Smart Winch Control Pack for Power Sensing and Overload Protection
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Solution Overview
Problem
Existing winches lack accurate measurement and control of electrical power delivery, leading to potential mechanical overloading and failure due to power overload, with existing systems failing to provide instantaneous power metric measurement and communication to control units.
Innovation Solution
Integration of a smart control pack with a bus bar and Hall effect sensor to measure current and voltage, coupled with a remote clutch system using electromagnetic solenoids for mechanical load management, ensuring safe operation and preventing overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing winch technology is used without smart controls, then the device complexity is low, but the measurement precision of electrical power delivery is insufficient leading to inability to detect power metrics
Solution Approach 1:
The patent replaces mechanical power transmission monitoring with electrical sensing systems. Hall effect sensors and current sensors are integrated into the drivetrain to electrically detect power metrics without mechanical intervention, enabling precise measurement of electrical power delivery while maintaining system compactness.
Solution Approach 2:
The patent introduces a control unit as an intermediary between the motor and drivetrain components. This control unit receives electrical signals from sensors, processes power metric data, and communicates with remote controls, serving as a mediator that enables intelligent power management without direct mechanical coupling.
2Measurement precision
If instantaneous measurement of power metrics is implemented, then the measurement precision improves, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent merges multiple sensing functions into integrated sensor assemblies. Hall effect sensors and current sensors are combined within the drivetrain structure, and the control unit integrates data processing for multiple power metrics, reducing overall system complexity while maintaining instantaneous measurement precision.
Solution Approach 2:
The control unit is designed with multi-functionality, serving as both a sensor interface, data processing unit, and communication hub. This universal component handles multiple power metrics measurement and communicates with various control devices, eliminating the need for separate dedicated systems for each function.
3Reliability
If dynamic power control is implemented to prevent mechanical overloading, then the reliability improves, but the device complexity increases due to smart control integration
Solution Approach 1:
The patent implements feedback control where sensors continuously monitor power metrics and transmit data to the control unit. The control unit processes this feedback information and dynamically adjusts motor operation to prevent mechanical overloading, creating a closed-loop system that enhances reliability through real-time monitoring and adjustment.
Solution Approach 2:
The control system performs preliminary action by detecting power metric thresholds before mechanical overload occurs. The sensors and control unit identify approaching dangerous power levels and preemptively adjust motor operation, preventing mechanical failure before it happens rather than reacting after damage occurs.
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
Enables precise electrical power management and mechanical safeguarding, preventing overloading and mechanical failure by dynamically controlling power delivery and clutch engagement.
Implementation Method 1
a current sensor, such as a Hall effect sensor, to measure current
Data Source
AI summary
A winch includes a motor, a gear reduction unit, a tie structure, an external power cable, and a rotatable drum. The motor includes a motor housing with a motor case and a first drum support attached to the motor case. The gear reduction unit is drivingly attached to the motor and has a gear housing including a gear case and a second drum support. The tie structure connects said first and second drum supports. The external power cable having a first end and a second end. The first end of the external power cable is configured to be coupled to an external power source. The second end of the external power cable is coupled to a bus bar. The rotatable drum is drivingly connected to the motor and supported by the first and second drum supports.