Winch Clutch Dynamic Torque Adjustment via Ball-Ramp
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional winch clutches have a fixed torque setting, which can lead to premature slipping and payload drop due to increasing torque requirements as the winch cable winds up, as the effective drum radius increases, causing the clutch to slip and allow the drum to free-wheel.
Innovation Solution
A clutch system that adjusts its torque setting dynamically by varying the biasing force through an auxiliary system, using disc springs or other biasing members, and a ball-ramp assembly to maintain optimal friction engagement, allowing the clutch to increase torque transmission capacity as the drum winds up and decrease it when winding down, thereby preventing harmful loads from passing through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed torque setting is used in the clutch, then the structure is simple and easy to manufacture, but the clutch slips prematurely when the drum radius increases during cable winding
Solution Approach 1:
The clutch torque setting is made dynamic through a variable biasing force mechanism. As the drum winds cable and its effective radius increases, the biasing force automatically increases to maintain optimal friction engagement, preventing clutch slip while adapting to changing torque requirements throughout the winding operation
Solution Approach 2:
The friction coefficient and normal force parameters of the clutch are changed dynamically during operation. The biasing member (such as a spring) varies the normal force applied to the friction plates based on the drum radius, thereby changing the torque transmission capability to match the varying load conditions during cable winding
2Reliability
If the biasing force is increased to prevent clutch slip, then the torque transmission capacity is improved, but the friction wear between plates increases
Solution Approach 1:
The biasing force is dynamically adjusted to match the actual torque requirements at each stage of cable winding. Rather than using a constantly high biasing force, the system applies only the necessary force to prevent slip, thereby reducing unnecessary friction wear and extending clutch service life while maintaining reliable torque transmission
Solution Approach 2:
The clutch system incorporates a feedback mechanism where the drum radius (through the cable layer build-up) automatically influences the biasing force magnitude. This feedback loop ensures the biasing force increases only when and where needed to prevent slip, avoiding excessive force application that would accelerate wear
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 dynamic adjustment of torque settings ensures the clutch can handle increased torque without slipping, preventing payload drops and maintaining structural integrity by matching the torque requirements with the varying effective drum radius.
Implementation Method 1
the frictional engagement of the input and output friction plates varies, and as such, the torque setting at which the plates slip relative to each other also varies
Implementation Method 2
the biasing member may comprise one or more disc springs positioned around the output shaft
Data Source
Figure 1
Figure 2a
Figure 2b~2c
AI summary
A clutch (5;105) comprises an input shaft (10;110), an output shaft (12;112) and a biasing member (48; 148). The biasing member (48; 148) is arranged to provide a biasing force that allows torque transfer from the input shaft (10;110) to the output shaft (12; 112) via one or more input friction plates (44;144) and one or more output friction plates (32;132). Rotation of the output shaft (12; 112) may cause the biasing force to vary to adjust the maximum torque setting of the clutch (5;105) during reeling-in or reeling-out of a winch cable (7a) around a winch drum (7). A retainer (50;150) may be included in the clutch (5;105) which retains the biasing member (48; 148) in operative connection with the output shaft (12; 112) and translates axially relative to the input shaft (10;110) upon rotation of the output shaft (12; 112). The axial translation may cause the biasing force to vary by varying the compression of the biasing member (48; 148).