Motor-Mounted Contactor Assembly for Compact Winch Wiring
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Solution Overview
Problem
The existing winch systems have increased installation and setup times due to numerous wired electrical connections between the motor, contactor assembly, and power source, and these connections are prone to degradation from harsh weather conditions and tangling.
Innovation Solution
A motor assembly is designed with a contactor assembly integrated around and in face-sharing contact with the motor, reducing the length and number of electrical connections, and positioning all components within a shared housing or drum support space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contactor assembly is mounted to an exterior surface of the housing with multiple wired connections, then the electrical connections can be established between motor and contactor assembly, but the installation time increases and the wires are exposed to harsh weather conditions causing degradation
Solution Approach 1:
The contactor assembly is integrated with the motor assembly by mounting it to the exterior surface of the motor housing, combining two separate assemblies into one unified structure. This reduces the number of separate components and their associated wiring connections, thereby decreasing installation time while maintaining electrical connection reliability.
2Ease of operation
If multiple wired electrical connections are used between motor, contactor assembly, and power source, then electrical functionality is achieved, but the wires become exposed to harsh weather conditions and may become tangled and frayed
Solution Approach 1:
By integrating the contactor assembly with the motor assembly into a single unified structure, the patent eliminates the need for separate wired connections between these components. This reduces the number of exposed wires that are vulnerable to environmental factors such as weather, tangling, and fraying, thereby improving ease of operation while protecting against harmful environmental effects.
3Ease of operation
If the contactor assembly and motor are separate components with multiple wires, then electrical connections can be made, but the overall packaging space increases
Solution Approach 1:
The contactor assembly is mounted to the exterior surface of the motor housing, integrating two separate assemblies into one compact unit. This reduces the overall packaging space required while maintaining the electrical connection flexibility needed for operation.
Solution Approach 2:
The contactor assembly is positioned within the space defined by the drum support, effectively nesting it within the existing motor assembly footprint. This allows the contactor assembly to be housed within the same spatial envelope as the motor, minimizing the overall packaging volume required.
Data Source
AI summary
Methods and systems are provided for a winch including a motor and a contactor assembly coupled around the motor. In one example, the contactor assembly is coupled around and in face-sharing contact with a portion of an outer surface of the motor. Additionally, the contactor assembly may include two or more coils spaced apart from one another within the contactor assembly.