
means limited to an ordered crystalline structure such as found in most
metals. In the context
35 of this invention, the term "solid" means a state in which the material
does not flow
significantly under the influence of gravity. Thus, a soft but stable wax is
yet another
example of such a solid.
Molten lead was traditionally used as a potting compound for steel cables.
Once the
individual wires were splayed within the expanding cavity of an end-fitting,
molten lead was
40 poured into the cavity. The lead then solidified and locked a portion of
the cable in the
cavity. In more recent years lead has been replaced by high-strength epoxies.
Modern cables may still be made of steel, but high-strength synthetic
filaments are
becoming more common. These include DYNEEMA (ultra-high-molecular weight
polyethylene), SPECTRA (ultra-high-molecular weight polyethylene), TECHNORA
45 (processed terephhthaloyl chloride), TWARON (para-aramid), KEVLAR (para-
aramid),
VECTRAN (liquid crystal polymer), PBO (polybenzobisoxazole), carbon fiber, and
glass
fiber (among many others). Modern cables may also be made of older, lower-
strength
synthetic materials such as NYLON. In the case of high-strength synthetics,
the individual
filaments have a thickness that is less than that of human hair. The filaments
are very strong
50 in tension, but they are not very rigid. They also tend to have low
surface friction. These
facts make such synthetic filaments difficult to handle during the process of
adding a
termination and difficult to organize. Hybrid cable designs are also emerging
in which
traditional materials are combined with high-strength synthetic materials.
These present
additional challenges, since the metal portions may be quite stiff while the
synthetic portions
55 will not be.
Those skilled in the art will know that cables made from synthetic filaments
have a
wide variety of constructions. In many cases a protective jacket will be
provided over the
exterior of the synthetic filament. This jacket does not carry any significant
tensile load and
it may therefore be made of a different material.
60 Most larger cables are made as an organized grouping of smaller
cables. The smaller
cables are often referred to as "strands." One example is a parallel core of
synthetic filaments
surrounded by a jacket of braided filaments. In other cases the cable may be
braided
throughout. In still other examples the cable construction may be: (1) an
entirely parallel
construction enclosed in a jacket made of different material, (2) a helical
"twist" construction,
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65 (3) a more complex construction of multiple helices, multiple braids, or
some combination of
helices and braids, or (4) a hybrid construction including metallic
constituents.
The reader is referred to commonly-owned U.S. Patent No. 8,371,015 for more
detailed descriptions regarding the application of an attachment to a sub-
component of a
larger cable. The '015 Patent explains how individual anchors can be attached
to the strands
70 and the anchors can then be attached to a common collector to create a
uniform load-bearing
structure.
The present invention is not limited to multi-stranded terminations. Any form
of
cable termination may be used, such as a single socket for example. The
exemplary
embodiments depicted all include multi-stranded terminations but this fact
should not be
75 viewed as limiting. The embodiments specifically described pertain
primarily to the field of
deep water lifting and lowering. The invention is by no means limited to this
field, however.
Modern high-performance cables incorporating synthetic fibers (in pure form or
in
hybrid form) provide the same strength as steel cables but with a substantial
weight
reduction. For long hoisting operations the weight of the cable often exceeds
the weight of
80 the payload. A reduction in the weight of the cable results in a direct
increase in payload.
The inventive products described herein will most often be applied to high-
strength cables (5
Tons to 2000 Tons or even more). These applications are often critical in
nature. Thus, it is
useful to incorporate intelligent cable modules that can monitor a cable's
condition while it
remains in operation. The present invention provides such a capability.
SUMMARY OF INVENTION
The present invention comprises a cable including an integrated intelligent
cable
module. The module preferably includes an integral instrument package. The
instrument
package may assume many forms and may serve many purposes. In a preferred
embodiment,
the module includes a position-determining system and an on-board processor.
The
processor determines a current location in space for the module based on the
information it is
receiving. This positional information may then be transmitted to an external
receiver. In the
scenario where the module is attached to a termination near a payload, the
positional
information may be used by an external positioning device (such as a crane) to
control the
motion of the cable
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The module also preferably includes load-monitoring and recording features.
These
features act as a "black box" for the cable, monitoring its performance and
reporting (in real-
time or at a later time) any exceedances or any deterioration in performance
or structural
integrity.
100
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an exploded perspective view, showing an exemplary intelligent
anchor
made according to the present invention.
105 FIG. 2 is a sectional elevation view, showing one type of strand
termination that may
be used.
FIG. 3 is a sectional elevation view, showing representative instrumentation
that may
be added to a strand termination.
FIG. 4 is a sectional view, showing one possible construction for a multi-
stranded
110 cable.
FIG. 5 is a plan view, showing a collector.
FIG. 6 is an exploded perspective view, showing additional features of the
housing
and collector.
FIG. 7 is a sectional elevation view, showing a version in which a separate
collector
115 and housing is used.
FIG. 8 is a sectional elevation view, showing a completed assembly using the
components of FIG. 7.
FIG. 9 is a schematic view, showing a representative instrumentation package
for an
inventive termination.
120 FIG. 10 is a sectional elevation view, showing another embodiment of
the inventive
termination.
FIG. 11 is a perspective view, showing an inventive termination with
thrusters.
FIG. 12 is a sectional elevation view, showing a strand termination with an
embedded
sensing/comm element.
125 FIG. 13 is a perspective view, showing the use of the inventive
termination to place a
payload in the deep water lifting environment.
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FIG. 14 is a perspective view, showing the addition of an external camera to
the
assembly of FIG. 13.
FIG. 15 is a perspective view, showing the addition of a pair of ROV garages
and
130 ROV's to the intelligent cable termination.
FIG. 16 is a perspective view, showing one of the ROV's of FIG. 15 in
operation.
FIG. 17 is a perspective view, showing a different payload configuration.
FIG. 18 is an elevation view, showing a common construction for a braided
cable.
FIG. 19 is a perspective view, showing how the strands of a cable can be
loosened to
135 expose a central void and gaps between the individual strands.
FIG. 20 is a perspective view, showing an exemplary intelligent cable module
configured to fit in the central void of a braided cable.
FIG. 21 is an elevation view with a cutaway, showing the intelligent cable
module of
FIG. 20 installed inside a cable.
140 FIG. 22 is a sectional elevation view, showing the use of clamping
collars to hold the
module of FIG. 21 in position.
FIG. 23 is a perspective view, showing an embodiment of the intelligent cable
module
including radial prongs to stabilize its position.
FIG. 24 is an elevation view, showing an embodiment of an intelligent cable
module
145 configured to clamp to the exterior of a cable.
FIG. 25 is an elevation view, showing the use of multiple intelligent cable
modules
along a cable in a marine lifting application.
FIG. 26 is a perspective view showing how an intelligent cable module can be
added
at any desired position along a cable's length.
150 FIG. 27 is an exploded perspective view, showing the addition of an
intelligent cable
module in a length of cable.
FIG. 28 is an elevation view, showing the addition of two intelligent cable
modules in
a length of cable.
FIG. 29 is a schematic view, showing a master-based network among intelligent
cable
155 modules and other systems.
FIG. 30 is a schematic view, showing a masterless network among intelligent
cable
modules and other systems.
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FIG. 31 is a perspective view, showing an intelligent cable module integrated
into a
ship mooring system.
160 FIG. 32 is a plan view, showing the system of FIG. 31
FIG. 33 is a perspective view, showing the incorporation of an intelligent
cable
module in a small single-strand termination.
FIG. 34 is a sectional elevation view, showing internal details of the
embodiment of
FIG. 33.
165 FIG. 35 is an elevation view, showing an exemplary graphical user
interface.
REFERENCE NUMERALS IN THE DRAWINGS
cable
12 strand
170 18 anchor
cavity
22 potted region
24 loading stud
26 male thread
175 28 threaded engagement
strand termination
34 collector
38 receiver
nut
180 44 hemi bearing
46 opening
48 through hole
central opening
64 middle strand collector
185 66 distal strand collector
68 load cell
70 jacket
72 core
74 housing
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190 76 clevis structure
78 transverse hole
80 bolt
82 receiver
84 recess
195 86 cavity
88 first instrument package
90 second instrument package
92 connection
94 core termination
200 96 battery
98 power supply
100 inertial measurement system
102 processor
104 memory
205 106 external power connector
108 external data connector
110 acoustic antenna
112 acoustic transducer
114 1/0 port
210 116 I/0 port
118 I/O port
120 load cell
122 load cell
124 load cell
215 126 I/O port
128 pressure sensor
130 temperature sensor
132 intelligent cable termination
134 thruster controller
220 136 salinity
138 extended housing
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140 thruster
142 trunnion mount
144 sensing/comm element
225 146 sensor
148 sensor lead
150 sensor lead
160 potting surface
162 payload
230 164 lifting tang
166 connector
168 cable
170 camera
172 ROV garage
235 174 ROV
176 ROV garage
178 ROV
180 tether
182 connector
240 184 cable
186 connector
188 tang
190 sling
192 release mechanism
245 194 pallet
196 leg
198 central void
200 inter-strand void
202 intelligent cable module
250 204 communication strand
206 connector
208 module casing
210 bulging portion
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212 clamping collar
255 214 radial prong
216 casing half
218 casing half
220 antenna
222 external display
260 224 vessel
226 through hole
228 nut
230 master node
232 node
265 234 controlling computer
240 vessel
242 bollard
244 mooring line
246 sling
270 248 transition
250 mooring stay
252 quay
254 winch
256 controller
275 258 termination
260 anchor
262 loading flange
264 antenna
266 strain gauge
280 268 connection
270 monitor
272 windows display
274 line identification data
276 monitoring parameters
285 278 potting transition
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280 filament limit
DESCRIPTION OF EMBODIMENTS
FIG. 1 provides an exploded view of an exemplary intelligent cable module that
is
290 configured to be located near one end of a cable. The intelligent cable
module is therefore
referred to as an "intelligent cable termination." Intelligent cable
termination 132 is shown as
an exploded assembly in FIG. 1. The particular cable 10 shown has nine
individual strands 12
surrounding a core. All these components are encompassed within a surrounding
jacket. A
portion of the jacket is removed to reveal the individual strands and the
core. A strand
295 termination 30 is affixed to the end of each individual strand 12. Each
strand termination 30
is then attached to collector 34.
The intelligent cable termination 132 is configured to attach to an external
element
(such as a payload to be hoisted and placed by a crane). A connecting feature
can be added to
collector 34. However, in the version shown, the connecting feature (clevis
structure 76) is
300 incorporated as part of a separate housing 74. Housing 74 connects to
collector 34. Using
this approach, tension carried by strands 12 is transmitted to the collector,
then to housing 74
and finally through clevis structure 76 to an external element.
In addition to carrying the cable's load, housing 74 in this embodiment
provides
additional internal space for housing an instrument package or packages. The
instrument
305 package or packages allows the integrated termination to become an
"intelligent" termination,
as will be described subsequently.
Middle strand collector 64 slides over the splayed strands and attaches to the
perimeter of collector 34. Distal strand collector 66 (which is split into two
halves in this
version), clamps over the small end of the middle strand collector and seals
the interface
310 between the middle strand collector and the jacketed portion of the
cable. These components
direct the transition of the strands from their configuration within the cable
to the "splayed"
state proximate collector 34.
FIG. 2 is a sectional elevation view showing an exemplary structure for a
strand
termination 30. The individual filaments within strand 12 (which may be a
million filaments
315 or more in the case of an advanced synthetic material) are connected to
anchor 18, such as by
potting a length of the filaments within cavity 20 to form potted region 22.
Loading stud 28
is connected to anchor 18 via threaded engagement 28. The loading stud is
equipped with a
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suitable force-transferring feature ¨ in this case male thread 26. This
assembly thereby
transmits tensile loads from strand 12 to loading stud 24.
320 FIG. 3 is a sectional elevation view depicting an exemplary
connection between
strand termination 30 and collector 34. In this version a ball-and-socket
connection is used.
Opening 46 passes through collector 34 at an angle. A hemispherical receiver
38 is provided
in the portion of the opening opposite the strand. Hemi bearing 44 rests in
receiver 38.
Loading stud 24 passes through hemi bearing 44. Load cell 68 is placed on top
of hemi
325 bearing 44. Nut 40 secures the assembly in place. Each individual
strand termination
includes its own adjusting nut. The nuts may be used to individually allocate
the total tension
among the strands. Load cell 68 provides an electrical output that corresponds
to the amount
of compressive load it is presently experiencing. Each individual strand
termination is
preferably provided with a load cell so that the load on each strand can be
monitored. In this
330 example the intelligent cable module receives and monitors the
information from the load
cells. It can also place this information in a suitable communication format
and transmit it to
an external monitoring system.
The load cell shown in this version is illustrative of any load/stress/strain
sensing
device that is incorporated into a cable or strand's load path. Other types of
devices may be
335 substituted. As an additional example, a pressure sensing device
can be provided within the
potted region inside the anchor. As still another example, a strain gauge may
be attached to
the exterior surface of the strand termination.
FIG. 4 shows a cross sectional view through an exemplary cable assembly of the
type
depicted in FIG. I. This particular cable has ten sub-groupings ¨ core 72
surrounded by nine
340 strands 12. Optional jacket 70 may be provided to surround and
protect the other
components. While cable jackets are not common in the field of deep water
lowering and
lifting (primarily due to inspection limitations), with the addition of
sensory technologies, an
external jacket may be an advantageous feature. External jackets are more
common in other
applications.
345 FIG.
5 depicts a plan view of collector 34 (the same version as shown in FIG. 1).
Center opening 50 receives core 72. Nine openings 46 are provided for the nine
strands 12.
Nine through holes 48 are provided for bolts that are used to attach the
collector to the
housing.
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FIG. 6 provides a perspective view of collector 34 and housing 74. The reader
will
350 note how the nine through holes 48 in the collector align with nine
receivers 82 in housing
74. Each receiver 82 includes a female thread. Nine bolts 80 are passed
through the receiver
and into the nine threaded receivers 82 in the housing. The bolts are then
tightened to secure
the collector to housing 74.
In this example housing 74 is machined as one integral piece. It includes
clevis
355 structure 76 with transverse hole 78. This is configured to receive
a tang and cross-pin in
order to attach the housing to some external element. An example of an
external element
would be a payload that is to be lifted and moved using the inventive cable
termination. In
many cases additional rigging (such as lifting slings) and hardware will be
added to the clevis
structure shown. Thus, the clevis structure should be viewed as exemplary and
non-limiting.
360 Housing 74 includes an internal recess 84 that may be used to house
one or more
instrumentation packages. FIG. 7 shows a sectional elevation view through
collector 34 and
housing 74. Cavity 86 is provided in the portion of the housing that faces the
collector. One
or more additional recesses may be provided where the limitations of
structural strength
requirements permit. In the example shown, two such recesses 84 are provided.
365 It is preferable to provide space for instrumentation within the
integrated termination
itself. However, any available region around the integrated termination could
be employed as
space for instrumentation ¨ provided that it is sufficiently protected (for
applications needing
such protection). The protective body for the instrumentation need not be the
same body
that is used for the integrated termination. Housing 74 is preferably quite
robust, and in some
370 cases may be sealed from water and/or water pressure. Given that
most instruments are
sensitive to water and / or the pressures of deep water operation, a boundary
will typically
need to be established for ocean lifting applications. This can either be done
within housing
74 as an example, or individually between instrument package components. For
example the
power source and sensors may have independently sealed packages for this
purpose. Housing
375 74 would then not require an overall seal.
The user will note in FIG. 7 how bolts 80 may be placed in through holes 48
and
threaded into receivers 82. FIG. 8 shows a sectional view through an assembly
made
according to the present invention (The section is taken on the same plane
used for FIG. 7).
Core termination 94 is provided on the end of core 72 in this example. It is
secured within
380
central opening 50 in collector 34. In this version core 72 is not intended to
carry significant
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tension. It houses communication and / or power lines that extend along the
entire length, or
in some cases a portion, of the cable.
First instrument package 88 and second instrument package 90 are contained
within
housing 74. These instrument packages are connected to the elements in core 72
(such as
385 fiber optic lines and electrical conductors). The instrument
packages are also connected (in
this version) to the load cells monitoring the load on each individual strand.
As will be
known to those working in the field of deep water lifting, the addition of
power,
communication, data, air, fluid, or any form of auxiliary service line can be
incorporated
within the strength member to increase the service context of the intelligent
cable module.
390 These service lines can be incorporated in countless
configurations, such as inside strands,
between strands, within layers of the jacket, temporarily wrapped and
unwrapped around the
outside of the cable, etc. The proposed invention is not limited to any
specific cable design.
However, the addition of auxiliary service lines can significantly increase
the advantages of
the inventive termination.
395 As an example of the above, the addition of fiber optics and in
some cases power
within the lifting cable may allow high speed data transfer for real-time
feedback of position,
or operation of subsea ROVs and/or AUVs. In such cases, the intelligent
termination can
more easily become the power and/or communication hub for additional machines
and/or
devices operating at depth.
400 The reader will also note in the example of FIG. 8 that middle
strand collector 64 has
been attached to the outer perimeter of collector 34. The unification of these
elements (see
FIG. 1 - housing, collector, middle strand collector, distal strand collector,
and cable) creates
a solid and protective assembly. As shown in FIG. 8, the instrument packages
and associated
connections are well-protected inside a very solid surrounding structure. This
configuration
405 is preferable, as a cable termination frequently lives in a hostile
environment. As covered
previously, this housing may take on many shapes and forms, including separate
or attached
housings that may not be within the termination casing.
The instrument package(s) may include many types of electronic devices. FIG. 9
schematically depicts an exemplary embodiment to aid the reader's
understanding. The
410 reader should first bear in mind that some versions will include
external power and/or
communication connections, while others will not. The unconnected versions
will run on
internal power and may save information for subsequent downloading, or pulse
information
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to other sources on an interval or as-needed basis (such as a strand integrity
breach alarm
signaling an acoustic transmitter to communicate to a ship-board receiver).
The connected
415 versions may transfer information up the cable (to a receiver on board
a surface vessel) as
they are being used. FIG. 9 shows an externally-connected version (meaning a
version that is
designed to maintain communication up the cable).
The instrument package(s) may include only analog devices. An example would be
load cell circuitry that sends a sensed value up the cable. It is preferable
in most cases,
420 however, to include digital devices such as one or more processors.
These may be used to
convert information to a digital format and thereby facilitate easier
retention and transmittal.
The example of FIG. 9 uses digital circuitry.
Processor 102 is ideally a programmable device capable of running suitable
software.
It includes an associated memory 104. The memory is preferably non-volatile so
that it may
425 store data over time even if the power is lost. Power supply 98
provides stable power to all
the components shown (The power connections are not depicted). The power
supply may
draw input power from battery 96, from external power connector 106, or both.
Additionally
it may draw power from an alternate source such as an ROV tether or auxiliary
power source
on the sea floor.
430 Inertial measurement system 100 ("IMS") provides position and
orientation data to
the processor. It preferably provides full six degree of freedom information.
Using
conventional nomenclature, this means that the IMS provides such information
as X-axis
position, Y-axis position, Z-axis position, roll angle, pitch angle, and yaw
angle. The IMS
may also provide such information as a rate-of-change for these values. The
information
435 provided by the IMS allows the processor to "know" the intelligent
module's position in
space and its orientation. This assumes, of course, that accurate initial
information is
provided (an initial value for all six state variables). Providing initial
state information is
well understood in the art. As one example, the termination might be placed in
an initial
"zeroing" fixture. After it is zeroed the cable to which the termination is
connected would
440 then be lifted by a boom on a crane and swung into service moving a
payload.
The IMS is not limited to any particular kind of system. Such systems have
traditionally used spinning gyroscopes in combination with linear
accelerometers. However,
since space will be somewhat limited inside the termination, solid state
solutions are
preferable. The preferred embodiments will likely employ "ring laser gyros."
As those
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445 skilled in the art will know, these devices are not gyros at all.
Rather, each individual ring
laser measures interference between counter-propagating laser beams to sense
angular
velocity.
Mathematical functions are used to convert the angular velocity to angular
position. Where less accuracy is required, MEMS devices (micro
electromechanical systems)
may be used for monitoring the roll, pitch, and yaw motion.
450 Linear accelerometers (essentially very accurate force detectors)
are used to measure
linear acceleration that is then integrated to determine position (X, Y, and
Z). Where high
accuracy is needed, three orthogonal ring laser assemblies are used and
multiple linear
accelerometers are used. The IMS generally contains its own internal processor
and memory.
These units integrate the received data to produce values for the six state
variables.
455 Alternatively, raw data may be fed from the IMS to the processor and
the processor may
perform the integrating functions.
The reader should bear in mind that not all inventive embodiments will include
a full
six degree of freedom IMS. As an example, some embodiments may provide only
positional
data without any attitude data. Others may provide attitude data with no
reference to
460 position. Still others may omit an IMS altogether.
Multiple input/output ports 114, 116, 118, 126 are provided for the processor.
I/O
port 114 provides connection to communication connector 108. In this example
the
communication connector provides a hard-wired connecting to the far end of the
cable. If,
for example, the cable is being paid off a shipboard crane, the far end of the
cable will remain
465 on the ship and the communication connector will allow real-time
communication between
the ship and the termination (even though the termination may be thousands of
meters below
the ocean's surface).
I/O port 116 connects processor 102 to acoustic transducer 112. The acoustic
transducer is connected to acoustic antenna 110. This is a device intended for
undersea
470 communications. It allows sonar-like signals to be sent by the
termination to other devices.
The termination can also receive these signals from an external source. This
type of
communication device is merely an example, as it is one of many potential
technologies that
can be used to either transmit or receive information. As an example, for the
standing
rigging on a drag-line crane, the communication is preferably via radio
signals and antenna
475 110 in that application would be an R/F antenna.
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I/O port 118 connects the numerous load cells 120,122, 124 (feeding load data
from
the individual strands) to processor 102 (any type of load sensor may be
substituted). I/O
port 126 connects multiple sensors to the processor. In this example, it
connects pressure
sensor 128, temperature sensor 130, and salinity sensor 136. These are merely
examples of
480 the many forms of sensors that may be tied into the instrument package.
These may reside
within the housing or be separate. In some cases they may be entirely
separate, such as those
on the subsea infrastructure ¨ and may simply communicate data to the
instrument package.
Returning briefly to FIG. 8, the reader will note the numerous wire
connections 92 to
the core and to the load cells monitoring the strand loads. The processor is
able to use these
485 connections to monitor position and loading information and to send
that data back to the far
end of the cable through the electrical and/or optical connections in core 72.
Of course if the
termination is designed to be a standalone system without power and / or
communication
running down the cable, this data is simply stored for ship-side retrieval or
transmitted on an
as needed basis. Power in that case is handed via a sufficient local power
source.
490 In the version shown in FIG. 9 the intelligent cable module is
configured for deep
water lifting operations. The exemplary termination is provided with a pair of
thrusters that
can provide limited positioning adjustment ¨ controlling both the twist in the
cable as it
moves down the water column, and the positioning of the payload as it nears
its point of
connection on the sea floor. Thruster controller 134 controls the orientation
and thrust =
495 provided by the thrusters. The thruster controller is integrated with
processor 102 as shown.
FIG. 11 provides a perspective view of the completed termination with a series
of
thrusters 140 included. Each thruster may be independently pivoted about its
trunnion mount
142. Each thruster may also be throttled and reversed in this embodiment. The
orientation
and affiliation of thrusters may vary widely, and may not necessarily be
integral to the
500 termination housing. For example these may be mounted to a large
external frame. In other
cases there may further be auxiliary thrusters or position orienting devices
mounted to the
actual payload.
FIG. 13 shows a view of the intelligent termination 132 attached to a
representative
payload 162 in a deep water lifting scenario. Lifting tang 164 on the payload
is connected to
505 the clevis assembly by a cross-pin. Cable 10 suspends the assembly from
a crane located on
a surface vessel. Thrusters 140 provide selective lateral and torsional
mobility on the sea
floor, as well as assuring that the cable is not twisted when traveling to and
from the vessel
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through the water column which has alternating currents. With synthetic fiber
and hybrid
ropes in particular, this is helpful in assuring that rope integrity remains
intact.
510 Surface vessel crane control systems include stabilization
functions that are generally
referred to as "anti-heave" functions. These are designed to minimize wave-
induced motion
of the payload on the end of the cable. However, these anti-heave functions in
the prior art
have no useful information regarding the exact motion of the termination and
its attached
payload when at depth. Rather, they attempt to compensate using only
information regarding
515 the motion of the surface vessel. This is a challenge when running
in deep water. It is
especially significant with the use of synthetic fibers as the delayed spring
response is more
difficult to predict. In the present invention (for embodiments including real-
time data
transmission), the termination can transmit accurate motion and position
information which
can then be used by the surface anti-heave systems or an inline device.
520 FIG. 10 shows another embodiment in which there is no communication
through the
cable. Extended housing 138 includes a larger cavity 86. A large battery 96 is
provided in
this cavity. The battery provides electrical power to the instrument packages,
the load cells,
and other items requiring electrical power. In this version the instrument
packages are more
akin to the "black box" of an aircraft (a flight data recorder). An external
port (not shown) is
525
provided so that when the termination is brought in for service the battery
can be recharged
and the internally-stored data can be downloaded. Of course, non-wired options
are also
possible for the battery charging and data downloading (such as an inductive
connection).
Other components may be provided to proactively monitor the state of the load
strands (as opposed to inferring their state from the loads applied to them).
FIG. 12 shows an
530 embodiment in which strand 12 includes embedded
sensing/communication elements 144.
These elements are intended to be used in monitoring the condition of the
cable (though they
may possibly be used for communication as well). In the version shown, these
elements are
optical fibers that stretch from one end of the cable to the other. Light is
applied to the far
end of the cable. Sensor 146 measures the light transmitted and sensor lead
148 passes
535 through the loading stud to carry this information to the processor
(sensor lead 150 carries the
load cell information). The optical fibers are sized to break as the strand is
over-stressed.
Alternately if a strand is damaged or cut in operation the ceased light would
indicate a
potential hazard. A reduction in light transmission thereby indicates a cable
overstress. This
example is one of many possible configurations. Fiber optics could run through
a jacket,
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540 down the center of the rope, etc. Alternatively, the use of electrical
conductors could carry a
similar function ¨ providing either strain or pass/fail criteria for damage to
the cable.
Importantly, in all cases the termination may aid in collecting or.
.transmitting the relevant
information to determine the health of the lifting cable. In the event of a
sensed problem, it
could further be used to communicate the hazard to the surface vessel and / or
other subsea
545 equipment.
Most damage, especially with synthetic fiber cables, would occur in the last
few
meters of the cable (as it reaches the termination). This is generally due to
the fact that ROVs
would be operating in this area. Thus, in some embodiments the sensing/comm
elements 144
may only be included in this portion of the cable. One approach is to embed a
20 meter loop
550 of conductive material and then monitor for breaks in this material
(such as by monitoring for
increased resistance).
The sensors and other components provided within the intelligent cable
termination
need not be connected directly to the termination itself. FIG. 14 illustrates
a placement
scenario where downward visibility is needed from payload 162. Camera 170 is
mounted on
555 payload 162 in a position providing a good downward field of view.
Cable 168 attaches to
camera 172 and to connector 166 on intelligent cable termination 132. In this
version, video
data is fed into the instrument package(s) within the termination and then up
cable 10 to a
surface ship. The video data is used to guide the placement of the payload.
The camera and
cable may be left with the payload when the payload is released from
intelligent cable
560 termination 132. Connector 166 may facilitate this detachment (by being
designed to reliably
pull free upon the application of a specified detachment force).
FIGs. 15 and 16 show still another embodiment in which ROV's (remotely
operated
vehicles) are used. It is common in undersea lifting operations to use ROV's
to guide and
place a payload. These ROV's are typically lowered and controlled using a
cable other than
565 the cable used for lifting the payload. Many ROV's are lowered into a
working position in a
protective "ROV garage." The ROV garage may contain a tether connected to the
ROV. The
tether often pays off a reel as needed. The tether may carry electrical power,
bidirectional
data signals, and air or fluid pressure. In recent years autonomous underwater
vehicles
("AUV's") are replacing ROV's in some applications. In this disclosure, the
term "ROV"
570 shall be understood to encompass both ROV's and AUV's. An AUV does not
usually have a
tether but it may still be deployed from a garage and it is often charged in
that garage.
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FIG. 15 shows an embodiment in which two ROV garages 172, 176 are connected to
intelligent cable termination 132. Each ROV garage contains an ROV 174, 178.
Using this
system, the ROV's are lowered with the payload. The ROV's may be used to
manipulate the
575 position and orientation of the payload, as well as operating other
systems such as the
mechanism that releases the payload from the cable. The ROV's may also provide
video data
so that a surface operator can see the state of the payload and its
surroundings.
FIG. 16 shows the same assembly with ROV 174 having left its garage 172. ROV
174 may be maneuvered as needed. It contains multiple thrusters that allow it
to orient itself
580 in a desired direction and provide force in a desired direction.
Information regarding the state
of the ROV may be sent via tether 180 back to ROV garage 172. This information
may then
be fed into the instrument package(s) within intelligent cable termination 132
(and possibly
back up cable 10).
It is also possible to establish communications directly between the payload
and the
585 intelligent cable termination. In the version of FIG. 16,
electrical cable 184 connects
connector 182 on the termination to connector 186 on the payload. If, for
example, the
payload contains a release mechanism, this connection may be used to instruct
the payload to
release itself from intelligent cable termination 132. Cable 184 would then
detach itself as
the intelligent cable termination is lifted away from the payload.
590 FIG. 17 depicts a more common configuration for a payload. In this
version payload
162 rests atop a standard pallet 194 with four legs 196. Rigging is used to
appropriately
suspend the load. In this case four slings 190 extend along the sides of the
payload and down
to the pallet. The four slings are joined to tang 188, which is connected to
the intelligent
cable termination. Release mechanism 192 is provided to selectively release
tang 188.
595 When the assembly reaches its destination (such as the seabed),
release mechanism
192 is actuated and the tang and slings fall free from the intelligent cable
termination. The
release mechanism may be actuated by an instrument package in the termination.
Alternatively, it may be released by an ROV. The rigging may remain with the
payload
indefinitely. In the alternative, an ROV can be used to detach and retrieve
the rigging.
600 As explained initially, an inventive intelligent cable module can
be provided at any
desired point along the cable. The preceding examples have been located near
the end of a
cable. In the following examples an intelligent cable termination is provided
at some point in
between a cable's terminations.
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FIG. 18 shows an elevation view of a 12-strand braided cable. The individual
strands
605 12 are interwoven to create the pattern shown. As those skilled in the
art will know, it is
possible to loosen the construction of such a cable in order to provide access
to the cable's
interior. This process is used when weaving a length of cable back into itself
to form an eye
(see, for example, commonly owned U.S. Patent No. 9,791,337).
FIG. 19 shows the cable of FIG. 18 after the strands have been loosened to
reveal
610 central void 198 within the cable. Many individual inter-strand voids
200 are also created by
the loosening process. FIG. 20 shows an embodiment of an intelligent cable
module
configured for insertion into the center of a braided cable. Intelligent cable
module 202 has a
smoothly shaped module casing 208. In this version communication strand 204
runs down
the center of a braided cable. A connector 206 is provided on each end of
module casing 208.
615 These connectors connect the devices within module casing 208 to
communication strand
204.
Module casing 208 typically contains a processor and other associated digital
devices
¨ such as shown in the diagram of FIG. 9. FIG. 21 shows a view of intelligent
cable module
202 installed within cable 10. The cable is cut away in the view (in the
vicinity of the
620 intelligent module). Communication strand 204 passes down the cable's
core and connects
to module casing 208. Multiple intelligent cable modules may be provided along
the cable's
length, with communication strand 204 providing communication between these
modules and
to devices external to the cable. Once the module is in place, the strands are
laid over the
module in the same configuration as the rest of the cable. The perimeter of
the cable is
625 shown in a phantom line in the view (bulging portion 210). From the
cable's exterior, a
bulge is evident in the vicinity of the intelligent cable module. However, the
intelligent cable
module itself is protected within the strands.
There are several ways in which an intelligent cable module such as shown in
FIG. 21
can be installed. One approach is to install the module(s) at the time the
cable is created. A
630 cable braiding machine creates a braid of strands around a core. In
some cases the core is
empty (a spacing mandrel may be used during the manufacturing process). In
other cases the
core contains a "filler" strand. Communication strand can be fed into the core
as the braid is
created. Module casings can also be added at desired intervals. In this case
it may be
necessary to modify the braiding machine to have a larger core diameter in the
vicinity of the
635 intelligent cable module.
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A second approach to installing an intelligent cable module is to add the
module after
the cable has been braided together with communication strand 204 at the core.
FIG. 26
shows cable 10 with the strands urged apart to reveal the interior void. A
portion of
communication strand 204 is exposed and then cut to leave two cut ends as
shown.
640 Communication strand 204 in this case is a simple bundle of electrical
conductors in a jacket.
Each of the conductors is made part of a connector 206 (such as shown in FIG.
21) and then
slipped back into the void inside the cable. An intelligent cable module is
slipped into the
void as well, and the two connectors are then attached to the module to create
an assembly
such as shown in FIG. 21.
645 One of the issues with an assembly such as shown in FIG. 21 is the
tendency of the
intelligent cable module to move longitudinally within the cable's core. Other
components
may be added to fix its position. FIG. 22 shows the assembly of FIG. 21 with
the addition of
a pair of clamping collars 212. Each clamping collar 212 is a split collar
that clamps to the
cable's exterior. The two clamping collars may be joined by a protective cover
214. Cover
650 214 keeps the two clamping collars from moving away from each other.
The result is that
module casing 208 is trapped between the two clamping collars.
FIG. 23 shows another approach to maintaining the longitudinal position of the
intelligent cable module. In this embodiment module casing 208 features an
array of radial
prongs 214. These protrude outward. Returning briefly to FIG. 18, the reader
will note how
655 the braided strands 12 have intersections at regular intervals both
laterally and longitudinally.
FIG. 19 shows how the strands can be urged apart. Once the module casing 208
is placed
into the interior of the cable, tension is placed on the cable gradually and
each radial prong
214 is urged into the intersection of two adjacent strands. When additional
tension is added
the strands will grow taut around module casing 208. The module casing 208 is
then held in
660 place via the fact that each radial prong is engaging the strands
passing over the exterior of
the module casing.
Once module casing 208 is secured in the cable's interior, inward pressure on
the
module casing can be correlated to cable tension. Thus, it is possible to
measure tension at
intermediate points along the length of the cable without interrupting any of
the cable's
665 strands.
FIG. 24 shows another embodiment for the intelligent cable module. In this
version
the module is split into two halves 216, 218 that are clamped over the cable's
exterior. This
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embodiment is configured for use on a fixed cable for a dragline crane. The
intelligent cable
module contains tension monitoring instruments and a processor (with
components similar to
670 those depicted in FIG. 9). However, because this example operates in
air, radio
communication is preferred. Antenna 220 is provided on the module's exterior.
This sends
and receives radio signals.
In some applications a single cable will have multiple intelligent cable
modules. FIG.
25 shows a single cable extending from a crane on board vessel 224 to payload
162 near the
675 sea floor. Multiple intelligent cable modules 202 are installed along
the length of the cable.
The density of modules is varied in this example, with more modules being
provided adjacent
to the payload.
In some embodiments it is desirable to provide tension information for each
strand at
an intermediate point in the cable. FIGs. 27-28 depict an embodiment of an
intelligent cable
680 termination configured for this application. Intelligent cable
termination 202 is shown in an
exploded state. Housing 230 contains first instrument package 88, along with a
processor,
connectors, and communication hardware (such as depicted in FIG. 9).
As for the example of FIG. 1, cable 10 includes multiple individual strands.
Each
strand is attached to a strand termination 30. The strand terminations 30 on
the right side in
685 the view are attached to collector 34. The attachment for each strand
includes load cells that
monitor the tension on the strand.
The strands on the left side of the view are attached to strand terminations
30', and
these are attached to collector 34'. Housing 230 and collector 34' include an
array of through
holes 226. The components shown are secured together by passing bolts 80
through holes
690 226 and then applying and tightening nuts 228. This draws housing 230,
collector 34, and
collector 34' tightly together. Middle strand collector 64 is then secured to
collector 34 and
middle strand collector 34' is secured to collector 34'.
The result is an intelligent cable termination 202 in the middle of a cable
that can
monitor tension on each individual strand and transmit that information to an
external
695 monitoring system (or record it for future retrieval). FIG. 28 shows a
cable 10 with two
intelligent cable modules 202 installed. In reality the two modules may be
quite far apart
(such as 1 km).
Returning to FIG. 25 the reader will recall that multiple intelligent cable
modules may
be present in a given installation (including multiple modules on multiple
cables). These may
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700 be organized as network nodes. FIG. 29 shows an exemplary embodiment in
which
controlling computer 234 communicates directly with master nodes 230. Each
master node
230 then communicates with several nodes 232.
It is also possible to use a peer-to-peer network. FIG. 30 shows such a
network in
which multiple users (directly or indirectly) access a sensor network as
embodied in the
705 intelligent cable modules. Such a network can be a mobile ad hoc
network ("MANET")
where nodes come and go depending on availability. Consider for example the
depiction in
FIG. 25. Communication in this example can be via sonic pulses. Those modules
near the
bottom may have good communication with the payload while the surface vessel
does not. In
a MANET each node can be configured to disseminate information to other
available nodes,
710 which then further disseminate the information. In this way
information could be conveyed
back up to the surface.
Another good example is found in offshore mooring operations such as are used
for
oil drilling platforms. In a common configuration 16 separate mooring lines
extend from the
floating platform down to anchors on the sea floor. These mooring lines are
tightened until
715 the platform reaches a desired level of stability. If such cables
include intelligent cable
modules then a network will not normally be confined to a single cable.
Rather, the network
may include all modules in all 16 cables. If a MANET is used then a module in
one cable
may have a stronger communication link with a module in a second cable instead
of another
module within the same cable (particularly if sound pulses are used for
communication).
720 Modules in different cables can then relay messages back and forth
to create a robust
communication network.
FIGs. 31 and 32 depict still another application for intelligent cable
modules. FIG. 31
shows a large vessel 240 moored alongside a quay. Multiple mooring lines 244
locate the
vessel with respect to the quay by securing it against mooring stay 250. Each
mooring line
725 includes a sling 246 configured to encircle a bollard 242 on the
quay. The shipboard end of
each mooring line is attached to a winch that can be controlled to apply
tension as necessary.
The mooring lines travel with the vessel. They are an expensive piece of
hardware that must
be inspected, maintained, and periodically replaced. At present they are just
visually
inspected.
730 In the example of FIG. 31, intelligent cable module 292 has been
added to the
transition 248 between mooring line 244 and sling 246. This module can be
configured to
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measure and transmit many different values, including (1) simple tension on
the mooring
line, (2) the "pinching" force imparted by the diverging legs of the sling,
(3) motion of the
module (via an on board 3-axis or greater measurement system, (4) the number
of loading
735 cycles, and (5) ambient conditions such as temperature and humidity.
FIG. 32 shows a plan view of the configuration of FIG. 31. The shipboard end
of
each mooring line 244 is connected to a separate winch 254 on board the
vessel. The shore
end of each mooring line is connected to a bollard on quay 252. Controller 256
adjusts the
tension on each mooring line (via its associated winch) to hold the vessel
properly positioned
740 against mooring stay 250. Such automatic tensioning systems are known
in the art.
However, such prior art systems do not incorporate an intelligent cable module
to monitor the
condition of each mooring line.
The present inventive system preferably includes an intelligent cable module
on each
mooring line. These modules provide data (directly or via periodic downloads)
to a remote
745 processor which then assembles the data and presents it to a user. The
user interface can
assume many forms. FIG. 35 provides a simplified depiction of such an
interface. Monitor
270 presents a conventional windows-type display 272. The
display includes an
identification of a particular mooring line selected by the user (line
identification data 274).
The display also provides a list of significant parameters concerning the
selected lint
750 (monitoring parameters 276). In this specific example the monitoring
parameters are:
1. The number of mooring cycles in which the line has been used;
2. The number of fatigue load cycles (meaning the number of instances in
which
the load on the mooring lien has exceeded a defined fatigue load threshold for
the type of line
in question);
755 3. The total load cycles for the line;
4. The peak load that has been placed on the line; and
5. A derived value for the number of mooring cycles remaining for the line.
Many other parameters could be stored and displayed. The data selected will
vary with the
application. The user interface preferably includes the ability for the user
to make selections.
760 As an example, for each parameter displayed the user could select the
parameter and see
more information. The user could be allowed, for example, to pull up a plot of
peak loading
cycles over time.
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The previous examples have pertained to large, multi-stranded cables. The
invention
is by no means limited to such large cables and may in fact be applied to
small cables as well.
765 FIGs. 33 and 34 provide an example of an application for a cable that
is smaller than a
mooring line.
In the example of FIG. 33, cable 10 consists of a single strand (though that
strand may
still be a complex braided or twisting construction and may still incorporate
a jacket).
Anchor 260 is affixed to an end of cable 10 to create termination 258. Loading
flange 262 is
770 provided on anchor 260. The anchor is designed to rest in a hole
through a plate. Loading
flange 262 transmits load from the anchor to the plate. An intelligent cable
module is located
within anchor 260. It transmits radio frequency signals using antenna 264.
FIG. 34 shows a sectional elevation view through the assembly of FIG. 33.
Anchor
260 is affixed to cable 10 in this example by potting. A length of filaments
near the end of
775 the cable are placed within a hollow passage through the anchor's
interior. The filaments are
then splayed apart. Liquid potting compound is added to the splayed filaments
(either before
or after they are placed in the anchor's cavity). The term "potting compound"
means any
substance which transitions from a liquid to a solid over time. A two-part
epoxy is an
example of a potting compound. Once the potting compound solidifies, the
length of
780 filaments within the anchor cavity is mechanically linked to the
anchor. Potting transition
278 represents the transition from a composite mass of filaments locked within
solidified
potting compound to the freely flexing filaments within the cable.
In this example additional operations are performed before the potting
compound is
added. First, one or more strain gauges 266 are adhered to the interior wall
of the anchor
785 (within the hollow central cavity). Strain gauge 266 is connected to
intelligent cable module
202 by electrical connection 268. The filaments near the end of cable 10 are
placed within
the cavity in the anchor and splayed apart. The filaments only extend up to
filament limit
280. Above that level the anchor's interior cavity is empty volume.
Intelligent cable module
202 is suspended in this empty volume. Potting compound is then added until it
(1) saturates
790 all the filaments, and (2) covers some or all of intelligent cable
module 202. The potting
compound then solidifies to create a unified assembly (Note that the order of
operations can
be varied while still producing the same result).
Once the potting compound is cured the example of FIG. 34 can be placed into
service. Strain gauge 266 monitors the amount of elastic wall deformation of
the anchor, and
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795 this value can be correlated to the tension on cable 10. Provide the
correlation is performed
properly, the strain gauge reading will very accurately provide the tension on
the cable. The
tension values may then be stored within intelligent cable module 202 and/or
sent out to a
separate control system.
In some installations, many such assemblies may form part of a larger system.
For
800 such an example, intelligent cable module 202 can be programmed to send
a radio signal only
in the event of an "exceedance." An exceedance means an instance in which the
cable
tension has exceeded a defined warning limit.
Having described some embodiments in detail the disclosure will now turn to
more
general concepts regarding the invention and its applications. This invention
may be said to
805 apply to the "Internet of Things" ("Jot"). Applications include
synthetic fiber tensile strength
members, commonly referred to as fiber ropes, cables, tethers, cords, or
tendons. It also
covers hybrid strength members incorporating metal and/or composites, as well
as round
slings, wound slings, rope grommets, and synthetic fabric slings.
(Collectively referred to as
"rope/cable/tension member"). More specifically, this disclosure covers
multiple concepts
810 for synthetic fiber-based strength member systems used principally in
high capacity and/or
performance critical applications in conjunction with a termination and/or
electronic module
¨ whereby many more intelligent and connected synthetic rope-system
technologies and
overall data accumulation, communication, networking systems can be made
possible.
While traditional strength members are passive in nature, the present
invention seeks
815 to collect important usage data ¨ either directly or indirectly from
the strength member and/or
termination and/or connected module. Traditional strength members
incorporating synthetic
fiber can easily incorporate fiber optics, wires, hoses, and other means of
communicating,
powering, or transmitting. The traditional cable strength member can in fact
include much
more functionality than is presently included. This additional functionality
enabled by
820 incorporating either a rope-affixed module, or a rigid body termination
(of any design ¨
hereinafter mechanical termination) that can serve as a stable junction point
for connecting,
harnessing, and/or transmitting, power, data, fluid transfer, etc. This
functionality has not
traditionally been included as part of a high-load structural element. For
example, electro-
mechanical and opto-mechanical umbilical cables are common industry products.
However,
825 these umbilicals do not carry significant tensile loads. For example a
fiber optic or electrical
wire cable may commonly include a synthetic fiber to act as the load bearing
element, but
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this is only to support the fiber optic or electrical wire and not to support
a significant
external load.
Whether at the end of the fiber rope as part of a "termination" or simply a
rope-
830 attached device, the concepts of the inventive intelligent cable
module generally include a
multifunctional rope module (or modules) that offers a wide range of data
collection, storage,
computation, machine interfacing, communication, and/or networking options.
These
functions turn traditionally passive strength members into intelligent data
gathering and
dissemination devices.
835 Current offshore lifting operations can be very challenging -
especially when the
operator needs to place a very large, complex and heavy module that can have a
value of
many millions of dollars to a positional accuracy of centimeters in water
depths up to 3,000m
or more. Typically the operators have to rely on secondary sensors that are
not directly
connected to the payload/lift line system (such as the use of separate
remotely operated
840 vehicles, ROV's). These secondary devices watch and sometimes
physically guide the
payload as it travels through the water column and is placed on the sea floor
or connected to
another structure already in location. Sometimes guide wires are also used.
These are just
some of the methods and tools used today.
The majority of lifting operations are monitored closely throughout the
lifting
845 operation to ensure the process is effectively executed. In the
case of offshore lifting using a
crane on a vessel, the monitoring is achieved primarily by instrumentation
located on the
vessel lifting device such as the crane or winch system. There are many
different types of
sensors used to control the descent and recoveiy speed and landing of the
payload. This also
includes the motion reference sensors that control the winch and crane to
reduce the effect of
850 vessel rolling and pitching motions on the payload. This technique
is widely known as AHC
(active heave compensation). It should be remembered that all of these sensors
are located on
the deployment vessel and all other external monitoring is carried out by
secondary devices
such as the ROV which require separate control systems and operators dedicated
to this task.
Occasionally the use of motion reference units are attached to the payload as
a method of
855 monitoring the payload during descent. However there are many
challenges in direct
communications with these devices through the water column.
The simplest form of intelligent cable module is one that is passive and
standalone.
An example of this is where an internal battery, data processor, and
transmitter are used.
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Alternately of course these could be data storage devices. As is probably
evident, these
860
devices could rest anywhere inside or outside a cable termination (or at some
intermediate
point along the cable). In this example, a strain gauge, load cell, or series
of devices are
added to the cable module to accurately monitor the load and/or peak stress
conditions.
The cost of failure during offshore lifting operations creates a need to
develop the
capability to record the operation at the interface point between the object
under lift and the
865 lift line interface (an intelligent cable module proximate the hook
termination). The module
effectively becomes the equivalent of a flight data recorder used in
commercial aircraft. The
presence of the module will enable the operator to record the complete
operation at the
payload. There are many reasons this would be advantageous including providing
a better
understanding of the performance of the AHC systems, recording load swings and
all changes
870 that related to the vessel systems and their impact on the payload.
Examples of data using
integrated sensors or recorders are peak loads, load trends, stresses within
the termination
(such as strand termination loads), payload pitch/yaw/roll, position,
acceleration, pressure,
temperature, vibration, distance from another object, material contact point,
etc. Position and
movement sensors could include multi-axis gyroscopes (whether of the physical
or ring-laser
875 type), accelerometers, etc. If going into something such as a
downhole tool or pipe as
another example it may include sensors that measure diameter, speed, distance,
gases,
material composition, time, etc. It could include video of the operation as
yet another
example, or use a 3D camera or ultra-sonic camera that can make certain
measurements. Any
number of sensors could be utilized.
880 The intelligent cable module can also incorporate communication
tools for more
automated operations. Examples for lifting could be a location/position
pinger, light
tranpnitter, or other communication device for working with other devices or
machines, such
as an ROV or AUV. In such a case, the ROV need not use a traditional vision or
camera
system to do certain functions ¨ it may be more easily automated as a machine-
to-machine
885 method of communication. Such a tool could have significantly more
precision and enable a
more autonomous operation on the sea floor when coupled with other
technologies.
With such a device, there is also the opportunity to extend the capability of
the
intelligent cable module to provide the services and capabilities of the ROV
or other external
devices. For example the module may include a significant power source that
can be used as
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890 a charging station or outlet for ROVs or AUVs. This could have a
significant impact of the
amount of secondary equipment deployed during any offshore lifting operation.
In its most general state, what has been described in the preceding
embodiments is an
intelligent cable module for rope systems, which incorporate sensors,
communication
devices, and/or power in standalone form. These devices may be powered within
the module
895 (such as with batteries for example), or alternately the power may come
from a separate
source. This could be for example a wire running up the fiber rope, or a wire
ported out the
anchor and run separately to a power source. While the latter configuration is
clearly not
preferable for offshore lifting, in other applications such as a structural
pendant, this would
often be the most preferred means of powering the termination module.
Likewise, sensors or
900 communication devices are preferably mounted within a rigid housing.
However, in some
cases there may be some external affixation involved. For example a
termination may
include internal batteries but an external 3D camera or laser sensor mounted
in a non-
hazardous area.
The next level of sophistication is an "active" intelligent cable module. Such
a
905 module can provide active data/power/communication, on a real-time
basis, and/or be able to
respond autonomously to certain conditions. For example an acoustic pinger may
signal
pressure achievement, depth, position, etc, for other machines/tools to
operate a certain
function. As an example where the termination module reacts to other devices,
the
termination hook or load pin may be released when receiving a signal from
another
910 device/machine, or alternately a communicated signal from the operator
above water.
As an example of the user interface for real-time data, a graphical user
interface can
present current loading and recent peak loading for every strand of a 12
strand rope. In this
example each of the rope's primaiy strands has a load cell, and connecting
hardwiring to this
termination provides a real-time health monitoring tool.
915 Any of the examples above may be further developed with the addition
of active
components whereby communication between machines (such as an AUV or other
data
collection devices) or the operator (such as the vessel crane operator or an
ROV pilot), is
made possible. This real time information coming from the termination module
can be used
to automate industrial processes, improve safety, operating speed, and provide
system
920 integrity / health data.
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In many cases in order to make real-time data, power, communication, or other
capability a realistic possibility, it would be most advantageous to run these
types of services
inline with the high load tension member ¨ as the lines are often quite long.
Externally
affixing or helically wrapping these components around the high load strength
member is a
925 possibility in certain static cases, such as structural pendants.
However, a far preferred
method where possible is to incorporate these service lines into the strength
member itself.
For the purpose of this disclosure, a "service line" is any line other than
the strength member
that is added to expand the service context of the strength member and
termination ¨ such as
a fiber optic line used for communicating data from one intelligent cable
module to the next
930 in a string of interconnected mooring lines. Any number of service
lines can be used to
improve the capability of the termination and system as a whole.
How these service lines get included into the strength member is entirely
dependent
on the strength member construction and the application. For example a crane
line that runs
at very high loads around sheaves would require a different construction than
a semi-static
935 pendant line or offshore mooring rope that is nearly always linear.
With this in mind, below
are a few distinct possibilities for incorporating service lines into the
strength member:
1. Fiber optics, fluid or pressure hoses, electrical wires, etc. ¨ for data
transfer,
communication, gas or fluid exchange, etc.
2. Service lines externally affixed to the strength member
940 3. Service lines helically wrapped around the strength member
4. Service lines located in the center of the strength member
5. Service lines located in the center of one or some of the primary
strands of the
strength member (In a 12 strand braided rope this may be one line per 12
strands)
6. Service lines alongside the strands or in place of certain strands in
the strength
945 member.
In most cases additional armoring or components will be needed to either
protect the
service line within the strength member, or protect the strength member from
wearing on the
service lines. Referring back to the offshore lifting example, very high
stresses will be placed
both on the service lines and the interface between these lines and the
fibers. This may
950 commonly require careful engineering to ensure the service line does
not get damaged in use
or compromise the performance of the strength member.
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One can easily envision the technology being used for more than monitoring
health at
the termination point to more holistically monitoring the tension member
system as a whole.
As one practical example, the wires, optics, or other communication devices
previously
955 discussed may not be used necessarily for communicating to/from the
termination, but rather
monitoring the health or integrity of the strength member. In some cases, the
intelligent cable
module may also be beneficial as a receiver, collecting data from other nearby
devices and
communicating this data through the included service line. In such as case the
high load
tension member becomes the hub for a greater network of devices, not just the
strength
960 member itself. This could be a string of rope products, or entirely
other machines such as
AUVs, a subsea station that needs to report real-time data, etc.
In the field of offshore lifting, this type of device may also be considered
an active
and instrumented hook. This type of arrangement would allow for continuous
communication with the hook during deployment and recovery to collect and send
data from
965 the hook to the operators on the vessel in real time. With the data
from the hook in real time
it would be possible to improve the ARC (active heave compensation)
performance and
reduce the actual load swings on the payload. This also gives the opportunity
to monitor load
positioning and many other instruments.
Yet another very powerful configuration based on the components above is the
ability
970 for the fiber rope termination to become a production / service tool ¨
a machine at the rope
that includes many potential service functions. Referring back to the offshore
lift example,
now with a real-time data feed to the surface, and the ability to sense
location/position/heading/etc, the incorporation of payload position thrusters
(on or near the
termination or payload) becomes a practical and unique option. Due to the
ultra-low weight
975 of synthetics in water, the payload can more easily be manipulated in
the water column.
Further, the lack of line weight allows for more tooling to be added to the
end of the rope,
such as battery packs for ROV or AUV charging, an ROV garage, integrated tools
with
actuators, etc. For example, if thrusters are added to the termination to
position payload, they
may be powered internally by a battery source, since the fiber rope has
displaced so much
980 mass in the steel-to-fiber conversion. Alternately, based on examples
provided previously,
power or other key service lines could be run down the strength member. Such a
configuration can in some cases displace the current ROV configuration.
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This active payload positioning becomes the next logical step for the concepts
above.
The intelligent cable module in this version is used to both gather important
information and
985 guide the payload. If thrusters are added to the termination module,
they could be manually
driven like the ROV's used in the process today, or fully automated like an
AUV, where
machine-to-machine communication can provide higher levels of production and
safety. In
the later example, communication between subsea machines may help to guide the
payload
into position, manipulate the payload, and/or make more automated connections
possible.
990 The intelligent termination or module could include many forms of
sensor
technologies ¨ creating near countless forms of data. Below are examples:
1. Movement / position / heading / G-shock / inertial sensors
2. Accelerometers
3. Magnetometers
995 4. Gyroscopes
5. GPS devices
6. TIMU devices
7. MEMS devices
8. Acoustic / Ultra-Sonic Sensors
1000 9. Pressure Sensors (atmospheric, liquid, solid)
10. Strain Sensors
11. Load Sensors
12. Torque / Torsion Sensors
13. Humidity Sensors
1005 14. Temperature Sensors
15. Proximity Sensors
16. Vision or Image Sensors (2D / 3D)
17. Relative Movement Sensors (3D camera, laser, etc)
18. Light Sensors (UV or other)
1010 19. Distance / Displacement Measurement Sensors (laser, linear
encoder, camera,
radar, etc)
20. Rotary Sensors
21. Code Reader / OCR Sensors
22. Photoelectric Sensors
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1015 23. Photomicro Sensors
24. Fiber Optic Sensors
25. Gas Sensors
26. Flow / Micro-Flow Sensors
27. Liquid Leakage Sensors
1020 28. Contact Sensors
29. Dielectric Sensors
30. Electrical Conduction / Resistance Sensors
31. Data Transmission / Communication Examples
32. Torque sensors for the cable as a whole or subcomponents thereof.
1025 The data communication to and from an intelligent cable module can
assume many
forms, including:
1. Wireless communications such as Wi-Fi, Bluetooth, Passive or
Active RFID,
Zigbee, BAW, LTE, LTE-Advanced, or other radio or micro waves. Cellular,
satellite,
acoustic energy, sonic, electromagnetic induction, free-space optical, radar,
or other.
1030 2. Wired communications such as conductive elements, fiber optic
elements, and
the like.
3. The use of electronic or other data storage devices to store data for
later
retrieval.
Data may be pushed / transmitted only, pulled / received only, or both.
Transmit vs
1035 receive capability may vary depending on module capability and
application needs. Rope
modules can include one or multiple methods of data transmission /
communication. In the
case of a wireless design, the addition of a hardwired-access component will
typically be
preferred for items such as system redundancy, backup, big data transfer,
programming, or
debugging as examples.
1040 The intelligent cable modules can be powered by a wide variety of
sources, including:
1. Stored / Battery Power: Batteries may be designed for inductive
charging,
regular replacement, or life-use. System may be designed for ultra-low power
consumption
so that multi-year life is possible.
2. Self energizing systems such as a power cell
1045 3. RFID or similar which is energized by another device
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4. Trickle charge systems such as with solar, wind, or other
small auxiliary
device
5. Auxiliary battery that is used to charge primary battery and
be removed
While it is possible that the rope module (s) are always connected directly to
a power
1050 source (such as at the end or with conductors running down or around
the rope), it is most
common that there will also be a local battery or storage. For example, wired
power may be
used to power tools or maintain charge. Battery or stored power will likely be
common to
maintain data integrity and operate light ongoing functions.
The CPU or similar data-processing device(s), serves as the programmable
device that
1055 can be used to define the module intelligence and logic. This includes
managing information
such as:
I. Global Positioning System (GPS) satellite receiver
2. Data input digitization
3. Data computation
1060 4. Data compression
5. Data encryption
6. Data storage
7. Module time / date stamp
8. Signal conditioning and processing (from various inputs such
as sensors)
1065 9. Sending and receiving of defined information packages (ex:
email alert,
network communications whether packaged or real time, etc)
10. Measure defined limits (tension, pressure, shock, etc) ¨ deploy
reaction signals
to adjacent tools or receivers for network communication.
11. Determine light, sound and other operator or networking signals based
on
1070 certain conditions (low battery, overused rope, etc)
12. Manage hibernate/sleep modes for low power consumption
13. Review the strand-integrity data (via fiber optics, conductive
elements, etc)
The modules can incorporate different operator/system alerts, including:
1. Visual alerts such as a status light (see external display 222 in FIG.
27)
1075 The electronic design could take on countless shapes/forms, depending
on desired function.
2. Colored stack/condition lights, pulsing light patterns to communicate
different
conditions, etc.
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3. LCD or other electronic data panel on or near or insertable into the
module
4. Acoustic alerts
1080 5. Acoustic chirps or pings
The intelligent modules can achieve machine-to-machine interfacing in many
different ways, including:
1. Machine-to-machine Interfacing
2. Laser, UV light, wireless or wired transmission, ultrasound, wireless,
or other
1085 method to communicate to another machine or onto the data network for
alarming the
operator or larger piece of equipment as a whole
3. Communication to a smart tablet or the local network so that computers
are
able to transmit conditions (electronic stack lights for example, or signal to
operate a separate
machine function) to any location
1090 4. Real-
time communication, or conditional data-transmission around certain
events (shock load, time interval, etc).
For the purpose of this overall disclosure, intelligence can come from many
potential
forms including some form of bodies that house sensors and allow data to be
managed.
Generally speaking, this may be within the end (termination point), or
anywhere along the
1095 rope, or both. While a termination is often at the end and used to
transmit a load with a load
connection point (such as an eye, hook, or stop), a module / IoT module is any
device that is
connected to the rope assembly, regardless of proximity. While it may be in or
around the
termination, it many cases it is preferable to be along the rope to provide
intelligence. An
IoT module would not typically be used to transmit a load, although this can
be made
1100 possible. One should assume that throughout this disclosure a
termination or module, while
having different end-purposes, should be considered synonymous in its ability
to provide the
disclosed smart services / intelligence. Some ropes need only a smart module,
some need a
smart termination, some need both. In many cases the smart module rest inside
or is adjacent
to the termination. While the early disclosure was more focused on the
termination point,
1105 this section will detail other means by which a more universal
module or modules can be
considered as primary and/or secondary devices. They may be used in place of
an intelligent
termination or used to support such a device.
Variations for the intelligent cable module include:
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1. An intelligent cable module can be applied (mounted/inserted/affixed)
1110 anywhere on or within the rope or strands. This may be at the
ends, in the midspan
(anywhere along the rope), near one end, or in segments.
2. There may be one or several modules serving different functions or
communicating with each other. A module need not have a CPU or be independent
¨ it may
serve to function as a web to support other more intelligent devices or one
central device.
1115 3. A
module in a termination may serve as an end-hub for several midspan
modules that gather other data. The mid span modules may simply provide load,
position,
temperature ¨ they may be sensors alone and be used to interface with a CPU
(such as in the
termination), or otherwise a hub for data transfer means to another source
(such as when
hardwired).
1120 An intelligent cable module can be connected to a cable in many
different ways,
including:
1. Mounted inside the rope
2. Mounted to the outside of the rope (in symmetrical or asymmetrical form)
3. Mounted to certain strands of the rope (such as inside each of the
primaty sub-
1125 ropes)
4. Tethered to a rope as an attached node
5. Mounted on one or both ends of the rope
6. Mounted in one or both legs of a typical rope splice
7. Mounted in the thimble of a spliced termination
1130 8. Mounted inside or affixed to another form of termination
9. Mounted
permanently to a rope (tamper resistant),or designed to universally
attach or clip on/off
Multiple modules may also be present in a single location. FIG. 21 provides an
example of a single module casing 208 placed in the center of a cable. In this
instance the
1135 cable shown is a braid of 12 separate strands. In some cases each
of these strands will itself
be a braid of 12 smaller sub-strands. A smaller module casing could be placed
within each of
the 12 strands by separating some of the sub-strands. Some of these modules
can even
incorporate a removable data cartridge.
The intelligent cable module may rest on a sacrificial tail alone (such as
where one
1140 end
has a termination and the opposing end is later spliced into another rope),
This
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configuration could be used to make a passive rope intelligent. It also allows
the intelligence
to be calibrated to the rope in a factory-controlled setting.
Monitoring examples include:
1. Termination drops or max shock. Rate of shock, duty cycles, cut strands,
rope
1145 modulus, rope dielectric properties, rope length change, etc. Boom
jacks (machine
shocking), resonation, natural frequency, rope or strand torque, rope or
strand imbalance,
rope diameter, helix change, rope near-sheave or related device via prox
sensors. Period of
connection to another device via dielectrics, etc. Chemical contamination,
line security,
temperature etc. Chemical exposure, strand integrity, rope life management.
1150 2. Cycle Counting: Using inertial module or a RFID or other
position sensor to
count machine cycles in a rope. For example a hoist device that goes up/down.
3. Module to log hours via movement/load/etc. ¨ record life/use. Data
store/collect ¨ then send package as needed.
4. Appropriate connection and load rating: Used to detect and indicate
whether
1155 the appropriate rope and hardware are being used for a certain job,
such as a lifting sling and
shackle combination.
5. Chip or communicated data can signal operator or machine of any desired
condition (load, depth, recommended operating hours, temperature overage, etc)
6. LCD panel or nearby tablet could identify peak conditions for inspection
/
1160 review of system health (rope life, max operational load received,
loading cycle count, etc)
Exemplary applications for the inventive intelligent cable modules include:
1. Crane / Winch lines (Offshore or land cranes, deep shaft mines, etc)
2. Large Vessel Ship-to-Shore & Ship-to-Ship Moorings (L&G tankers, Barges,
etc)
1165 3. Structural Boom Pendants (cranes, draglines, shovels, etc)
4. Civil structures tendons (bridge stays, post tension concrete
structures, cable-
rebar systems, etc)
5. Towing lines (commercial fishery lines, nets, etc)
6. Bridals (trawl doors, lifting assemblies, etc)
1170 7. Floating structure moorings (oil platforms, vessels,
windfarms, wave energy,
commercial docks, boats, etc)
8. Tie-downs (cargo, aircraft, earth anchors, utility securement, etc.)
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9.
Lifting or Towing Slings (heavy lift round slings, rope grommets or light
factory fabric slings)
1175 10. The
technology could also be deployed in miniature and/or simplified form
into small cable assemblies, such as used in fitness equipment, aircraft
control cables,
automotive control cables, safety tethers, boat lifts, medical devises, etc.
11. As covered throughout this disclosure, the intelligent module(s) and/or
terminations will commonly be linked to a greater network of devices. In
principal, the
1180 devices when linked in some way can be viewed as rope networking modules
¨ turning a
physical rope system into a digital tool by which entirely new service
functions may be
derived. For example, a vessel mooring system that has been digitized not only
allows an
operator to understand each individual unit, but also how the system as a
whole is functioning
as well as stress that is imparted to the winches and other vessel components.
The series of
1185 ropes become an input for data that is valuable for the entire
machine/operation.
12. On a mining dragline multiple modules may communicate with one central
collection device. They may be hardwired or wirelessly linked.
13. All rope-related devices on a machine or operation with intelligent
cable
modules could be linked to create a complete / closed loop data set to then
perform more
1190 sophisticated analysis. For example, load long-range distribution
and interaction amongst 4
boom supporting pendant cables can be assessed, or overall load across certain
connected
vessel mooring lines can be managed. One can use this macro-data to better
manage the asset
or field as a whole ¨ not just each individual tension member.
15. Just
like that of an electrical system shown in the picture below, the rope
1195
network can be configured in many ways, such as spoke and hub, pier to pier,
multi-hub with
boosters, interconnected, work through a gateway IoT module, a hybrid, etc.
This may be
considered as a distributed sensing network, and include items such as a smart
hub, a
digitized operator tablet to perform certain functions. This may be a slave or
master network
design ¨ depending on the data collected, pushed, or pulled, and the overall
system goal.
1200 16.
Scanners may be used to ping for data. Technologies such as RFID allow a
passive system to ping the regional network to gather certain data. For
example this may be a
ping to communicate peak loads on an hourly basis, whereas other data is
stored and removed
in other ways.
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17. The
network rope IoT devices may all be interconnected and/or independently
1205
designed to push data into the cloud or a local server for networking with
other sites or
locations worldwide. In other works, the network may then be used to even more
broadly
evaluate systems performance or activity of geographies, countries, companies,
equipment
types, operation types, etc. An organization may gain visibility on the
company-wide
performance of critical equipment or operations. Of relevance is that tension
members (such
1210 as fiber ropes) generally communicate meaningful data for heavy
industries as they represent
activities performed (for example payload values, hours operated, etc). Being
able to digitize
and communicate data from tension members in big/heavy equipment and
operations is
valuable in many ways. Countless user interfaces and analyses of key
performance metrics
are possible.
1215 18. While
much of the above would suggest broad distribution, in many cases the
network may simply be a single operator interface, such as a ruggedized tablet
that can be
brought onto a particular site to monitor data in real time or extract
historical / stored data on
an as-needed bases. Additionally, these devices may be used to program or
reprogram the
networked modules.
1220 For the embodiments in which information is transmitted from the
intelligent cable
module up the cable, the reader should bear in mind that the extraction point
for this
information may be in different locations. The "payload end" of the cable is
the end to which
the termination is attached. A cable is often paid off a drum on a surface
vessel. Information
applied to the cable at the payload end must be extracted at some point distal
to the payload
1225 end. This extraction point may simply be the opposite end of the
cable. However, it may
also be some intermediate point where the information carrying components of
the cable
depart the load carrying components.
One may make some generalizing statements regarding the invention that will be
true
for many embodiments:
1230 1. It is
advisable to place the instrument package(s) above the payload release
point. An objective of the present invention is to use the instrument package
many times in
the deployment of multiple payloads, so it is undesirable to place the
instrument package in a
position where it is difficult to "bring home" with the termination when the
payload is
released. The
payload release point may be in the vicinity of the intelligent cable
1235
termination (as shown in FIG. 17). However, it may also be far below the
termination. In
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some instances the release mechanism may lie 20 meters below the termination.
This will be
true where long slings connect the termination to the payload and the release
mechanism is
located on the payload end of the long slings.
2. For the versions incorporating force sensing devices (load cells, strain
gauges,
1240 etc.), the instrument package may transmit the sensed forces directly
or record them for
subsequent transmission.
3. The preferred embodiments will all include a processor and the ability
to
transmit digital signals. However, it is possible to implement the invention
using only analog
components and no processor. As an example, a very simple version might
include only load
1245 cells, a local battery, and possibly an amplifier set in the
integrated termination. These
analog devices could then send analog signals directly up the cable and all
the processing
would be done outside of the integrated termination.
4. The instrument package ideally includes an inertial measurement system.
Such a system, combined with real-time (or near real-time) data transmission
back to the
1250 surface, allows a surface operator to know the precise location and
orientation of the
integrated termination (and by inference the payload itself).
5. The use of synthetic filaments in the cable provides a large weight
saving in
comparison to prior art steel cables. This weight savings allows additional
weight to be
carried at the termination (or in the vicinity thereof). Batteries may be
added to the
1255 intelligent termination to provide an ample power source without
having to send power down
the cable. Data may still be send through the cable in this scenario, but the
greater challenge
of sending power through the cable would be avoided.
6. The camera such as shown in FIG. 14 may be a stereo camera, a laser
scanner,
or some other suitable device capable of allowing the intelligent termination
to "home" on a
1260 target. As an example, a visual fiducial might be provided as the
desired placement point on
an undersea platform. A stereo camera could be used to guide the payload onto
this target. A
3D object could be used as a target for a laser scanner. The camera could also
be provided on
the intelligent termination itself (perhaps offset on a lateral boom).
7. If a visual guidance system is provided then the inertial measurement
system
1265 does not have to be terribly accurate. The inertial system may be used
to get the payload "in
the ballpark" and the visual guidance system could then take over for the
final placement.
The combination of the two systems allows for greater accuracy while holding
down costs.
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Many other features can be included with the inventive termination, including
one or
more of the following:
1270 1. The memory may be used to log strand loads for future
analysis regarding
needed cable maintenance and possible removal from service.
2. Communication and power wires may not travel through the core of the
cable
but rather may travel externally. As an example, they might be embedded in the
cable's
jacket or wrapped helically around the cable.
1275 3. The collector and housing could be made as one integral
unit.
4. The instrument package functionality can be applied to a cable having
only a
single strand (rather than a multi-stranded cable incorporating a collector).
5. The instrument package may be included as part of a ruggedized ROV
garage.
Although the preceding description contains significant detail, it should not
be
1280 construed as limiting the scope of the invention but rather as
providing illustrations of the
preferred embodiments of the invention. Those skilled in the art will be able
to devise many
other embodiments that carry out the present invention. Thus, the language
used in the
claims shall define the invention rather than the specific embodiments
provided.
1285
1290
1295
