Optical Fleet Angle Sensor for Winch Cable Alignment

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Solution Overview

Problem

Existing fleet angle sensors struggle to provide accurate, real-time measurements of the cable angle in dynamic environments, such as sonar dipping, due to vibration, swaying, and bouncing, which can lead to cable damage and safety concerns.

Innovation Solution

A fleet angle sensor system featuring a frame with quadrant photodiodes and light sources that determine the angular orientation of the cable through signal analysis, providing high resolution and fast response times, and includes a shield device to block ambient light and contaminants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a mechanical follower is used to guide the cable, then the cable can be guided during spooling, but timing errors accumulate as the cable diameter changes

Engineering Contradiction:

Improvecable guidanceVSAvoidfleet angle measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical follower system with an optical sensing system using light sources, photodetectors, and quadrant photodiodes to measure cable angle. This substitution eliminates mechanical contact and timing errors associated with mechanical followers, providing accurate real-time measurements without accumulation errors from cable diameter changes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If drum controls are used to vary rotational speed, then fleet angle can be controlled, but accurate real-time measurements require complex sensors

Engineering Contradiction:

Improvefleet angle controlVSAvoidsensor system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent uses an optical measurement system with light sources and photodetectors arranged around the cable path to directly measure fleet angle without complex mechanical sensors. The system uses light blockage detection by the cable to determine angular position, providing simple yet accurate real-time measurements that work with existing drum controls.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the winch operates at high speeds in sonar dipping, then productivity increases, but cable vibration and movement make accurate measurement difficult

Engineering Contradiction:

Improvesonar dipping speedVSAvoidfleet angle measurement accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent employs an optical sensing system that measures cable angle through light blockage detection, which is insensitive to cable vibration and high-speed movement. The non-contact optical method captures real-time fleet angle data even during rapid sonar deployment and retrieval operations, maintaining measurement accuracy at high productivity speeds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses periodic light pulses or continuous light modulation to detect cable position, allowing measurement synchronization with the winch operation cycle. This periodic optical sampling captures fleet angle information at critical moments during the high-speed sonar dipping cycle, ensuring accurate measurement despite rapid cable movement.

Inventive Principle:

Principle #19Periodic action

4Adaptability or versatility

If the photodetector is exposed to ambient light, then the sensor can operate in various environments, but measurement accuracy decreases

Engineering Contradiction:

Improveenvironmental adaptabilityVSAvoidfleet angle measurement accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent introduces a light shield or housing as an intermediary element that blocks ambient light from reaching the photodetector while allowing the controlled light source to illuminate the cable. This shielding mechanism creates a controlled optical environment that maintains measurement accuracy across various external conditions including sunlight and artificial lighting.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 sensor system accurately measures the fleet angle of the cable within one-tenth of a degree, even in challenging conditions, preventing cable damage and ensuring safety by maintaining optimal cable alignment.

Implementation Method 1

A first light source is mounted on the frame opposite the first photodetector

Methodology Applied

Scientific EffectLight propagation: Light

Implementation Method 2

A first photodetector with multiple light-receiving zones is mounted on the frame

Methodology Applied

Scientific EffectPhotoelectric effect: Photoelectric Effect

Data Source

PatentUS12066285B2Hoist and winch cable angle sensor

Publication Date: 2024.08.20 HORNET ACQUISITIONCO LLC

AI summary

An assembly includes a hoist or a winch, a cable, and a fleet angle sensor. The fleet angle sensor includes a frame disposed around an opening and the cable extends through the opening. A first photodetector with multiple light-receiving zones is mounted on the frame. A first light source is mounted on the frame opposite the first photodetector. A shield device is under the frame and includes a shield frame and a cover. The shield frame is around the cable and the cover extends from the shield frame toward the cable, with the cable extending through the cover.