Aided Freewheel Winch Sensor Control for Manual Release
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Solution Overview
Problem
Freewheel winch operations require high manual force to release the winch line due to resistance and friction, leading to bird-nesting and uneven wrapping, while traction winches cannot be manually released, limiting operator convenience.
Innovation Solution
An aided freewheel device with a rigid base structure, winch guides, a roller, actuator, and sensors that detect operator input to control the winch motor, maintaining tension and allowing freewheel-like functionality while enabling manual release of the winch line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If freewheel winch operation is used to allow manual release of the winch line, then the winch line can be released manually by disengaging the winch drum from the winch gearbox, but the force required to release the winch line is very high due to resistance and friction
Solution Approach 1:
A sensor acts as an intermediary between the operator's manual pulling action and the winch motor control system. The sensor detects tension changes in the winch line and converts them into control signals, allowing the motor to assist the operator during release without requiring direct mechanical disengagement of the drum
Solution Approach 2:
The patent replaces the traditional mechanical freewheel mechanism (which requires direct mechanical disengagement and high manual force) with an electronic control system using sensors and motor control. This substitution eliminates the need for mechanical drum disengagement while providing motor assistance to reduce the force required for line release
2Ease of operation
If traditional freewheel operation is used, then manual release is possible, but bird-nesting and uneven wrapping of the winch line occurs during winch pay-in
Solution Approach 1:
The sensor provides continuous feedback about winch line tension and operator input during both pay-in and release operations. This feedback enables the control system to adjust motor operation dynamically, maintaining proper line tension and wrapping uniformity during automated pay-in while still allowing manual release when needed
3Shape
If traction winch is used to maintain constant tension and eliminate bird-nesting, then winch line wrapping is improved, but the winch line cannot be released manually as the construction does not allow for freewheel functionality
Solution Approach 1:
The patent creates a multi-functional system that combines the tension-maintaining capabilities of traction winches with the manual release capability of freewheel systems. The sensor-controlled motor can operate in multiple modes: maintaining constant tension during pay-in to prevent bird-nesting, and assisting manual release when the operator pulls the line, thus providing both functions through a single integrated system
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The aided freewheel device reduces the force required to release the winch line, prevents bird-nesting and uneven wrapping, and allows for manual release, enhancing operator convenience and winch operation efficiency.
Implementation Method 1
a sensor disposed on the arm for measuring a change in position of the roller from a reaction force of the winch line
Implementation Method 2
the force maintains contact of the roller with the winch line
Implementation Method 3
one or more winch guides secured to the rigid base structure and in contact with the winch line for reducing friction on the winch line as the winch line is moved
Data Source
AI summary
Systems, devices, and assemblies for providing winch freewheel functionality and maintaining tension in a winch line of a winch system. An operator input is detected using at least one sensor. The operator input is associated with an operator pulling on the winch line and a pay-out function of a winch motor of the winch system is controlled based on the operator input.