Percussion cable deicer

Custom-made autonomous and portable tools

Following the expressed need to “De-ice an enclosed cable (cable car, zip line, etc.) to allow its use after a period of frost and ice accumulation,” we developed this prototype of an autonomous cable de-icer.

Here’s a look back at this innovative prototyping project…

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Search for principles

Starting from the expressed need, we explored various principles that could be implemented to achieve the objective. We conducted research to review existing solutions in the field.

After comparing different techniques, the most suitable and promising one for testing was:

De-icing and breaking the ice through impacts and vibrations applied to it.

Monitoring technological developments

To develop this new percussion-based de-icing tool, we closely studied the operating principle of an electro-pneumatic chisel. This combination of a portable power tool and a device delivering percussive impacts to a material showed great potential.

Through analysis of technical documentation, construction blueprints, exploded views, and the disassembly and measurement of a device to understand its functioning and design, we began the development of our percussion cable de-icer.

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Calculations and sizing

Developing the tool required several technical calculations to determine the specifications of the motor and the kinematic chain leading to the percussion tool.

We defined the motor’s operating speeds and torques, battery capacity, and the kinematics needed to meet the performance objectives we had set.

Mechanical and electrical design

The equipment’s design addresses challenges related to setup, stabilization, and movement along the cable. Its modular design allows it to adapt to various cable diameters.

The device is autonomous, powered by a rechargeable and easily swappable battery, ensuring operational flexibility.

Prototyping

The design phase culminated in the creation of a functional prototype.
Thanks to our local suppliers, stainless steel and aluminum parts were machined and treated based on our blueprints.

We supplied commercial components, then carried out the mechanical assembly and wiring in our own workshop.

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Functional testing

After assembling and conducting no-load tests on the prototype, we also tested it under winter conditions: cold, humidity, ice, and frost.

To simulate these conditions, we used a refrigerated truck set to around -30°C. This allowed us to verify that the de-icer’s functions remained operational even in such a frozen and humid environment.

We also created ice accumulation on a metal bar to simulate a cable section and analyze the percussion de-icer’s performance against ice. After a few adjustments, the system produced promising results!

Real-world testing

The de-icer was then tested on an actual cable in the mountains, with the support of our client, Aerofun, which specializes in the sale and installation of recreational zip lines. The weather conditions were ideal for ice and frost accumulation on the cable, making it the perfect time to test the percussion de-icer in a real-world scenario.

Result: The de-icer performed its job, successfully removing all ice and frost. The zip line could be immediately used afterward.
This trial also revealed areas for improvement to enhance the device’s performance and build quality.

Stay tuned for updates!

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If this application of our engineering skills has interested you, do not hesitate to contact us!