Winch Overwinding Sensor Electrical Contact Detection
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Solution Overview
Problem
Existing winch overwinding prevention mechanisms, such as contactless sensors and mechanical pressure switches, face issues with variability in magnetic fields and sensitivity, and can exert additional tension on the rope, leading to a risk of rope breakage due to sudden stops during winding.
Innovation Solution
A winch with a movable overwinding sensor that includes a first and second electrically conducting member, allowing for precise electrical contact to stop winding when the sensor reaches a specific position, utilizing a resilient member to absorb energy and prevent sudden stops, and an integrated control unit for detection and calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a contactless sensor (magnet and Hall sensor) is used for overwinding prevention, then the sensor can detect rope position without mechanical contact, but different magnets and Hall sensors vary in magnetic field strength and sensor sensitivity, leading to measurement inconsistency
Solution Approach 1:
The patent replaces contactless magnetic field detection with direct mechanical electrical contact detection. The overwinding sensor uses electrical conducting members that make physical contact to detect rope position, eliminating variability in magnetic field strength and sensor sensitivity while maintaining contactless operation relative to the rope itself.
Solution Approach 2:
The electrical conducting members of the overwinding sensor serve dual functions: they detect rope position through their own electrical contact capability and simultaneously provide the detection signal without requiring separate sensing components, reducing variability inherent in separate sensor-magnet systems.
2Productivity
If a mechanical pressure switch or actuator is used for overwinding prevention, then the mechanism can provide direct mechanical stopping, but additional tension force is exerted on the rope and inertia of the winch motor prevents immediate stop, creating rope breakage risk
Solution Approach 1:
The patent replaces mechanical pressure switching with electrical contact detection. The electrical conducting members detect overwinding conditions through electrical contact, triggering motor control to stop winding, thereby eliminating the additional mechanical tension and inertia-related rope breakage risks associated with mechanical pressure switches.
Solution Approach 2:
The electrical conducting members act as intermediaries between the rope position detection and the motor control system. They detect rope position through electrical contact and transmit this information to the control unit, which then controls motor stopping, avoiding direct mechanical force transmission to the rope that causes tension and breakage risks.
3Device complexity
If a simple electrical contact mechanism is used for overwinding detection, then the device complexity is reduced, but the ability to provide precise stop and prevent rope slack during transport and unpowered states is limited
Solution Approach 1:
The electrical conducting members of the overwinding sensor perform multiple functions: they detect overwinding conditions through electrical contact, provide precise stop positioning, and prevent rope slack during transport and unpowered states. This multi-functionality achieves reliable rope slack prevention without increasing device complexity, as the same electrical contact mechanism serves all purposes.
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 provides a simple, precise, and safe overwinding prevention mechanism that minimizes the risk of rope breakage by ensuring a soft stop and precise control over winding, even when the winch is transported or unpowered, while maintaining a minimal component count.
Implementation Method 1
an overwinding sensor (106) coupled to the rope (105), wherein the overwinding sensor (106) is moveable between a first position and a second position upon winding and/or unwinding of the rope (105)... a resilient member arranged between the support member and the first electrically conducting member, wherein the resilient member is configured to bias the support member away from the contact member upon winding of the rope
Data Source
AI summary
A winch (100, 200) includes a rope (105), an overwinding sensor (106) coupled to the rope (105) where the overwinding sensor (106) is moveable between a first position and a second position upon winding and/or unwinding of the rope (105). The overwinding sensor (106) includes a first electrically conducting member, a contact member (104) having a second electrically conducting member which is contactable by the first electrically conducting member when the overwinding sensor (106) is in the second position. The second electrically conducting member is not contactable by the first electrically conducting member when the overwinding sensor (106) is in the first position. The winch (100, 200) is configured to stop and/or prevent and/or hamper winding of the rope (105) upon establishment of an electrical contact between the first electrically conducting member and the second electrically conducting member when the overwinding sensor (106) is in the second position.