Winch Lighting and Sensor Integration for Low-Light Inspection
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Solution Overview
Problem
Operators of winches, especially in low-light conditions, face challenges in visually inspecting and managing winch operations due to the lack of external lighting, which can lead to equipment degradation and reduced longevity.
Innovation Solution
Integration of a lighting system with sensors into the winch, including directional and accent lighting sources and sensors like proximity, light, and cameras, that provide visual and audio alerts to the operator about the winch's operational status, such as rope position and degradation, allowing for real-time feedback and corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external lighting is not available in dark conditions, then the operator cannot effectively operate the winch, but adding external lighting equipment increases device complexity and energy consumption
Solution Approach 1:
The patent combines the lighting system with the winch system by integrating lights onto the winch drum and housing. This merging eliminates the need for separate external lighting equipment, reducing overall device complexity while providing necessary illumination for operator visibility during winch operations in dark conditions.
Solution Approach 2:
The winch system is designed to perform multiple functions: it not only performs the primary winching operation but also provides illumination through integrated lights. This multi-functionality allows the winch to serve as both a pulling device and a lighting source, eliminating the need for separate lighting equipment.
2Reliability
If the operator cannot visually inspect the rope and equipment in low-light conditions, then equipment degradation occurs, but continuous monitoring increases energy consumption
Solution Approach 1:
The lighting system operates periodically rather than continuously - lights are activated during winch operations and deactivated when not needed. This periodic operation provides necessary illumination for equipment inspection and monitoring while significantly reducing overall energy consumption compared to continuous operation.
Solution Approach 2:
The system incorporates sensors that detect rope position, drum rotation, and operational status, providing feedback to the control system. This feedback mechanism allows the winch to monitor equipment conditions automatically, reducing the need for constant visual inspection by the operator while maintaining equipment reliability.
3Measurement precision
If sensors are positioned at or near light sources to determine rope and hook position, then measurement precision improves, but device complexity increases
Solution Approach 1:
The sensor system is integrated with the lighting system and winch structure, combining multiple functions into unified assemblies. Sensors are positioned at strategic locations near light sources to detect rope and hook position, and this integration reduces the number of separate components needed, thereby managing device complexity while maintaining measurement precision.
Data Source
AI summary
The present application relates generally to systems and methods for controlling operation of a winch system. As one example, lighting control system of the winch system may include a plurality of lights coupled to the winch, a plurality of sensors coupled to the winch, and a controller including memory with instructions for: adjusting an output of the plurality of lights in response to signals received from the plurality of sensors to indicate an operational status of the winch. In this way, the plurality of lights and plurality of sensors may work together in a synergistic manner to create alerts for an operator of the winch system.