Winch Cable Wrap Vision Sensing for Groove and Slack Detection

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Solution Overview

Problem

Current winch systems require multiple sensors to monitor cable wrapping and unwrapping conditions, which are inefficient and slow to respond, leading to disruptions and potential equipment damage.

Innovation Solution

A single computer vision sensor system that analyzes cable conditions on a winch drum, detecting anomalies such as skipped grooves, overlaps, and slack, and initiates control signals to the winch and motion control system to prevent disruptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate sensors are used to monitor cable wrapping conditions, then monitoring coverage is improved, but device complexity and response time worsen

Engineering Contradiction:

Improvemonitoring coverageVSAvoidnumber of sensors

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate sensors into a single computer vision sensor system that can simultaneously detect cable wrap position, groove alignment, cable tension, and drum rotation. This merging approach maintains comprehensive monitoring coverage while reducing device complexity and the number of separate components required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The computer vision sensor system performs multiple monitoring functions simultaneously - detecting cable position, groove alignment, tension conditions, and drum rotation - all through a single multi-functional device. This universal approach improves reliability without requiring multiple specialized sensors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple separate sensors are used to monitor cable wrapping conditions, then monitoring coverage is improved, but response speed worsens

Engineering Contradiction:

Improvemonitoring coverageVSAvoidresponse speed

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

By merging multiple sensor functions into a single computer vision system, the patent enables simultaneous detection of all cable wrapping conditions through one coordinated sensor, improving response speed while maintaining comprehensive monitoring coverage.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical sensors with a computer vision-based optical system that processes images to detect cable conditions. This substitution enables faster data acquisition and processing, improving response speed while maintaining reliable monitoring of all cable wrapping parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If traditional sensors are used to detect cable anomalies, then detection capability is adequate, but control efficiency worsens

Engineering Contradiction:

Improveanomaly detection capabilityVSAvoidcontrol efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical sensors with a computer vision system that captures and processes images to detect cable anomalies. This substitution maintains adequate detection precision while significantly improving control efficiency through integrated processing and faster anomaly identification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The computer vision system provides real-time feedback on cable wrapping conditions by continuously monitoring and processing visual data. This feedback mechanism enables rapid detection and response to anomalies, improving control efficiency while maintaining precise measurement capability.

Inventive Principle:

Principle #23Feedback

4Device complexity

If a single sensor is used to monitor all cable conditions, then device complexity is reduced, but measurement precision worsens

Engineering Contradiction:

Improvenumber of sensorsVSAvoidcondition detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The computer vision sensor system performs multiple specialized monitoring functions through a single device, including cable position detection, groove alignment verification, tension assessment, and rotation monitoring. This multi-functional approach reduces device complexity while maintaining measurement precision through integrated processing capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent transitions from one-dimensional mechanical sensor measurements to two-dimensional image-based detection, enabling a single sensor to capture multiple cable conditions simultaneously. This dimensional change allows comprehensive monitoring with reduced complexity while maintaining or improving measurement precision.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12540059B2CV camera cable wrap sensor

Publication Date: 2026.02.03 TAIT TOWERS MANUFACTURING LLC

AI summary

A computer vision camera sensor apparatus for motorized winches capable of monitoring multiple conditions relating to the cable and drum and a processing system capable of analyzing the camera sensor output to identify multiple conditions relating to the winch cable and drum and initiate appropriate control signals to the winch to protect the equipment and loads supported by the hoist.