All power line workplaces heavy physical strain on linemen, with one of the most demanding tasks being pulling power lines to the correct tension. These lines can weigh thousands of pounds, increasing the risk of injury. We designed a portable, battery-powered hoist system to make power line work safer and easier by replacing the manual pulling process. The device mounts directly onto a power line and pulls it to a set tension, eliminating the need for constant manual force.
We worked with Florida Power & Light to establish clear design goals. The system is light enough for one person to carry and use while still producing up to 4,000 pounds of pulling force. An electric motor generates the necessary force, which is amplified through a gear system to keep the device compact and user-friendly.
We integrated sensors to measure line tension during operation, ensuring accurate and repeatable results. A temperature sensor prevents the device from overheating and protects the equipment from damage. Safety features include an emergency stop button and audio-visual warnings to quickly alert linemen about any issues. Testing demonstrates that the device reduces physical strain while maintaining steady performance. The final design meets our strength, accuracy, and portability goals and shows strong potential to improve safety and reduce setup time for power line work.
