Patent Application
20210130144
The present invention describes a compact winch with a motor and gear assembly disposed within the winch drum, reducing the size and clearance profile of the winch while providing a high strength hauling capacity. As well as a compact, simplified, single support level wind system for winch assemblies,
Winches are most often used in commercial and research operations for the hauling, retrieval, or otherwise adjustment of cable tension of heavy loads both on land and in marine environments. Generally, the basic elements of a winch system include a wide spool or winch drum mounted by a frame and rotated by a motor assembly or drive mechanism. The motor assembly connects to the winch drum to drive rotation to reel in or reel out cable wound around the winch drum.
Moreover, winches are often used in locations and settings with limited real estate to place and mount the winch. For example, industrial marine winches are generally attached to the deck of a vessel and are limited to specific regions of the vessel due to size clearances. Many conventional winches are not optimally configured to reside in limited spaces such as the deck of a vessel. Typical winches are configured with the motor assembly and other auxiliary components positioned adjacent to the winch drum, creating a large footprint on the deck. The overall housing for the assembly of the winch often comprises a large protective housing with an additional case for containing the motor assembly to prevent damage from external forces such as water, salt, dust, and other environmental and circumstantial conditions to the electronics. This extra space consumed by the protective winch housing makes it difficult to secure the winch in certain positions or at certain angles on the already limited vessel deck, thereby limiting the effectiveness of the winch.
Furthermore, the conventional housings are also not conducive to motor access as the motor assembly and other components have been fit tightly within the housing and sealed from the outside environment. Maintenance or repair to the motor assembly requires extensive dismantlement of the housing and/or winch assembly, consuming additional time and manpower. Providing easy access to the main motor assembly is a valuable feature especially when maintenance of the winch is necessary at the site of operation.
Prior efforts to integrate the entire winch motor assembly into the winch drum have encountered problems mainly due to the dispersal of heat. It is often difficult to provide a motor with the necessary torque capacity for the hauling purposes while adequately dispersing the heat generated by the enclosed motor assembly which is most often enclosed to protect the motor components from the external environment (e.g., water, salt, dust). While some internal motor designs utilize a completely closed drum filled with oil to surround the motor assembly and diffuse heat, this method precludes access to the motor assembly without complete drainage of the oil and the dismantlement of the winch. Other conventional methods have employed a series of electric fans to blow air through channels to cool the motor assembly, requiring additional components, maintenance, and energy.
Additionally, at the site of operation, more than one size winch is often required to manage the various vehicles or loads as each winch is usually only compatible with one cable type and/or cable length, limiting the weight hauling capacity and depth range of deployment. Few winches are currently available which allow the mounting of a plurality of cable types and lengths particularly both cable wire and synthetic rope.
Winches are hauling or lifting devices that are used to play out, or haul in a length of rope, chain, cable, line, or other type of tension member. Lines used on a winch are gene generically referred herein as “tension members”. Proper wrapping of the line is crucial for proper operation of the winch. Line wrapping is the process of adding wraps of lines (i.e., a “line wrap”) to the winch drum. A line wrap is a single turn of the line around the drum. Line wraps are added consecutively, from one end of the drum to the other. Once complete, a set of line wraps is referred to as a wrap level. A proper wrap level does not have gaps between line wraps and no two line wraps of a single level are on top of or underneath another. In typical winch operation, as tension member is hauled onto the winch drum, the tension member is added in many wrap layers.
Improper wrapping can result in uneven wrap layers, build-up on the drum sides, and ‘diving’, where the tension member from one wrap layer is forced down into the layer below it. Uneven forces are applied to the tension member when improperly wrapped tension member is played out, applying unnecessary and dangerous stresses to the tension member and the attached gear. In the best cases, stress forces can damage the tension member, reducing lifetime, result in tangling that stops tension member movement, or damaging the winch motor. In the worse cases, stress forces can snap a tension member, resulting in equipment loss and life-threatening snap-back towards the winch and winch operator.
Drawbacks in the commonly known level wind systems are, significant. Sheave diverter level winds typically have three structures, two offset supports and a leadscrew. The offset between sheave center and weight-bearing supports introduces a significant moment arm. A moment arm is the length between an axis (e.g., the support) and the force acting on it (e.g., the tension member going through the sheave). The longer the moment arm, the more force that is built up. Moment arms are useful when removing a tight fixture (i.e., with a long-handled wrench), but present a serious problem in the moving, highly stressful environments of a marine winch level wind.
Furthermore, due to their construction, the commonly utilized level wind systems cannot take advantage of benefits of a system situated immediate to the spooling device. Namely, a sheave or guide that moves the tension member onto or off the spool experiences the actual load of the wire as it moves. When weight-bearing is loaded onto a plurality of supports, the load of the wire cannot be easily measured. Common winch apparatuses use a computational method and overall winch assembly weight (including winch drum, motor, and support super structure) to calculate load. A calculated load is significantly prone to error.
Therefore, having a versatile, compact industrial winch with a motor assembly that is accessibly secured within the winch drum and is also capable of mounting to multiple positions on a platform and handling a plurality of hauling needs is greatly advantageous in both the marine and land setting. It is also therefore desirable to reduce the complexity and forces applied to a winch level wind apparatus, while preserving the level wind functionality. An object of the present invention is to overcome the aforementioned problems, and to further improve the functionality of the level winding and winching system.
The invention relates to a compact, low profile winch for hauling and retrieval purposes in a variety of land, offshore, and aquatic applications, particularly in a marine environment including the deployment and retrieval of mooring lines, floats, buoys, underwater vehicles, scientific instruments, or other loads. In one or more embodiments, a lightweight, industrial winch, is discussed herein, generally comprising: a horizontal winch drum for storing cable, rotatable in a forward and reverse direction, further comprising a non-load bearing flange on each axial end; a disengagable motor assembly comprising a motor, a gearbox, and a housing; a drive means; a bearings means; a base; and a quick removal means; wherein the motor assembly is self-centered within the housing, the housing entirely disposed within the winch drum with a gap between the outer face of the housing and the inner face of the winch drum, and the housing is connected to the base; the motor assembly is engaged with the winch drum by means of the drive means at one axial end; the bearing means supports the winch drum, and the bearing means is attached to an axial end of the winch drum and is attached to the base; the motor assembly may be disengaged from the winch drum using the quick removal means without dismantling the entirety of the winch; and the winch is capable of hauling and supporting a heavy load on a cable.
An object of the present invention is to provide an improved level winding system to simplify and reduce the weigh, complexity, and size of the level wind system for winding a tension member about a winch.
Another object of the present invention is providing a level wind system with a single support member, often utilizing a hollow support to reduce complexity of the system. Another object of the present invention is to provide direct tension member metering and load sensing.
This invention features a level wind system for applying a tension member onto a winch, the system including a support, a leadscrew, a guide, a motor, and a shuttle. The motor being connected to the leadscrew and configured to apply a motive force onto the leadscrew. The leadscrew is connected to the shuttle, which is in turn connected to the guide. The shuttle is designed to transfer the motive force from the leadscrew onto the guide. The guide rests on, and is supported by the support, and is configured to (i) move along the support, (ii) receive a tension member, and (iii) transfer any force experienced by the tension member onto the support. The system is further defined by the support being positioned substantially between the leadscrew and the guide.
In some embodiments, the support is at least partially hollow, or has a void in its interior, and the leadscrew is substantially within the support. In some of the preceding embodiments the support further has an opening along its lateral length, allowing the shuttle to connect the leadscrew from within the support to the guide outside the support. In some embodiments, the support shares the same longitudinal axis with the leadscrew. In a set of the preceding embodiments, the guide also shares the same longitudinal axis as the leadscrew and support. In some embodiments, the leadscrew and guide share the same longitudinal axis. In other embodiments, the leadscrew has one longitudinal axis, and the guide and support share a different longitudinal axis.
In some embodiments, the support is divided into two ends on either longitudinal end of the support and these ends are adapted for the system to be mounted onto a winch. In some embodiments, the system further has two flanges, each flange on one longitudinal end of the support and the flanges are adapted to be mounted onto a winch. In some embodiments, the system further includes a controller and a position sensor, where the controller partitions and assigns different regions (i.e., partitions) of the winch drum for different tension members and different operations by the guide.
In one embodiment, the level wind system has no additional supports, and is limited to the single elongate support described above. In some embodiments, the motive force from the motor applied to the leadscrew is rotational, and the leadscrew rotates about its longitudinal axis in response to that motive force.
In some embodiments, the guide further has a first and second portion, the first portion being rigidly connected to the shuttle, and the second portion being moveable about the first portion. In some embodiments, the second portion rotates about the first portion. In additional embodiments, the second portion rotates about the common axis of one of the leadscrew and support. Some embodiments further include a load sensor on or within the first portion of the guide and a controller connected to the load sensor; where the load sensor measures the force experienced by the tension member and applied to the guide, and sends those measurements to the interconnected controller. In some of these embodiments, the load sensor is connected the controller wirelessly, in other embodiments it is connected by a wired-connection.
Some embodiments, the system further includes a metering sensor and a controller, the metering sensor measuring the movement of the second portion, the movement being in response to movement of the tension member, and the metering sensor sends these measurements to the controller.
This invention may also be expressed as a method of winding a tension member about a winch. The method includes the steps of selecting a level wind system including a support, a leadscrew, a guide, a motor, and a shuttle. The motor being connected to the leadscrew and configured to apply a motive force onto the leadscrew. The leadscrew is connected to the shuttle, which is in turn is connected to the guide. The shuttle is designed to transfer the motive force from the leadscrew onto the guide. The guide rests on, and is supported by the support, and is configured to (i) move along the support, (ii) receive a tension member, and (iii) transfer forces experienced by the tension member onto the support. The method includes mounting the level wind system onto a winch, applying a tension member to the guide of the system, and operating the winch to spool the tension member to and from the winch. During operation, the tension member applies a force onto the guide, which is transferred to the support.
In certain embodiments, the method includes the guide further having a first portion, a second portion and a load sensor, where the first portion is fixedly attached to the shuttle, the second portion is movably attached to the first portion and the load sensor being within or on the first portion. The load sensor is adapted to measure the force applied by the tension member onto the guide and directs those measurements to an interconnected controller. In some embodiments, the method includes selecting a system where the support has a longitudinal axis that is shared by the longitudinal axis of the guide. In some embodiments, the method includes selecting a system where the support is substantially hollow and where the leadscrew is substantially within the interior of the support. In some embodiments, the method includes selecting a system where the support shares a longitudinal axis with the leadscrew.
The drawings constitute a part of this specification and include exemplary embodiments of the Compact Winch apparatus, which may be embodied in various forms. It is to be understood that in some instances, various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention. Therefore, the drawings may not be to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements. Embodiments of the present invention are represented in the accompanying drawings, wherein:
The term “tension member” used herein encompasses all types of structures adapted to be spooled by a winch apparatus. Common types and terms such as “line”, “cable”, “rope”, “wire” and “chain” are included as tension members. These terms are typified by a length of approximately cylindrical structure of various make-up. Tension members includes natural and synthetic braded fiber, braded and unbraded metallic wire, multi-layered cables, CTD cables and the like.
The term “drum” as used herein refers to the drum of a winch that accepts a tension member, most often as multiple levels of wrapped tension member. The term drum further includes reels, spools, and other like structures adapted for tension members.
The term “central axis” is used herein to describe the typically longitudinal axis of at least one of the leadscrew, the support member, and the guide. In embodiments where more than one component shares the same central axis (i.e., they are coaxial), the central axis may be referred herein as the “common central axis.” In the currently preferred embodiment, the leadscrew, support member and guide all have a single, common central axis.
The term “load sensor” as used herein generically refers to a mechanism that detects a load, pressure, or other stress placed on or between two components. Load sensors are also commonly referred to as “load pins” or “load cells” and these terms are meant to be interchangeable with load sensor. A load sensor detects the force applied across the sensor, often by strain gauges installed within a small bore through the center of the sensor pin; grooves may be machined into the circumference of the pin to define the shear planes, each plane located between the forces to be measured.
The terms “shuttle” and “connection means” as used herein refer to the mechanism by which the guide interacts with the leadscrew and the leadscrew's force (e.g., rotational force) is translated into motion of the guide. The translated motion moves the guide along the support member, parallel to the leadscrew's central axis. The shuttle is also commonly known as a nut, or split nut, ball nut, or follower.
The term “leadscrew” as used herein refers to the linking mechanism that translates a first motion (i.e., rotation) to a second motion (i.e., linear movement). Most often the linking mechanism is a mechanical linkage, embodied by an assembly of connected bodies to manage forces and movements. In the preferred embodiment, the leadscrew is a threaded, elongated cylinder connected to a motor. Here the word elongated is defined as the common adjective form of the word, meaning slender or longer in one, longitudinal dimension than other dimensions. The term leadscrew encompasses other suitable screw-like and non-screw-like mechanisms. For example, the leadscrew may comprise pneumatic or hydraulic actuators, power screws, or translation screws. Common applications include linear actuators, machine slides (e.g., in machine tools), vices, presses, and jacks.
The term “longitudinal” as used herein refers to the lengthwise dimension of a given component. For example, a longitudinal axis as described herein, is the lengthwise axis of a component, for example the elongate support 102, depicted in
The term “guide” as used herein refers to a diverting mechanism designed to at least partially restrain and to change the direction of a tension member. Most often, the guide receives the tension member from a first direction outside of the system described herein (e.g., a ship's a-frame) and redirects it to the winch drum. The guide moves on an axis parallel to the winch drum's longitudinal axis such that it is positioned to deposit successive portions of a tension member in a level wrap on the winch drum, without creating gaps between tension member wraps, or doubling tension member layers during a single transect between winch drum ends.
The terms “winch” and “winch apparatus” as used herein is defined as any device or mechanical assembly designed to spool or wrap at least one tension member around a rotating drum. Most often winches are used as hauling, lifting or hoisting devices, by attaching a tension member to both the winch and an object to be manipulated.
The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different components or combinations of components similar to the ones described in this document, in conjunction with other present or future technologies.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of platforms, winch components, motors, propulsion means, attachment means, drum bodies, cords, cables, drive means, and other various components. One skilled in the relevant art will recognize, however, that the Compact Winch apparatus may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth for numerous uses. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
Unless defined otherwise, the terminology used herein has the meaning commonly understood by a person skilled in the art to which this invention belongs. As used herein, the following terms have the meanings ascribed to them below, unless otherwise specified.
When a component is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another component, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening components or layers may be present.
In contrast, when a component is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another component, there may be no intervening components or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise.
In this disclosure, “comprises,” “comprising,” “containing” and “having” and the like can have the meaning ascribed to them in U.S. Patent law and can mean “includes,” “including,” and the like; “consisting essentially of” or “consists essentially” likewise has the meaning ascribed in U.S. Patent law and the term is open-ended, allowing for the presence of more than that which is recited so long as basic or novel characteristics of that which is recited is not changed by the presence of more than that which is recited, but excludes prior art embodiments.
The present invention describes a lightweight, industrial winch design for use in a plurality of configurations and applications, particularly in the marine environment. While the winch 100 may be used in any suitable capacity, overall, the winch 100 is capable of hauling and supporting a heavy load on a cable such as a vehicle (e.g., an autonomous underwater vehicle (AUV), a remotely operated vehicle (ROV), a human occupied vehicle (HOV), a glider, or the like), a crate, a scientific instrument, deck equipment, moorings, or any other loads which require or may benefit from mechanical lifting, deploying, or supporting. As illustrated in
The winch 100 comprises a motor assembly 130 residing within the housing 128 which disengagably (e.g., removably) slides into an axial end of the winch drum 102. The removable installation of the motor assembly 130 is aided, in some embodiments, by the self-centering feature of the compact housing 128, as shown in
As the depicted embodiment of the present invention uses a winch drum 102 open (i.e., unsealed) on at least one axial end, passive air is allowed to flow through and around the motor assembly 130 to dissipate heat without hindering access to the motor assembly 130 or requiring added cooling components. In additional embodiments, the winch drum 102 is open on one end, while in alternate embodiments it is open on both ends. In yet alternate embodiments, the winch drum 102 has apertures to allow air to pass into it. Furthermore, centering the motor assembly 130 via a housing 128 within the winch drum 102 allows more surface area of the motor assembly 130 to be air-cooled.
As shown in
The overall footprint of the winch 100 is also substantially reduced by the new design, which further expands the possible attachment or operation positions of the winch. This decrease in footprint will have immediate impact in numerous fields of use such as the marine environment where space on a vessel is limited. Conventional winches routinely require large and bulky frames to secure the winch, the motor assembly, and the plurality of other components. The inventive winch 100, as illustrated in
The side clearances of the inventive winch 100 is also condensed by replacing the conventional pillow blocks typically used in winch constructions for rotation with a slimmer bearing means 104, which in preferred embodiments are lightweight rolling element bearings (e.g., slewing bearings) with the strength capacity and force resistance equal or greater than heavy pillow block bearings or similar mountings.
The overall size reduction adds additional advantages which can be seen in various embodiments including lighter weight, easier transportation, simpler installation, and/or cost-effective fabrication. In at least one embodiment, the winch 100 requires no additional housing or framing; however, the winch 100 may be integrated into an existing housing or frame to mount to a desired position on a platform. In many cases, the winch 100 may be easily manually adjusted due to the reduction in weight and/or size.
The winch 100 also includes an improved lightweight level wind mechanism 108 which further reduces the winch's 100 size clearance and weight. Conventional winch constructions spool the cable through the level wind mechanism 108 disposed at a frontal position level with the winch drum 102. At this position, the level wind must bear the weight and torque of the cabled load which most often requires a high strength double beam design. One or more embodiments of the inventive winch 100 reduces the level wind mechanism 108 to a single lightweight beam 112 arranged above the winch drum 102 to remove any substantial torque forces from bearing upon the level wind mechanism 108 during operation. Alternate embodiments may move the single lightweight beam 112 to other suitable non-load bearing positions. The level wind motor assembly 110 is often mounted to the winch base 106 keeping the profile of the winch 100 as compact as possible.
As previously mentioned, the motor assembly 130 may be easily accessed and disengaged from the winch drum 102 via the quick removal means. As various vehicles or loads may be deployed and retrieved with a winch, it is common to have more than one size or type of winch available on site in order to manage all of the loading demands. One feature provided by various embodiments of the inventive model is the ability to utilize a plurality of cables or ropes of various type, length, and/or gauge (e.g., diameter), including synthetic rope, which may be exchanged with the inventive winch 100 to suit a specific load. Likewise, it is an object of at least one embodiment of this invention to provide a winch wherein the winch drum and/or motor assembly may be timely exchanged to one of suitable abilities for the task at hand and limit the individual winches required.
As shown in
Rotation of the winch drum 102 is further facilitated by the bearing means 104 which is generally disposed on one or both adjacent axial ends of the winch drum 102. The winch drum 102 is attached to the rotatable inner surface of the bearing means 104, while the fixed outer surface of the bearing means 104 connects to the winch base 106 (which comprises the winch frame and drum mount). In some instances, the winch base 106 is directly mounted to the platform but is often attached to a turntable 116 which is attached to the platform.
The system comprises additional components such as the level wind mechanism 108 which is attached to the winch base 106 and in contact with the cable being wound about the winch drum 102. The level wind mechanism 108 is powered by the level wind motor assembly 110 to drive rotation of the lead screw 122 and screw nut 120 which is attached to the carriage 118 engaged with the sheave 114. The cable wound about the winch drum 102 passes over the sheave 114 to connect to the vehicle, heavy load, or other rigging for deployment/retrieval.
Another advantageous aspect of the present embodiment is the redesigned portable controller to provide remote operation around the platform. The motor assembly 130 is connected to a power source and is regulated by the controller. The controller may plug into a suitable terminal wherein the terminal is appropriately connected to the motor assembly 130 to signal control of motor speed and rotation direction.
The winch 100 comprises a horizontal winch drum 102 for storing cable and withstanding distortion under applied torque and tension forces. As illustrated in
The winch drum 102 is generally a horizontal cylindrical shape open (i.e., unsealed, accessible, exposed, or at least partially open) on at least one axial end, preferably open on both of the axial ends (as illustrated in
In conventional winch constructions, the flange is an integral structural member of the winch which bears the torque forces applied during winch operation. In design of the flange, it is general practice to provide a flange at each end of the drum to resist the lateral and torsional forces and crushing cable load during winch operation. The flange of those constructions must be of a diameter and thickness to prevent shearing or deforming under force and maintain uniformity and parallel drum ends which in some cases requires heavy reinforcing webs or trusses to further strengthen the flange. Such reinforcements add more weight and cost to the winch. The present inventive winch 100 shifts the torsional forces off of the flanges 140 and onto the winch drum 102 to lessen the need for reinforced additions and reduce material and weight while providing comparable hauling capacity for industrial purposes.
The flanges 140 are secured (e.g., welded, bolted, adhered, mechanically attached) at each axial end of the winch drum 102 to prevent overspill of cable off of the drum 102. Overspill of the cable occurs when the cable jumps out of its designated position on the winch drum 102 or is not wound directly adjacent to the already laid cable. By replacing the traditional bulky pillow block bearings with the highly reliable and high strength bearing means 104, the winch 100, particularly the winch drum 102, is capable of bearing more force (e.g., heavy load) to reduce the strain on the flanges 140. Thus, the flanges 140 are designed to be non-load bearing in some embodiments which allows for manufacture from a lighter and/or thinner material to further facilitate a lightweight, compact design. For example, conventional winches may require the flanges to be constructed from 3¼″ thick steel whereas the winch 100 may be made of a material less than 3¼″ thickness, be it steel or a lower strength, more cost-effective material. In some embodiments, the flanges 140 are less than ¼ inch, less than ½ inch, less than 1 inch, less than 2 inches, less than 3 inches, or equal or greater than 3¼ inches thick. However, the flanges 140 are preferably constructed from an appropriate material and set of specifications to maintain proper form and resist shearing. The diameter of the flange 140 is most often determined by the diameter of the winch drum 102 and the amount of flange 140 exposed radially past the top layer of the wrapped cable (i.e., freeboard).
In some embodiments, one or more additional flanges 140 is provided at a vertical middle position on the winch drum 102 (e.g., split drum) to allow more than one cable to wrap around the winch drum 102 without entanglement (e.g., interaction).
The winch drum 102 may be any suitable size for the desired application. In general, the winch drum 102 is kept to a compact size to house the motor assembly 130 and to withstand torque and other forces without deforming. However, other considerations for diameter size include the speed of rotation and the cable storage capacity. In some embodiments, the winch drum 102 is the same size as a conventional winch drum. In other embodiments, the drum 102 is larger in diameter than conventional drums. When a larger winch drum 102 is selected, greater torque is generated, and the winch drum 102 rotates at a slower speed in comparison to a smaller diameter winch drum 102. Slower rotation may be beneficial in some cases as the slower speed and reduced number of turns reduces wear and tear on both the cable and the mechanical components of the winch 100 to extend the lifespan. In some embodiments, a larger winch drum 102 is used for the subject invention for the above reasons which may be accommodated by the reduction in winch size by the narrow bearing means 104, the level wind mechanism 108 arrangement, the internally disposed motor assembly 130, and/or a combination of the aforementioned components.
The winch drum 102 is generally constructed from a high strength material and designed to a specific thickness to adequately resist distortion by torque and tension forces applied under load. In conventional winch designs, a level wind is often a structural member of multiple high strength beams to bear a significant portion of the applied forces; however, as many embodiments of the inventive winch 100 utilize the disclosed level wind mechanism 108, the winch drum 102 bears most and in some cases, all of the applied forces. In other embodiments, the winch drum 102 may bear only a portion of the applied forces. Suitable materials are described in more detail below. As discussed herein, the thickness of the winch drum 102 is measured as the distance of material between the inner face of the winch drum 102 to the outer face of the winch drum 102 which can vary depending on the needed weight-bearing capacity. In some embodiments, the winch drum 102 is less than ¼ inch, about ¼ to ½ inch, about ½ to 2 inches, about 2 inches to 5 inches, or greater than 5 inches thick.
In one or more embodiments, the winch drum 102 is substantially smooth or at least grooveless to accommodate different types and sizes of cable and may rely on the level wind mechanism 108 or other suitable method to evenly distribute the cable on the winch drum 102 during operation. In other embodiments, the winch drum 102 is grooved to assist with symmetrical cable loading/winding. The grooves can be cast on the winch drum 102 or machined as separate pieces that are mechanically affixed to the winch drum 102. In various applications of such an embodiment, it may be desired that the grooves be slightly larger than the cable in use to avoid pinching and allow cable to adjust itself to the curvature of the winch drum 102, although this would not be necessary for every embodiment to function.
In yet some alternate embodiments, the winch 100 utilizes a split winch drum 102 for providing one or more cables on the same winch drum 102.
The motor assembly 130, which is disengagable in some embodiments, provides the power and control of rotation to turn the winch drum 102 for extending and retrieving the cable and the attached load. As further depicted, the motor assembly 130 is disposed at least partially.) if not entirely within the housing 128. For example, in alternate embodiments, this may mean that only the gearbox 134 is disposed internally, half of the motor assembly 130 disposed internally, half is disposed internally, three quarters of the motor assembly 130 is disposed internally, or the like. In many embodiments such as the one shown in
The disengagable motor assembly 130 comprises the motor 132, the gearbox 134, the housing 128, a motor brake, and a controller. A feature of the present invention is the flexibility to integrate numerous suitable motor assemblies 130 within the housing 128 which can then be easily removed without the complete dismantlement of the winch 100 through the quick removal means. While most constructions integrate a single motor assembly 130 into the winch drum 102, additional embodiments are envisioned to include multiple motors (e.g., 2, 3, 4, 5, 6, 8, 10 motors or more) within the internal space of the winch drum 102, of the housing 128, or other component. The multiple motors may be arranged in any suitable fashion, but in most cases are evenly distributed (such as radially distributed in some embodiments) to balance weight and torque forces. For example, in embodiments comprising multiple motors, each of the multiple motors may be provided within an individual housing 128 within the winch drum 102 or may be arranged together within a single housing 128 in the winch drum 102.
The motor 132 is generally an electric motor. However, the winch 100 and the motor assembly 130 are readily adaptable to allow different types and sizes of motors and motor components like a gearbox, motor brake, and/or drive means to be utilized. In order to be a “suitable” motor, the motor 132 must be able to provide the necessary torque for the intended use and accommodate the size and weight parameters of the cabled load. In addition to common electric motors, other motors that may be suitable include without limitation synchronous motors, induction motors, AC motors, DC motors, slip ring motors, hydraulic motors, permanent magnet motors, or any motor suitable for integration into a compact region. In a certain embodiment, the motor 132 is a variable speed DC electric motor.
The gearbox 134 transmits the force generated by the motor 132 to a plurality of gears arranged in an assembly which revolve and rotate the drive means 136. The gearbox 134 is generally matched to the motor 132 to mechanically fit and provide adequate rotation of the drive means 136. In many cases, the gearbox 134 is a helical gear assembly engaged with the motor 132 and the drive means 136, although other gears such as planetary gears, worm gears, or the like may be used. In many embodiments, the gearbox 134 is a compact arrangement of gears disposed in a closed housing 128 to protect the gears from environmental factors such as water, salt, or dust. In some constructions, the gearbox 134 is filled with oil or other fluid like lubrication, mineral oil, synthetic oil. In other cases, the gearbox 134 is not filled with fluid or may comprise openings.
The motor assembly 130 includes a motor braking system to slow down, stop, and prevent rotation of the winch drum 102 such as when a load is held in midair or disposed off of the platform or the winch 100 is not in operation. Suitable motor brakes depend on the type of motor 132 in use with the winch 100. In general, the motor brake acts in an On/Off manner, allowing or preventing rotation of the winch drum 102. In some embodiments, the motor brake is used to regulate or limit the speed of the winch 100. Suitable braking systems for the motor assembly 130 include an electrical dynamic brake, a hydraulic brake (which may comprise a wet disc, dry disc, and/or band), electric brake, a fail-safe brake for automatic stop for power interruption), a manual brake, a locking pawl (ratchet) brake, a magnetic brake, or other suitable braking means.
In some embodiments, the motor brake acts upon the motor 132 or other appropriate motor component. In some embodiments, the inner or outer surface of flange 140 provides a surface for a motor brake (i.e., the brake disc) to press against to prevent rotation of the winch drum 102. In other embodiments, the motor brake is fitted to act upon the winch drum 102.
The motor assembly 130 is connected to a power source by a means known to one skilled in the art. In some embodiments, a suitable cable or terminal connects the motor assembly 130 to the power source through a means such as a junction box. The power source may be any suitable means for providing the energy to drive rotation for the winch 100 such as a battery, hydraulic power pack, power generator, but in most cases is a plug-in connection to a nearby outlet.
As illustrated in
In the depicted embodiment, the housing 128 is capable of sliding into the winch drum 102 wherein one end of the housing 128, comprising the motor assembly 130, is disposed within the winch drum 102 with a gap or space between the outer face of the housing 128 and the inner face of the winch drum 102, and the second end of the housing 128 is connected to the winch base 106. The motor assembly 130 is most often self-centered within the housing 128. The self-centering feature of the winch 100 is provided by securely attaching the housing 128 (disposed within the winch drum 102 and comprising the motor assembly 130) to the winch base 106. When the housing 128 is attached in stationary position to the winch base 106, the winch drum 102 and the bearing means 104 are free to move independently relative to the housing 128. In some embodiments, the gap between the outer face of the housing 128 and the inner face of the winch drum 102 may be less than 12 inches, less than 10 inches, less than 8 inches, less than 6 inches, less than 4 inches, less than 2 inches, less than 1 inch, less than 0.5 inch, or less than ¼ inch, while in other embodiments it may be greater.
In at least one embodiment, the housing 128 enters one axial end of the winch drum 102 by sliding through an open portion on the side of the winch base 106 which is aligned with the center of the bearing means 104, as shown in
The motor assembly 130 is disposed within the housing 128 with a space between the inner surface of the housing 128 and the internally disposed motor assembly 130 to allow air to pass by and cool the motor 100 components. The housing 128 incorporates this ventilation to easily exchange the hot air for ambient or cool(er) air. Furthermore, the housing 128 resides in the winch drum 102 evenly disposed from the inner face of the winch drum 102 as to least hinder airflow through the winch drum 102.
In accordance with a feature of this invention, this compact motor assembly housing 128 may be greatly reduced in size and weight from the standard motor housings or cases. In general, the diameter and length of the housing 128 is dependent upon the size of the motor assembly 130, the diameter of the winch drum 102, and/or the desired gap distance between the outer diameter of the housing 128 and the inner face of the winch drum 102. In some embodiments, the gap is less than ¼ inch, less than ½ inch, ½ to 1 inch, 1 inch to 2 inches, 2 inches to 3 inches, 3 to 5 inches, or greater than 5 inches. In other embodiments, there is no gap between the outer face of the housing 128 and the inner face of the winch drum 102. Additionally, the housing 128 facilitates the connection of the motor assembly 130 with the controller and the power source.
The housing 128 is generally cylindrical in shape with an outer diameter less than the inner diameter of the winch drum 102 to center the housing 128 within the winch drum 102. Other shapes, such as a box, may be used as well so long as the motor assembly 130 is capable of being secured and mounted within the winch drum 102. In some embodiments, the housing 128 is a platform (e.g., plank, slab, support, board) which supports the motor assembly 130 within the winch drum 102. Further embodiments provide a platform which slides in and out of the winch drum 102.
The housing 128 is often comprised of a sheet metal but may be any suitable material capable of resisting deformation in cases of excess heat produced from the motor assembly 130. Such materials that have been identified may include, but are not limited to, aluminum, thermoplastics, steel, and stainless steel. Other materials include the disclosed materials below or any material thereof capable of supporting the weight and operation of the motor assembly 130.
In many instances, the housing 128 is open on at least one axial end of the winch drum 102, preferably both axial ends, to provide adequate passive air flow through and around the motor assembly 130 to dissipate heat and allow easy access to the motor assembly 130. The housing 128 centers the motor assembly 130 within the winch drum 102 to allow more surface area of the motor assembly 130 to be cooled. Air flow may be permitted through both ends of the housing 128 or may be restricted to flowing in and out by one end only. For increased air cooling, an air blower or impeller may be installed to provide active air circulation. In some embodiments, air flow is directed through specific channels (e.g., ducts). In other embodiments, the housing 128 is partially closed on one or more ends or is completely enclosed (e.g., waterproof, liquid-tight).
The drive means 136 directly engages the gearbox 134 of the motor assembly 130 and connects to the winch drum 102 to translate the torque and power generated by the motor 132 into rotation of the winch drum 102.
The drive means 136 comprises a drive shaft 139 and a drum engagement means 138. In general, the drive shaft 139 is a mechanical part such as a rod, shaft, bar, element, or connection device capable of connecting the motor assembly 130 (most often the gearbox 134) with the drum engagement means 138. When engaged with the drum engagement means 138, the rotation of the drive shaft 134 transmits to rotation of the winch drum 102. The drum engagement means 138 comprises a suitable connection between the drive shaft 139 and the winch 100 to accommodate rotation of the winch drum 102 by way of the turning of the drive shaft 139 which most often is made by a connection to the winch drum 102 but may be any appropriate portion of the winch 100 including bearing means 104 or external portion of the winch drum 102. In some embodiments, the drum engagement means 138 is engaged with the inner face of the winch drum 102. The drum engagement means 138 may be any suitable connector to cause rotation. Exemplary connectors include a disk like a drive plate, flex plate, flywheel, or web, a mount, a bar, a gear, or the like. In one embodiment, the drum engagement means 138 is a metal drive plate which is attached to the inner face of the winch drum 102.
The drive shaft 139 projects from its engagement with the motor assembly 130 gearbox 134 residing in the housing 128 through the hollow center region of the winch drum 102 to connect to the drum engagement means 138. The drive shaft 139 transmits the movement of the gearbox 134 components (i.e., the gears therein) into rotation of the winch drum 102 wherein the drive shaft 139 is rotated about a longitudinal axis by the turning of the gearbox 134 which thereby turns the drum engagement means 138. During the operation of the winch 100, the drive shaft 139 rotates and turns the drum engagement means 138, rotating the winch drum 102 in the forward or the reverse direction. When the winch 100 is stationary, the drive shaft 139 does not rotate.
The drive shaft 139 may connect to the gearbox by any suitable manner now known to or later discovered by those in the art. Examples of suitable connections include, but are not limited to a universal joint, a jaw coupling, a splined joint, a key joint, a Hirth joint, a prismatic joint, or other attachment to align and complete the distance between the motor assembly 130 and the drum engagement means 138 and translate the relative movement of the gearbox 134 to the axial rotation of the drive shaft 139.
The winch base 106 provides the interface for mounting to the platform (be it the deck of the vessel, truck bed, ground, or other external surface) for secure attachment and support of the winch 100 assembly. The winch drum 102 is mounted across the winch base 106, as shown in
The winch base 106 most often comprises a flat mounting surface, however this portion of the winch base 106 may be any appropriate design or shape (e.g., rectangular, square, free form, round) capable of supporting the winch drum 102 and other components securely to the platform. In some embodiments, the mounting surface comprises cutout regions to reduce weight and consumed space (as shown in
In several embodiments, the winch 100 comprises a low level winch base 106 wherein the low level winch base 106 allows the winch drum 102 to be mounted substantially close (e.g., low) to the platform to which it is mounted. In some embodiments, the low level winch base 106 supports the winch drum 102 with a substantially close distance 141 between the flange 140 and the mounting surface. Said close distance 141 may be less than 12 inches, less than 10 inches, less than 8 inches, less than 6 inches, less than 4 inches, less than 2 inches, or less than 1 inch. In other embodiments, the low level winch base 106 supports the winch drum 102 at a space 142 between the bottom of the winch drum 102 and the mounting surface wherein the space 142 is less than 36 inches, less than 30 inches, less than 24 inches, less than 18 inches, less than 12 inches, less than 10 inches, less than 8 inches, less than 6 inches, or less than 4 inches.
Furthermore, the distance between the mounting surface of the winch base 106 and the platform when the winch 100 is mounted on a turntable 116 may be less than 24 inches, less than 18 inches, less than 12 inches, less than 10 inches, less than 8 inches, less than 6 inches, less than 4 inches, less than 2 inches, or less than 1 inch. Obviously, embodiments may be made at greater distances.
From the mounting surface, two side portions project vertically to support the winch drum 102. Each side portion may comprise a plurality of attachment points for securing other winch 100 components such as the bearing means 104 and/or the level wind mechanism 108 with the attachment means 112. The side portions are generally symmetrical but may individually vary in size and shape.
Depending on the maximum weight rating for the winch 100, the winch base 106 is formed from a high strength material of an appropriate thickness; in some embodiments, the winch base 106 is made from steel or a steel alloy material of a thickness of less or equal to ¼ inch, less than ½ inch, less than 1 inch, 1 to 2 inches, 2 to 4 inches, or in some cases, greater than 4 inches up to 10 inches in thickness. Furthermore, some embodiments include a winch base 106 which has certain portions of the winch base 106 at a select thickness and other portions at a different thickness.
The bearing means 104 is a load-bearing assembly and provides for the rotatable interface between the winch base 106 and the rotatable winch drum 102, allowing the winch drum 102 to move independently of the winch base 106 when the motor assembly 130 provides the means for rotation or when manipulated manually. The bearing means 104 supports the winch drum 102, and reduces the load bearing on the flanges 140.
The bearing means 104 is generally a bearing comprising a rotatable surface and a fixed surface. The rotatable surface most often attaches to the winch drum 102, and the fixed surface attaches to the winch base 106; in some embodiments, the rotatable surface attaches to the winch base 106, and the fixed surface attaches to the winch drum 102. In many embodiments, the bearing means 104 is attached to an axial end of the winch drum 102 by the flange 140. In other embodiments, the bearing means 104 is attached to an axial end of the winch drum 102 at another suitable position such as any point along the circumference of the winch drum 102 end.
Suitable bearings generally have a diameter capable of interfacing with the winch base 106 and the winch drum 102, a narrow profile for maintaining a compact winch footprint, and the ability to manage heavy loads or force reliably. Preferred bearings for some embodiments may additionally comprise an open internal diameter suitable for sliding the housing 128 comprising the motor assembly 130 through the center of the bearing into the winch drum 102. Any appropriate rotational means as used by one in the art includes roller bearings, angular contact bearings, ball bearings, spherical bearings, plain bearings, magnetic bearings, thin section bearings, thrust bearings, needle bearings, or the like. In some embodiments, the bearing means 104 uses one or more rolling element bearings such as ball bearings, and in particular slewing bearings. In further embodiments, the bearing means 104 is comprised of single row ball bearings which provide high rotational precision. Other embodiments use other types of ball bearings including two row ball bearings, cross roller bearings, or three row ball bearings as found to be appropriate considering the hauling criteria.
In many embodiments, the winch 100 comprises a bearing means 104 disposed on each axial end of the winch drum 102. In some embodiments, the winch 100 comprises one bearing means 104 disposed on one axial end of the winch drum 102.
The bearing means 104 is attached to the winch base 106 and to the winch drum 102 using bolts to allow secure attachment that can be removed for inspection or maintenance. In some embodiments, the bearing means 104 is secured by the means of welds, rivets, pins, nuts, threaded fasteners, or other means less removable than bolts.
In some embodiments of the winch 100 may also comprise a level wind mechanism 108 to assist the spooling (e.g., winding) of the cable evenly by providing tension to the cable and moving along the revolving axis of the winch drum 102 to carefully lay down the cable during retrieval or to unwind cable during deployment. In the absence of a level wind, the cable is more prone to bunch or cluster in uneven mounds along the length of the winch drum 102, creating tangles in the cable and hindering the hauling activities. In general, the winch 100 may utilize any level wind (e.g., line guide, cable guide, guide, spooler) or other suitable mechanism for laying down or winding cable along any shaped path of the axial length of the winch drum 102. In some embodiments, the winch 100 comprises the improved level wind mechanism 108, shown in
One major aspect of the level wind mechanism 108 is the lightweight design due to the reduction in material. In conventional level wind constructions, a high strength beam assembly, employed at a frontal level position with the winch drum 102, is necessary in order to maintain cable organization under the torsional forces applied by the cable under load. The improved level wind mechanism 108 is reduced from two high strength bars down to a single lightweight beam 112, as shown in
The level wind mechanism 108 comprises a sheave 114, a carriage 118, a screw nut 120, a lead screw 122, a beam 124, a level wind motor assembly 110, and a level wind frame 126. As illustrated in
The sliding motion of the carriage 118 and attached assembly is provided by the level wind motor assembly 110 rotating the guide beam 124. The level wind motor assembly 110 is often powered by an electric motor but may be any motor or any motive force including a DC electric motor, AC motor, hydraulic motor, manual crank, gear drive, chain drive, belt drive, hydraulic drive, winch drive, electric drive, etc. known in the art. Rotation of the guide beam 124 revolves the lead screw 122, resulting in the axial movement of the carriage 118 and sheave 114 assembly along the length of the winch drum 102.
The level wind mechanism 108 is typically comprised of metal or mechanical grade plastic but may also be constructed from other suitable materials or composites. Furthermore, the level wind components may be formed of any shape and size such as the sheave 114 to accommodate various cable types. In some embodiments, one or more of the components of the level wind mechanism 108 is coated in a protective coating (such as one described below) for increased resistance to the environment.
The level wind mechanism 108 may be operated by the controller or by a separate means of operation. Additional sensors may be added to the level wind mechanism 108 to assist guidance of the sheave 114 and/or cable such as a sheave sensor (e.g., motion sensor) for monitoring upward and downward motion in a marine setting, load sensors for cable tension control, or the like.
The controller controls the various operations of the winch 100 by regulation of the motor assembly 130 which in one or more embodiments may include on or more of the following: activation of rotation, stopping of rotation, forward or reverse rotation direction, speed of rotation, and other functions. In some embodiments, the controller is engaged with the winch 100 power supply and provides a signal(s) to the motor assembly 130 to activate the motor 132 and provides the motor assembly 130 with power to rotate the winch drum 102 in the desired direction to raise or lower the cabled load. In other embodiments, the controller is engaged with the winch motor assembly 130 by any suitable means.
The controller comprises an operator station and a motor control means, and in some embodiments, an additional remote control device to operate the winch 100 from a separate position on the platform. The controller may comprise a Programmable Logic Controller (PLC), a touch screen, a monitor, a plurality of buttons, an emergency stop, etc., although any controller found suitable by one skilled in the art for the operation of the winch 100 may be employed. In some embodiments, the controller is waterproof.
Generally, the operator station transmits signals to the motor control means via a connection to the motor assembly 130 that may be wired or wireless. The operator station is capable of transmitting commands such as start and stop of rotation in either the forward direction and the reverse direction and the speed at which the winch drum 102 turns. The controller may comprise additional features including an emergency stop function or monitoring of parameters such as cable position, cable overspill, cable slack, level wind control, etc.
The controller may be affixed to the winch 100 (“at winch” controller) or may be plugged into the winch 100 (“local” controller) to allow the operator to stand at a nearby location. In some embodiments, the winch 100 is operated by a handheld controller (“remote” controller) either through a wired or wireless (e.g., Bluetooth, optical, acoustic, or other suitable means) connection. In some embodiments, the controller is a portable unit which can be plugged/unplugged into the winch 100.
In some embodiments, additional components are used with the controller such as sensors for cable tension, cable length deployed, cable speed, cable angle, cable slippage, motion (e.g., vertical heave, sideways motion, heave sensor), and other similar or like sensors.
The winch 100 comprises the means to easily access, remove, and exchange the motor assembly 130 and/or drive means 136 disposed within the winch drum 102 via the quick removal means. The quick removal means allows one or more components disposed within the winch drum 102 to be disengaged by any suitable manner without dismantling the entirety (e.g., removing the winch drum 102 from the winch base 106, removing the level wind 108, detaching the winch 100 from the platform or turntable 116, disconnecting the bearing means 104, etc.) of the winch 100. The motor assembly 130 held center by the housing 128 is disengaged and removed by sliding the housing 128 through one axial end of the winch drum 102. In some embodiments, the quick removal means involves detaching the drum engagement means 138 from the winch drum 102, allowing the entire assembly comprising the drive means 136, the motor assembly 130, and the housing 128 to exit the winch drum 102. In other embodiments, the drive shaft 139 disengages the drum engagement means 138 to permit the drive shaft 138, the motor assembly 130, and the housing 128 to be removed from the drum 102. In other embodiments, the drive shaft 139 disengages from the gearbox 134, allowing the gearbox 134, the motor 132, and the housing 128 to exit the winch drum 102. In other embodiments, the motor 132 is disengaged from the gearbox 134, and only the motor 132 and the housing 128 are removed.
In instances where the winch 100 is made for operation in the marine or an otherwise wet environment, the winch 100 is most often fabricated from materials capable to resist corrosion and oxidation while providing the strength and fatigue properties to resist wear and tear as subjected to under the demands of heavy cabled loads.
The winch 100, including components such as the winch drum 102, the winch base 106, the level wind mechanism 108, the housing 128, and other components which bear weight are comprised of one or more high strength structural materials capable of resisting deformation under applied force. Although several types of material may be suitable for construction, the winch 100 components are generally fabricated from metal, preferably steel, stainless steel, steel alloys, titanium, cast iron, copper, mechanical grade plastics like thermoplastics, fiberglass, composite materials, or any combination thereof. In many embodiments, the winch drum 102, the winch base 106, and the housing 128 are manufactured from metal, and more preferably steel, of a suitable thickness and strength for withstanding the forces applied thereto. In some embodiments, some or all of winch 100 components are built using aluminum or aluminum alloy to greatly reduce the weight of the winch 100 and provide a more portable version suitable for lighter hauling tasks.
Various components of the winch, including the winch drum 102, the winch base 106, the attachment means 112, the housing 128, or other suitable parts, may be laminated in a protective coating to increase resistance to corrosion or decay from the surrounding environment. In some embodiments, components of the winch 100 are furnished with a suitable coating such as zinc (e.g., inorganic zinc), chrome plating, paint, epoxies (e.g., ceramic epoxy), polymers (e.g., fluoropolymer, polytetrafluoroethylene (PTFE), polyphenylene sulfide (PPS), ethylene propylene, polyurethane, polyvinylidene fluoride (PVDF), ethylene chlorotrifluoroethylene (ECTFE)), paint (e.g., molybdenum disulfide, phenolic, phosphate) or other coatings known in the art. In other embodiments, metal components of the winch 100 are composed of materials which have been galvanized (e.g., hot-dipped galvanized, electrogalvanized) or chrome plated.
In general, the winch components are assembled and attached using attachment means 112 (as illustrated in
The winch 100 may be adapted to use a plurality of cables or ropes of various materials and breaking strengths depending on the hauling load. Suitable cables or lines include rope, strap, cord, tube, wire, chain. Further examples include but are not limited to wire (e.g., metal, steel, stainless steel, copper, titanium), synthetic rope (e.g., polyester, polyethylene, thermoplastics, polytetrafluoroethylene, and/or nylon ropes), aramid fiber, liquid crystal polymer fiber, Polyethylene terephthalate (PET) fiber, single strand line, multi-strand (e.g., weave) line, fiber optic (e.g., light guide), 0.322″ CTD cable, or any other appropriate cable for use with winches or for hauling purposes. In one embodiment, the winch 100 employs a 3×19 (3 strands, 19 wires per strand) wire rope.
In some cases, the cable is coated or jacketed for additional break resistance against abrasion, salt, water, marine biofouling, or chemical corrosion such as from oxidation. Such protective coatings or treatments include galvanized coating with zinc, a jacket (e.g., braided jacket, plastic jacket, extruded plastic jacket, combination material jacket), lubrication, polyurethane, resin, heat treatment, or any appropriate method to minimize wear and tensile fatigue.
Any length of cable may be used on the winch 100 which is dependent on the diameter and length of the winch drum 102 up to 50,000 feet or more. In certain embodiments, the winch 100 comprises 100 feet, up to 500 feet, up to 1,000 feet, 1,000 to 5,000 feet, 5,000 to 10,000 feet, 20,000 feet, 30,000 feet, or more of cable wrapped on the winch drum 102. In some embodiments, the cable is rated for ocean bottom exploration and made of wire rated for about 100,000 psi, 200,000 psi, or 300,000 psi or more.
Cable sizes include less than ⅛ inch, ¼ inch, 7/32 inch, 5/16 inch, ⅜ inch, 5/16 inch, 7/16 inch, ½ inch, ⅝ inch, ¾ inch, ⅞ inch, 1 inch, 1⅛ inches, 1¼ inches, 1 ⅜ inches diameter, 2 inch or more, or any suitable cable capable of winding about the winch drum 102. Cables may be rated for working loads less than 100 lbs, up to 1,000 lbs, up to 2,000 lbs, up to 5,000 lbs, up to 10,000 lbs, and up to 50,000 lbs, to or greater than 100,000 lbs or more.
The winch 100 may be directly mounted to a platform for a fixed position or may be attached to an additional mounting plate or structure such as a turntable 116. An exemplary turntable 116 is found in the U.S. Provisional Patent Application No. 62/090,672 “Portable Turntable and Winch” which allows the winch 100 to be easily manually rotated in any direction or locked to a fixed position. As shown in
The winch 100 is generally operated as follows. The winch 100 is secured to a platform (e.g., deck), directly or to a turntable 116 mounting base by attachment means 112 and mounted to the platform relative to where the winch operation will occur. Upon suitable rigging of the cable and the load for deployment or retrieval, the winch 100 is attached to a power source and in communication with the controller by the operator.
As the operator employs the controller, signals are provided to the motor assembly 130 (or other suitable component) to actuate the winching mechanism for hauling, deploying, supporting etc. (depending on the application), causing the winch drum 102 to rotate in a forward or reverse direction as determined by the operator. Power is provided to the motor assembly 130 which is translated into rotational motion via the drive means 136 coupling the drum engagement means 138 to turn the winch drum 102. The turning of the winch drum 102 winds the cable on or off of the winch drum 102 in a speed-controlled manner which is determined by the controller or by a pre-set speed. After a series of rotations, the attached load is deployed, retrieved, or supported from the platform. The repetitive turning of the winch drum 102 for retrieval winds the cable back onto the winch drum 102 in an evenly distributed manner via the level wind mechanism 108 (or other method), returning the cable back to its storage position.
The level wind mechanism 108 guides the cable onto the winch drum 102 through the sheave 114 to evenly spool the cable about the revolving axis and equally across the axial length of the winch drum 102. The level wind mechanism 108 may also lead the cable from the winch drum 102 over to additional sheaves 114 or other rigging components set up on the platform for the deployment of the attached load.
When the winch 100 in not in operation, the motor brake or similar means prevents the unnecessary rotation of the winch drum 102.
In instances where the winch 100 is desired at another position on the platform, the winch 100 may be uninstalled by removing the single lightweight beam 112 from the winch base 106 or from the turntable 116. The lightweight winch 100 may then be moved and re-bolted to another selected position on the platform. In some embodiments, the winch 100 is repositioned by rotation on the turntable 116.
The terms and expressions employed herein are used as terms and expressions of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof. In addition, having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein may be used without departing from the spirit and scope of the invention. The compositions, components, and functions can be combined in various combinations and permutations, to achieve a desired result. For example, all materials for components (including materials not necessarily previously described) that are suitable for the application are considered within the scope of the invention. Accordingly, the described embodiments are to be considered in all respects as only illustrative and not restrictive. Furthermore, the configurations described herein are intended as illustrative and in no way limiting. Similarly, although physical explanations have been provided for explanatory purposes, there is no intent to be bound by any particular theory or mechanism, or to limit the claims in accordance therewith.
For the purpose of understanding the Compact Winch apparatus, references are made in the text to exemplary embodiments of a Compact Winch, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, materials, designs, and equipment may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized should be or are in any single embodiment. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
Furthermore, the described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the act of hoisting, lifting, lowering, and supporting with a winch may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change to the basic function to which it is related.
The level wind aspect of the present invention may be further improved upon in some embodiments such that it may be applied to other winches than the winch embodiments described herein. The universal level wind system 200 and method of using the same, will be described presently. The level wind system 200 includes a hollow, elongate support member, a leadscrew, a guide substantially supported by the support member and adapted to (i) move along the support member, (ii) accept a tension member and a force from that tension member, and (iii) transfer the tension member's force to the support member, a motor connected to the leadscrew and adapted to apply a motive force to the leadscrew, and a connection means interconnecting the guide and leadscrew, and adapted to move along the leadscrew along the leadscrew's longitudinal axis in response to the motor's applied force.
The inventive system described herein is contrasted by level wind systems that have a plurality of supports, often two, adjacent to the sheave (i.e., the disclosed guide), and linked to the sheave's axis of rotation by a connector (i.e., the disclosed shuttle). The tension member applies force to the sheave, the connector and the plurality of supports. Due to the location and the fact that there is more than one support, the force from the tension member is applied in a two dimensional manner, in the x and y planes. The cumulative force then acts on each support in a rotational manner.
The currently preferred embodiment achieves a reduction of components over currently known level wind systems by sharing a common central axis 201 upon which several of the components are centered (i.e., coaxial). The central axis 201 allow for a single support member 202 to form the structure upon which guide 206 moves along. The central axis 201 can also be thought of as a coaxial axis, where two or more components in the level wind system 200 share a common axis, here the longitudinal axis. Thus, in the currently preferred embodiment, at least guide 206, and support 202 form a concentric or substantially concentric, three dimensional form. In other embodiments central axis 201 is not shared by all components. A second longitudinal axis 203 may be defined that is shared by one or more components. For example, as illustrated in
The present invention provides a guide mechanism 206 that places the tension member TM in proper alignment and condition for placement on the winch drum WD and accepts the forces experienced by the tension member TM to support 202. Unlike guides used in the art, the present guide preferably is coaxial with the support 202, and in some cases the leadscrew 204. The central axis 201 greatly reduces the moment arm MA forces applied to the guide 206 from the tension member TM as the system is operated. Reduced moment arm MA forces reduce the risk of damage to the system during normal operation (e.g., wear and tear) as well as reduce the risk of level wind system 200 and winch W structural damage (e.g., a bent support 202) or collapse in the advent of a tangled or fouled tension member TM. Reduction of the moment arm MA forces further enables the reliance on a single support member 202, as opposed to two or more supports used in the art.
The guide 206 preferably is supported by support 202, and preferably rests substantially on support 202. Typically guide 206 moves along support 202, moving from one end 221 of the support 202 to another end 223, almost always moving end to end of the support 202 multiple times during system operation. The driving force applied to guide 206 will be discussed in more detail below.
In one embodiment of the current invention, the guide 206 is divided into a first portion 220 and second portion 222. The first portion 220 is connected to the shuttle 226 and is substantially supported by (e.g., rests on) on support 202. The first portion 220 receives the lateral force provided from shuttle 226 translated from leadscrew 204, resulting in a lateral movement of the entire guide 206 along support 202. The lateral force is defined as a force in the direction of the central axis 201, substantially parallel to the winch drum WD, and along the length of support 202. The first portion 220 is not rotatable but contains a bearing mechanism 228 on its outer circumferential surface, that is, the surface of the first portion 220 facing or between the first and second portions. Bearing mechanism 228 allows the second portion 222 to freely rotate without movement of the first portion 220 or rotational force transfer to the first portion 220.
The first portion 220, illustrated in
A guide 206 with a single support 202 also enables direct load force measurement of the tension member TM. The load sensor 236, often a load pin known in the art, receives the forces placed on the second portion 222 by the tension member TM. A load sensor 236 located within the guide 206 provides a novel, and much more accurate load measurement ability over the current method of load calculations based on entire winch assembly W weight.
In the currently preferred embodiment, the second portion 222 of guide 206 is configured to rotate freely about the first portion 220, and most often, about the common central axis 201. Rotation ability is provided by bearing 228 between the first and second portions. In the currently preferred embodiment, bearing 228 is a ring bearing as known in the art, preferably a slewing ring bearing. In another embodiment, bearing 228 is a roller bearing. A receptacle 228 accepts and guides the tension member TM through the system 200. In addition, receptacle 228 receives any forces experienced by the tension member TM. The received forces from the tension member TM are transferred to receptacle 108, second portion 222 overall, first portion 220 and finally to support 202.
The receptacle 228 has a groove 230, and at least two side walls 232, 234. Several embodiments of the receptacle 228 are shown in more detail in
Typically, receptacle 228 is about 3 to 8 inches wide. In the currently preferred embodiment, receptacle 228 is 5 inches wide, with a height of 0.5 to 5 inches, preferably 2 inches in height. The shallow nature (larger width than height) of receptacle 228 of the currently preferred embodiment provides system 200 to accept variable diameter tension member TM and attached objects without damage to or fouling of the system 200. Examples of objects attached to a tension member TM that this system 200 is designed to accept without stoppage are the Ocean Observatories Initiative (OOI) Pioneer Offshore Moorings line objects, including shackles, swivels, bushings, and sling links.
The guide 206 of the present invention is further interchangeable. The size of the groove 230, receptacle 228 and overall guide 206 is best suited for a single size, or at best, three sizes of tension member TM. Therefore, it is within the scope of the present invention for a plurality of guides, each guide sized for a size or sizes of tension member TM. To remove a guide 206, the currently preferred embodiment further comprises a guide 206 constructed of at least two sections. Both the first portion 220 and second portion 222 may be separated into sections, typically halves, and a mechanical key is used to lock and unlock the sections. The first portion 220 may be assembled from at least two sections, a first section 221a a second section 221b. Second portion 222 may also be assembled from at least two sections, a third section 223a and a fourth section 223b. A locking mechanism is located on or between sections and adapted to engage the adjacent section. As illustrated in
To remove a removable guide 206, first any sensors located in the guide 206 are disconnected, then a key 250 is inserted into the second portion's locking mechanism 246, the lock 246 is unlocked and the second portion is removed in its two sections. The key (either key 248 or 250) is entered into first portion 220 and that portion is unlocked and removed in a similar manner.
In further embodiments, guide 206 is not sectioned, but is removed by unbolting the drive pin 256 of shuttle 226, allowing guide 206 to move freely independent of leadscrew 204. Any sensors connected to the guide 206 are disconnected, and then a flange, typically the first flange 210 (without motor 224) is next unbolted and removed. The guide 206 is then slid off support 202 and a new guide, adapted for a differently sized tension member TM, is loaded onto the support member 202.
In additional embodiments, the guide 206 and the second portion 222 may comprise differently shaped means. In some embodiments, the second portion 222 is ‘V’ shaped with two rigid structures attached to the first portion 220. In other embodiments, the second portion 222 is selected from the list of at least two horizontal rollers, at least two vertical rollers, at least two cogs, an eyelet, and a pulley.
The invention provides a mechanism to transfer and convert the movement, or force, of leadscrew 204 into lateral movement of the guide; this mechanism is referred herein as the shuttle 226. In the currently preferred embodiment, shuttle 226 comprises a nut 226 that encompasses leadscrew 204 located substantially at guide 206. A drive pin 256 securely, but reversibly fastens nut 226 to hub 225. Shuttle 226 moves laterally along leadscrew 204 as it is actuated (e.g., turned by the motor in the preferred embodiment). In the currently preferred embodiment, shuttle 226 is fitted such that it passes through an opening 258 in the support member 202. In the embodiment illustrated in
An additional feature of the present invention is the direct measurement of the movement of guide 206. Current winch assemblies W use computational calculations to estimate the amount of tension member TM moved, and therefore the amount of time needed to run the winch before the target depth has been reached during deployment (or amount of tension member TM spooled out). Placing a piece of equipment (e.g., a sensor) or other object at a precise depth can be critical for a mission, especially when that location is near a floor (e.g., seafloor or mine shaft bottom). The present invention provides a guide movement sensor 260, referred herein as the metering sensor, typically within or on guide 206. The metering sensor 260 may comprise any suitable sensing mechanism as known in the art.
In the currently preferred embodiment, the metering sensor 260 comprises a hull effect sensor located on or within the first portion 220. Within the second portion 222 is a readout 262, typically set of magnets, preferably 10 to 20 magnets. The magnets may be in any section of the rotating second portion 222, but most often are located underneath groove 230, in the midpoint of the width of guide 206, as illustrated in
The presently described inventive system places forces experienced by tension member TM onto a single support member 202. Furthermore, the support 202 and leadscrew 204 are substantially interior to guide 206. In the currently preferred embodiment, support 202 is a hollow, coaxial (to at least leadscrew 204) cylinder-shaped member. In this arrangement, guide 206 is substantially supported by a single support 202 and that support is sufficient to withstand the forces applied guide 206 by tension member TM. The support member 202 most often comprises a hollow interior, enabling leadscrew 204 to fit inside and optionally, allows it to have the same common central axis 201 (coaxial) of support member 202 and guide 206. In embodiments that support 202 is not coaxial with leadscrew 204, support 202 has a second longitudinal axis 203. This axis may be coaxial with other components of system 200, most often guide 206, as illustrated by
In some embodiments, support member 202 further comprises at least one opening 258 along at least a portion of the support member's longitudinal length. Preferably, opening 258 provides the physical space for shuttle 226 to connect to the first portion 220 of guide 206 to the leadscrew 204. In some embodiments, support 202 further comprises at least one shelf 265, as illustrated in
In other, less preferred embodiments, support 202 is not hollow, and comprises a solid piece, or pieces interior to guide 206. These embodiments may comprise additional support members, as long as they are interior to guide 206. The at least first support member 202a receives the force applied to guide 206 by tension member TM. As illustrated in
In the currently preferred embodiment, support 202 comprises a straight physical piece that is substantially parallel to the winch drum WD. In some embodiments, support 202 and winch drum WD are exactly parallel or almost exactly parallel, such that the distance between the leadscrew and the winch drum does not change along the length of the longitudinal axis.
In the currently preferred embodiment, leadscrew 204 is located substantially within (i.e., interior to) support 202, but leadscrew 204 is not entirely encompassed, an elongate opening 258 is provided to act as a pass through, accepts shuttle 226. This opening 258 exists along the length of support 202. In further embodiments, support 202 only partially encompasses the leadscrew, surrounding leadscrew 204 by at least 25% to 99%.
The level wind system 200 disclosed herein comprises at least one support 202, and the at least one support 202 is interior to guide 206. In additional embodiments, the system further comprises at least a second support member 202b, the additional second support 202b is also interior to the guide, as illustrated in
The present level winding system 200 relies on a leadscrew mechanism 204 to move guide 206, across support 202, most often parallel to the drum WD. The leadscrew 204 may be any suitable mechanism as known in the art. In the currently preferred embodiment, leadscrew 204 is selected from the commercially available screws, for example an acme screw. The leadscrew 204 is connected to motor 224, such that motor 224 applies a force to leadscrew 204. Typically, leadscrew 204 is rotated to move shuttle 226 and guide 206 along support 202. In these cases, motor 224 turns the leadscrew 204. Typically, the selected leadscrew 204 fits at least substantially within the hollow support 202 with enough clearance for the nut 226 to move freely as motor 224 turns the leadscrew 204. In the currently preferred embodiment, leadscrew 204 is configured to rotate about its longitudinal axis. In the currently preferred embodiment, the leadscrew's longitudinal axis is also the common central axis 201. The leadscrew 204 may be coaxial with guide 206, or coaxial with support 202, as illustrated in
In many embodiments, leadscrew 204 is configured to reverse direction of the attached shuttle 226 (and therefore guide 206) by reversing the direction motor 224 is driven. In other embodiments, leadscrew 204 has a cut pattern such that shuttle 226 reverses at each end of the leadscrew because of the cut. In further embodiments, leadscrew 204 comprises a power screw, as known in the art. In still further embodiments, leadscrew 204 comprises a hydraulic or pneumatic actuator, extending and retracting to move shuttle 226. In these embodiments, leadscrew 204 does not rotate and the force applied to shuttle 226 is linear, not rotational.
In some embodiments, the support 202 and leadscrew 204 are combined, as illustrated in
The present invention provides for at least two connections, referred as flanges 210, 221, to support at least support member 202. Typically, the flanges further support leadscrew 204 and motor 224. Additionally, the flanges cap the support 202 and at least one end of the leadscrew 204. The flanges are bolted, or otherwise rigidly fixed to the winch W, such that the level wind system 200 is in a place that allows the tension member TM to be drawn off the drum WD over the guide 206 and to the object AF. In the currently preferred embodiment, flanges 210, 221 position system 200 above the winch assembly W. Preferably, flanges 210, 221 are rigidly and reversibly attached to the winch W, allowing for large forces to be applied to system 200, but still ensuring the ability for removal of system 200. Removal enables maintenance, upkeep or applying the level wind system 200 to another winch W. In other embodiments, system 200 is mounted directly to the winch W without separate structural flanges.
At least one of the flanges is reversibly attached to the winch W, to enable removal of system 200 for maintenance and in some embodiments, interchanging guides. For reversible attachment, the flanges 210, 221 can be thought of in two areas: a level wind attachment area 268 and a winch attachment area 270. The level wind attachment area 268 has support member attachment points 272a-d and leadscrew linker attachment points 274 (e.g., bolts holes for bolts). The leadscrew linker 276 is a physical piece designed to place the leadscrew 204 at the center point of a hollow support 202, and most often comprises a plate with a leadscrew attachment point 278 in the center that accepts the leadscrew 204, and a plurality of linker attachment points 278A-278D that attach onto corresponding points on the flange.
At least one flange, shown as flange 221 in
The winch attachment area 270 has a plurality of winch attachment points 280a-c from the flange to at least the winch W. In the currently preferred embodiment, at least a portion of connection at the winch attachment points 280a-c can be disconnected, allowing the level wind system 200 to swing, or otherwise move out of a first, operating position to at least a second position. The first position represents the normal location for level wind operation. The second position allows access to the winch assembly from the previously obscured approach. An example of a useful second position is during normal winch assembly movement, moving the level wind system 200 to one side to allow for easy crane attachment to the winch assembly. The winch assembly would provide additional attachment points at the second position to secure the level wind system 200 while it is in that position (i.e., to avoid damage while moving the winch).
In some embodiments a load sensor (in addition to or in place of load sensor 234) is placed through one winch attachment point 280, to measuring load placed onto the system 200. An embodiment with a load sensor placed between the flange and the winch may be duplicative of the load sensor in the guide, or may replace the load sensor in the guide, in other words the guide would not contain a load sensor.
The level wind system 200 is actuated by a motive mechanism 224. Most often the motive mechanism, referred for simplicity herein as the motor 224, comprises a direct drive electric motor. The motor 224 may be any motive force, as known in the art suited to apply a force from motor 224 onto leadscrew 204, to actuate leadscrew 204 and move guide 206 across the length of support 202.
In the currently preferred embodiment, motor 224 comprises a separate motor unit from the motor that drives the winch W. Typically, motor 224 and the winch motor have a virtual gear ratio, that is for every turn of the winch drum WD by the winch motor, motor 224 turns leadscrew 204 (and therefore guide 206) a specific distance. As a purely hypothetical example, for every single turn on the winch drum WD, the level wind motor 224 turns ten times, or a 1:10 turn ratio. Thus, controller 264 may command movement of guide 206 according to the turns of the winch drum WD and increase or decrease the amount of movement per winch drum WD turn, to accommodate different tension member TM diameters. For example, when handling 0.322 inch diameter tension member TM, the controller 264 is set to move the guide 0.322 inches for every turn of the winch drum. Likewise, when handling another size of tension member, the guide 206 moves a different distance per drum turn.
The present invention provides for a controlling apparatus to control the system 200, referred herein as the controller 264. In the currently preferred embodiment, controller 264 comprises a winch controlling system as known in the art and controls both the winch apparatus and the level wind system 200. The controller 264 is most often connected to motor 224, the winch motor, the metering sensor 260 and the load sensor 234. Connections are most often wired and connected as known in the art. Load sensor 234 and metering sensor 260 are wired most often through support 202, and the wiring is secured onto a shelf 266, as illustrate in
As illustrated in
In one example of the present level wind system, is combined with a winch and winch turntable as described in U.S. Patent publications 2028/0244507 and 2026/0267747, respectfully. Such a winching system enables simultaneous unspooling of one tension member TM from one drum partition 288, while a second tension member TM is spooled onto the winch W on a second drum partition 290. The unspooling tension member TM leaves the drum WD, is guided through guide 206 and off the winch W (often through a ship A-frame AF). In this example, the tension member TM is unspooled from the winch off the stern of the ship. On the opposite side (towards the bow), a user or machine spools a second tension member onto the turning drum WD, while the first tension member is played out. Most often the second tension member is applied by hand, but a second level wind system can be used to get a perfect winding on the drum WD. The second level wind would be connected to the same controller 264 as the winch W and level wind system 200, and built onto a separate support member, most often independent of the winch.
It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. Other embodiments will occur to those skilled in the art and are within the following claims.
The aforementioned patent applications US 2028/0244507 (and the PCT application it claims priority to, PCT/US26/45466), US 2026/0267747, WO 02/38487, WO 02/06246 and paper by Mortensen et al. Annals of Glaciology 55(68) 2024, pp.99-204 and any other reference cited herein is each incorporated by reference in their entirety.
This is a continuation-in-part (CIP) application that claims priority to and the benefit of U.S. application Ser. No. 15/747,611, entitled Compact Winch, filed on Aug. 5, 2015, now U.S. Pat. No. 10,889,475 issued on Jan. 12, 2021 and U.S. Provisional Patent Application No. 62/201,133. This application incorporates by reference the U.S. patent application Ser. No. 14/963,570, filed on Dec. 9, 2015, the contents of which are hereby incorporated as if set forth herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62201133 | Aug 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15747611 | Jan 2018 | US |
| Child | 17145902 | US |
