Hybrid Winch Torque Control for Operator Feedback
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Solution Overview
Problem
Existing winches lack the ability to provide manual operators with a 'feel' of the force applied to the line and load conditions, as they typically operate in a full-on or full-off mode without variable speed control, lacking power assistance during manual operation.
Innovation Solution
A winch system that combines manual input with motor-assisted torque, using a torque sensor to measure user input and adjust motor assistance based on the manual torque, allowing for variable power assistance in a fixed or variable ratio, enabling operators to feel the load without supplying full manual force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a motor is used to drive the winch at full speed, then productivity is improved, but the operator loses feel of the load and control precision
Solution Approach 1:
The patent merges manual operation with motor assistance in a hybrid drive system. The manual input drive allows the operator to directly feel the load while the motor provides power assistance to maintain productivity. This combination resolves the contradiction by allowing the operator to retain tactile feedback through manual engagement while the motor supplements the force when needed.
Solution Approach 2:
The system dynamically adjusts the ratio of manual to motor power contribution based on operating conditions. The controller monitors load conditions and automatically modulates the motor assistance level, allowing the winch to operate in different modes from fully manual to fully motor-driven, optimizing both operator feel and productivity for each specific situation.
2Ease of operation
If power assistance is added to manual operation, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The motor serves multiple functions: it provides power assistance during manual operation, enables fully automatic operation when needed, and can act as a brake or hold device. This multi-functionality justifies the added complexity by providing versatile operational modes from a single integrated system.
Solution Approach 2:
A controller acts as an intermediary between the manual input drive and the motor, coordinating their interaction. The controller processes sensor data and manages power distribution, enabling seamless transitions between operational modes while maintaining system simplicity through centralized control logic.
3Ease of operation
If variable speed control is implemented, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The system incorporates sensors that provide feedback on load conditions, motor status, and operational parameters to the controller. This feedback loop enables automatic adjustment of motor assistance and speed without requiring complex manual controls, as the system self-regulates based on real-time conditions.
Solution Approach 2:
The winch system automatically adjusts its own operation based on sensor feedback and controller logic. The system monitors its own state and makes real-time adjustments to motor power delivery, eliminating the need for complex external control mechanisms and simplifying the user interface.
Data Source
AI summary
A power assisted winch and method include a control system and method for detecting the amount of turning force or torque supplied by a manual input drive to the winch drum, supplying turning force or torque from a motor to the winch drum and controlling the amount of torque supplied by the motor to the winch drum as a function of the amount of turning force or torque supplied by the manual drive. The function may be a fixed predetermined ratio or it may vary depending upon the level of turning force or torque supplied by the manual input drive. A torque sensor may be utilized to detect the level of input manual torque and control apparatus controls the amount of torque supplied by the motor to gearing or coupling driving the winch drum.