Electronic Winch Control Circuitry for Off-Road Vehicles
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Solution Overview
Problem
Electric winches on off-road vehicles face issues such as personal danger and winch damage during hook parking, slow unwinding and rewinding, rope tangling, and inadequate protection for the winch motor and control module, particularly due to limitations in speed control and reliability.
Innovation Solution
The implementation of a control circuitry that switches from a 'slow start' mode to a normal speed after a short period and automatically switches to a faster 'boost' mode when unloaded, incorporating features like over-current protection, temperature protection, and reverse-battery protection, using pulse-width-modulation to control the winch motor speed and torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If gear ratios are changed to offer multiple winch speeds, then winch speed is improved, but winch torque increases by the same ratio resulting in increased risk of personal injury and winch system damage
Solution Approach 1:
The patent implements dynamic speed control by switching between different motor winding configurations (2-pole and 4-pole) based on operational needs. This allows the winch to operate at different speeds without permanent gear changes, and crucially enables automatic slow-start mode during retraction to prevent rope snap-back hazards while maintaining full torque capability when needed.
Solution Approach 2:
The patent changes the electrical parameters of the motor by switching between different stator winding connections (series-parallel configuration) to alter the number of poles. This electrical parameter change provides multiple speed modes without mechanical gear changes, and the system automatically adjusts these parameters to maintain safe torque levels during specific operations like rope retraction.
2Speed
If AC voltage with multiple stator windings is used to provide multiple winch speeds, then winch speed control is improved, but device complexity increases and AC voltage is not typically available on vehicles
Solution Approach 1:
The patent replaces the mechanical gear box system with an electrical control system that uses pulse-width modulation (PWM) and switching between different motor winding configurations. This substitution eliminates complex mechanical components while achieving multiple speed modes through electronic control of the DC motor's electrical characteristics.
3Speed
If higher DC voltage is applied to increase winch motor speed, then winch speed is improved, but torque increases making it easier to start vehicle engine but dangerous for winch operation
Solution Approach 1:
The patent employs periodic pulse-width modulation (PWM) to control the average voltage delivered to the motor. By switching the voltage on and off at high frequency with variable duty cycles, the system achieves variable speed control without permanently applying high voltage, thus preventing excessive torque while maintaining speed flexibility.
4Ease of operation
If electro-mechanical relay control module is used to power and reverse winch motor, then control function is achieved, but reliability is insufficient and protection features are inadequate
Solution Approach 1:
The patent replaces the electro-mechanical relay control module with a solid-state electronic control system using power transistors and microcontroller-based PWM control. This eliminates mechanical wear and contact degradation issues, significantly improving reliability while providing enhanced protection features through electronic sensing and control logic.
Solution Approach 2:
The patent implements feedback control through current sensing and microcontroller monitoring that continuously adjusts motor operation. The system monitors motor current, voltage, and operational state to automatically adjust PWM duty cycles and provide protection against over-current, over-voltage, and abnormal conditions, enhancing both reliability and safety.
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
This solution reduces the risk of personal injury and winch damage, minimizes rope tangling, and enhances the reliability and protection of the winch system by providing multiple speed control and robust protection mechanisms, allowing for safer and more efficient operation.
Implementation Method 1
using pulse-width-modulation to control the winch motor speed and torque
Implementation Method 2
a winch motor and control circuitry. The control circuitry is coupled to the winch motor
Data Source
AI summary
A winch control system having a solid state winch contactor and a boost power supply for a vehicle equipped with an electric winch and especially for off-road vehicles, is disclosed. This invention automatically provides three winch speeds: a “slow start” (“creep”) speed for “parking” the hook and for “sneaking” up on a load, a normal speed for normal winch operation and a fast speed for taking less time to unwind and rewind the winch rope when there is no load on the winch. Protection features for the winch contactor and/or the winch include, but are not limited to, electronic winch motor braking, current limiting, over temperature, undervoltage and reverse battery. Winch current limiting is adjustable from 100 amps to 300 amps, chosen for the purpose of accommodating various winch sizes.