Vehicle Winch Fairlead Assembly Reducing Profile
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Solution Overview
Problem
Conventional roller fairleads for vehicles with winches have a bulky profile due to vertically positioned rollers, which reduces the approach angle and can cause damage when navigating steep slopes, and often result in cable pinching between rollers.
Innovation Solution
A fairlead assembly with horizontally and vertically positioned rollers, where the vertical rollers are coplanar with the horizontal rollers, reducing the profile and preventing cable pinching by overlapping into the cable guide space, and featuring grooves to control cable motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical rollers are positioned in front of horizontal rollers in a conventional roller fairlead, then the cable is guided and friction is reduced, but the profile becomes bulky and the approach angle is reduced
Solution Approach 1:
The patent repositions the vertical rollers from protruding in front of the horizontal rollers to being recessed behind the plane of the horizontal rollers. This dimensional repositioning eliminates the bulky profile while maintaining the cable guidance function, as the vertical rollers now operate in a recessed space rather than extending forward.
2Length of moving object
If vertical rollers are repositioned to reduce profile, then the approach angle is improved, but cable pinching may occur between rollers
Solution Approach 1:
The vertical rollers are nested within a recessed space behind the horizontal rollers, with their outer surfaces positioned at or behind the plane of the horizontal roller surfaces. This nesting arrangement reduces the overall profile while the vertical rollers still extend sufficiently to guide the cable without creating pinching hazards.
Solution Approach 2:
The recessed portion is specifically designed with dimensions that allow the vertical rollers to be positioned optimally - far enough back to reduce profile but far enough forward to maintain cable guidance. The local geometry of the recessed space creates the ideal conditions for preventing cable pinching while achieving compact dimensions.
3Length of moving object
If a hawse fairlead is used instead of a roller fairlead, then the profile is compact, but cable friction increases and cable damage can occur
Solution Approach 1:
The patent merges the advantages of both hawse and roller fairleads by combining the compact profile of a hawse fairlead with the cable protection of roller fairleads. The recessed vertical rollers provide cable guidance and friction reduction similar to conventional roller fairleads, while the overall compact dimensions match those of a hawse fairlead.
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 solution enhances the approach angle of the vehicle, reduces friction, and prevents cable pinching, allowing for smoother operation and reduced risk of damage during winching operations.
Implementation Method 1
contact between the cable and the slot of the hawse can cause friction which can damage or even snap the cable under certain conditions. Roller fairleads provide an alternative to the hawse fairlead, and typically employ two horizontal rollers and two vertical rollers which guide the cable and rotate in order to reduce friction.
Data Source
AI summary
A fairlead assembly for use with a vehicle-mounted winch and cable, the fairlead assembly is adapted to guide and control the cable as it is spooled in or out by the winch. The fairlead assembly is attached to the vehicle, and comprises a pair of horizontal rollers positioned in parallel and separated by a cable guide space, along with a pair of vertical rollers positioned to the right and left of the cable guide space. The horizontal and vertical rollers control the vertical and horizontal motion of the cable within the cable guide space. The vertical and horizontal rollers may have coplanar central axes, allowing the fairlead assembly to have a reduced profile. The vertical rollers may also each comprise a cable control groove to guide and control the horizontal and vertical motion of the cable when the winch and cable are employed to execute a sideways pull.