Variable-Torque Winch Brake for Multi-Layer Cable Protection
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Solution Overview
Problem
Existing winches face challenges in protecting against sudden and violent force variations on cables, particularly in towing applications, leading to potential cable breakage and damage to surrounding equipment, which cannot be effectively addressed by oversizing or traditional torque limiters due to variable torque based on winding layers.
Innovation Solution
A winch design with a brake mechanism that adjusts torque based on the number of cable layers, using a screw-nut system to maintain a constant force by varying the brake's maximum torque, combined with a motor control module to manage brake engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque limiter is used to protect the cable from excessive force, then the cable is protected from breaking, but the force limitation varies with the number of cable layers on the drum
Solution Approach 1:
The brake torque is made dynamically adjustable through a mechanism that automatically modifies the braking force based on the number of cable layers on the drum. This dynamic adjustment ensures that the effective force limitation remains constant regardless of winding conditions, resolving the contradiction between protection reliability and force consistency.
Solution Approach 2:
The system changes the brake torque parameter in response to changes in cable layer configuration. By detecting or sensing the number of layers and相应地 adjusting the brake torque, the system maintains a consistent effective force limit on the cable, eliminating the variability that would otherwise occur with fixed torque limiters.
2Strength
If the winch is oversized to resist extraordinary forces, then protection against violent forces is improved, but the mass of the equipment increases significantly
Solution Approach 1:
Instead of statically oversizing the winch components to handle maximum possible forces, the invention uses a dynamic brake torque adjustment mechanism that adapts to actual operating conditions. This allows the use of lighter, more appropriately-sized components while maintaining protection against extraordinary forces through real-time torque control.
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 solution ensures consistent force protection across varying cable lengths, preventing cable damage and reducing risk to surrounding equipment by maintaining a constant maximum torque, even with multiple layers.
Implementation Method 1
a screw-nut system of which the nut is driven in rotation with the drum, and of which a translational movement of the screw driven by the nut is configured to adjust the torque exerted by the brake
Data Source
AI summary
A winch includes a rotary drum, a cable which can be wound on the drum in multiple layers, and a brake for braking the rotation of the drum, the brake being calibrated to permit the rotation of the drum beyond a variable torque which decreases as the length of the cable wound on the drum increases.