Winch Line Pull Calculation Using Dual Angle Sensors
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Solution Overview
Problem
Existing winch systems face challenges in accurately measuring line pull due to the random winding of ropes, which causes the distance from the winch center axis to the rope exit point to constantly change, complicating the calculation of torque and force.
Innovation Solution
A system comprising a torque sensor, first and second angle sensors, and a solid-state computer that determines the distance from the winch spool center to the rope exit point using measured angles and calculates the line pull by dividing torque by this distance, with sensors mounted on a swing arm or sliding bracket to maintain alignment with the winch line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the rope winds randomly onto the drum, then the winch system can handle varying load positions, but the distance from the center axis to the rope exit point constantly changes, making force calculation inaccurate
Solution Approach 1:
The patent applies the dynamics principle by making the angle sensors movable rather than fixed. The first angle sensor is positioned on a first arm that can rotate about the drum center, and the second angle sensor is on a second arm that can rotate about its own axis. This dynamic positioning allows the sensors to continuously track the changing rope exit point as the rope winds randomly onto the drum, maintaining accurate angle measurements despite varying load positions and random winding patterns.
Solution Approach 2:
The patent implements feedback by continuously measuring the angles between the rope and the drum center axis (first angle) and between the rope and the drum surface (second angle), then using these measurements to dynamically calculate the perpendicular distance from the center axis to the rope exit point. This feedback loop ensures that the force calculation F=T/X remains accurate even as the rope winding pattern changes, by constantly updating the distance parameter X based on current sensor readings.
2Adaptability or versatility
If the exit angle of the line changes, then the rope can accommodate different load positions, but the rope exit point moves relative to the center axis, causing the distance X to change and complicating force calculation
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical or electromagnetic angle sensors. Instead of using mechanical linkages or physical indicators to track the rope exit point, the system uses angle sensors that optically or electromagnetically detect the rope's angular position relative to the drum. This substitution simplifies the overall system while enabling continuous, accurate tracking of the changing exit angle and position.
Solution Approach 2:
The patent changes the approach from directly measuring the distance X (which would require complex mechanical gauging) to measuring angular parameters (first angle and second angle) and then calculating X through trigonometric relationships. By measuring angles instead of direct distance, and using computational geometry to derive the perpendicular distance, the system handles varying exit angles and positions through parameter transformation rather than direct mechanical measurement.
Data Source
AI summary
A device having a winch spool, a torque sensor that measures torque of the winch spool, a first angle sensor that detects a first angle of a winch line relative to a central axis of the winch spool, and a second angle sensor that detects a second angle of the winch line coming from a coil of line on the spool relative to a surface of the coil of line is disclosed.