Winch Controller Dynamics for Load and Temperature Adaptation
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Solution Overview
Problem
Pre-programmed winch operations often result in decreased performance due to non-adjustable mechanical and electrical limits, leading to inefficiencies and potential damage during various winching applications.
Innovation Solution
A system with a controller that adjusts winch motor operation based on load limits set to different levels depending on the winch mode, allowing for tailored performance across various applications while incorporating safety features to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-programmed winch operation limits are used, then winch operation is constrained within set current and speed limits, but winch performance is decreased during certain applications
Solution Approach 1:
The patent implements a controller that dynamically adjusts winch operating parameters including current limits, speed limits, and load limits based on detected winch modes and operating conditions. The controller transitions between different operational states (e.g., free spool, controlled spool, winch in, winch out) and modifies parameters in real-time to optimize both safety and performance for each specific application scenario.
Solution Approach 2:
The system changes multiple operational parameters simultaneously based on mode detection: current limits are adjusted according to motor temperature and load conditions, speed limits are modified based on drum tension and operational phase, and load limits are set differently for various winch modes. This multi-parameter adjustment enables the winch to achieve optimal performance while maintaining safety margins.
2Reliability
If pre-set motor performance curve is used, then winch speed is determined by tension-based curves, but winch speed is not adjustable during operation
Solution Approach 1:
The controller dynamically modifies speed limits and motor operating parameters based on real-time detection of winch mode, drum tension, and motor temperature. During free spool mode, higher speeds are permitted; during controlled spool and winch in/out modes, speed limits are adjusted according to the specific operational requirements and load conditions, enabling both protection and adaptability.
Solution Approach 2:
The system continuously monitors motor temperature, drum tension, and operational state, then feeds this information back to the controller which adjusts speed limits and performance parameters accordingly. This closed-loop feedback enables the winch to adapt its speed characteristics to match actual operating conditions while protecting the motor from overheating and overload.
3Ease of operation
If non-adjustable winch operating ranges are used, then winch operation is simplified, but winch performance is decreased during specific applications
Solution Approach 1:
The winch system automatically detects the operational mode (free spool, controlled spool, winch in, winch out) and self-adjusts its operating parameters including current limits, speed limits, and load limits without requiring manual intervention. The controller monitors sensor inputs and autonomously transitions between operational states, maintaining ease of operation while optimizing performance for each specific application through automatic parameter adjustment.
Data Source
AI summary
Methods and systems are provided for adjusting operation of a motor of a winch. In one example, a system for a winch includes a controller adapted to adjust operation of a motor of the winch based on one or more of and/or each of a winch load limit, a motor temperature, a distance of a hook coupled to an end of a rope of the winch to a winch fairlead, and an amount of rope wound onto a drum of the winch.