Planetary Gear Winch With Automatic Shifting for Light-Load Hoisting
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Solution Overview
Problem
Existing winches with fixed reduction ratios and hydraulic motors are inefficient for no-load and light-load conditions, leading to high energy consumption and limited speed regulation, especially in cranes and small electric vehicles, where energy-saving and speed-increasing capabilities are necessary.
Innovation Solution
A winch with an automatic shifting planetary gear transmission that adjusts gears based on the lifting load, featuring a simple structure with a driving shaft capable of rotating freely, a clutch gear shifter, and sensors connected to a programmable logic controller for automatic gear shifting, allowing for efficient energy use and speed adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a fixed reduction ratio winch is used, then the structure is simple, but the energy consumption is high and speed regulation is limited during no-load and light-load conditions
Solution Approach 1:
The patent applies a variable reduction ratio transmission system where the planetary gear transmission can dynamically switch between different gear ratios (first gear ratio for no-load/light-load conditions, second gear ratio for heavy-load conditions). This dynamic adjustment allows the system to optimize energy consumption by selecting the appropriate gear ratio based on the actual load, rather than using a fixed reduction ratio throughout all operating conditions.
Solution Approach 2:
The patent changes the transmission ratio parameter based on operating conditions. By switching between a first transmission ratio (higher speed, lower torque) for no-load and light-load conditions, and a second transmission ratio (lower speed, higher torque) for heavy-load conditions, the system optimizes energy efficiency across different operating scenarios while managing the complexity through controlled parameter variation.
2Speed
If a variable-speed hydraulic motor is used to achieve speed regulation, then the speed control is improved, but the cost increases and the variable-speed range is limited
Solution Approach 1:
The patent replaces the complex hydraulic variable-speed motor system with a simpler mechanical gear-shifting transmission system. Instead of using hydraulic controls, proportional electromagnets, and complex oil distribution mechanisms, the invention uses a planetary gear transmission with switchable gear ratios controlled by a gear shifting control valve, achieving speed regulation through mechanical means that are more cost-effective and have a broader speed range.
Solution Approach 2:
The patent segments the speed regulation function into discrete gear ratio steps rather than continuous hydraulic control. The planetary gear transmission provides at least two distinct gear ratios, allowing the system to achieve effective speed regulation by switching between segmented speed levels, which simplifies the control system while maintaining practical speed adjustment capabilities.
3Speed
If frequency conversion is used for speed adjustment in tower cranes, then the light-load fast heavy-load low-speed lifting is realized, but the electricity is not saved due to over-frequency operation
Solution Approach 1:
The patent implements dynamic gear ratio selection based on load conditions, switching to a first gear ratio (higher speed) during no-load and light-load conditions, and to a second gear ratio (lower speed) during heavy-load conditions. This dynamic adaptation prevents the energy waste associated with constant over-frequency operation by matching the transmission ratio to the actual operational requirements, thereby reducing overall electricity consumption.
4Extent of automation
If a clutch gear shifter is arranged between the planetary gear and the winding drum, then the automatic gear shifting function is achieved, but the device complexity increases
Solution Approach 1:
The patent implements a self-service gear shifting mechanism where the gear shifting control valve automatically directs oil flow to switch between different gear ratios based on operational conditions. The system uses sensors to detect load conditions and automatically actuates the clutch gear shifter without manual intervention, achieving automation while keeping the structural complexity manageable through the use of standard hydraulic control components.
Data Source
AI summary
A winch includes a power mechanism motor or a hydraulic motor, a transmission, a winding drum, a brake, a machine frame and a sensor. The transmission, the winding drum, the brake, the machine frame and the sensor are arranged in the winding drum. A driving shaft penetrates through a central hole of a central sun gear of each planetary gear. A clutch gear shifter is arranged between each planetary gear stage, the last planetary gear stage and the winding drum. The clutch gear shifter is connected with a power input side planetary gear rack and a power output side central sun gear during neutral gear. The driving unit drives the execution unit tubular member to move to the right side, and the clutch is disconnected from the connection with the left planetary gear. The right driving shaft power output gear is combined with the central sun gear to complete gear shifting. The empty hook or light-load power mechanism directly drives the winding drum to rotate through the driving shaft.