Wireless Winch Handle with Strain Gauges for Motor Assist
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Solution Overview
Problem
Existing power assist systems for manually operated winches are bulky, heavy, and limited in speed and force due to small motors integrated into the winch handle, and lack sophisticated control mechanisms to maintain consistent pulling force, leading to variations in winch operation and reduced operator 'feel'.
Innovation Solution
A power assist system featuring a winch handle with sensors and wireless communication that temporarily links to a motor control unit via a connection module below the winch, allowing a single handle to be used across multiple winches, with strain gauges to adjust motor power based on applied force and direction, and safety features to prevent unintended motor activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric motor is integrated into the winch handle itself, then the system is portable and can be moved between winches, but the motor size is limited making the system bulky, heavy, and difficult to move around while limiting speed and force output
Solution Approach 1:
The system divides the power assist components into separate modules: the electric motor and control unit are mounted below the winch, while the winch handle remains a separate, lightweight unit with only sensors and wireless communication components. This segmentation allows the heavy motor to be stationary while the handle stays portable.
Solution Approach 2:
A wireless communication link acts as an intermediary between the handle and motor control unit, transmitting control signals without requiring physical connection. This allows the handle to remain small and portable while still controlling a powerful motor through radio frequency communication.
2Adaptability or versatility
If the electric motor is integrated into the winch handle, then the system can be moved between winches, but the battery size must be small due to limited space, limiting operation time before recharging
Solution Approach 1:
The power system is segmented into a small wireless control unit in the handle and a separate power source for the motor. This allows the handle to remain lightweight and movable while the motor's power supply can be larger and stationary.
Solution Approach 2:
The wireless control handle is designed as a universal unit that can be used with multiple different winches. A single handle can control different motors mounted on different winches, eliminating the need for each winch to have its own integrated motor and battery system.
3Power
If the torque produced by the motor is countered by manual force applied to the handle, then the system can provide motor assist, but the possible amount of motor assist is limited by the operator's ability to apply force
Solution Approach 1:
Strain gauges on the winch handle measure the operator's applied force and provide feedback to the motor control unit. The motor compensates for the operator's effort by producing assistive torque proportional to the measured force, creating a force-matched assistance system that reduces overall operator effort while maintaining control.
Solution Approach 2:
The system replaces the purely mechanical force application with an electromechanical system. Sensors detect mechanical force and convert it to electrical signals, which control an electric motor to provide assistive torque, substituting electronic control for direct mechanical force multiplication.
4Reliability
If a dedicated winch system is built into the boat, then the system provides stable installation, but it lacks flexibility and requires separate controllers for each winch
Solution Approach 1:
The winch handle is designed as a universal control unit that can be used with multiple different winches. The wireless communication system allows a single handle to temporarily and uniquely link to different motor-control unit pairs on different winches, providing both stable motor installation and flexible handle reusability.
Solution Approach 2:
The system transitions from static dedicated connections to dynamic wireless linking. The handle can temporarily and uniquely link to different winches through wireless communication, allowing flexible reconfiguration while maintaining stable motor installations on each winch.
5Ease of operation
If the winch handle is rotated by the operator with varying manual force, then the operator can control the winch, but the variations in pulling force applied to the line increase due to lack of sophisticated control mechanisms
Solution Approach 1:
Strain gauges continuously measure the operator's applied force and provide real-time feedback to the motor control unit. The motor adjusts its output to compensate for variations in operator force, maintaining consistent total pulling force on the line while preserving natural manual control.
Solution Approach 2:
The system dynamically changes the motor's torque output parameter in response to measured operator force variations. By adjusting the motor assist level based on real-time force measurements, the system maintains consistent total pulling force while accommodating natural variations in operator effort.
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
Enables efficient, safe, and consistent operation of winches with reduced operator effort, maintaining consistent pulling force and providing a natural 'feel' for the load, while allowing a single handle to be used across different winches without accidental motor activation.
Implementation Method 1
strain gauges to adjust motor power based on applied force and direction
Implementation Method 2
send wireless control signals through radio transmitting and receiving means to the motor control unit
Data Source
AI summary
A power assist system for a manually operated winch includes a winch having a central winch shaft, an electric motor with a drive shaft and a motor control unit, a winch handle adjusted for manually operating the winch, and a control input device. The electric motor and the drive shaft are connected to the winch and the central winch shaft through a connection module placed below said winch. The winch handle is arranged to temporarily and mechanically connect with an upper end of the central winch shaft to allow manual operation of the winch. The control input device includes one or more electronic unit(s), built into, or mounted onto said winch handle. The control input device is further arranged to send wireless control signals through radio transmitter and receiver to the motor control unit. The wireless control signals are arranged to be temporarily but uniquely linked to the motor control unit to selectively control the winch that the winch handle is temporarily connected to. The control input device is adjusted to send different wireless control signals to the motor control unit depending on the direction the winch is manually operated in. The winch handle is adjusted to generate and/or store the energy needed to operate the control input device.