The disclosure is generally related to a motorized winch for positioning a load. More particularly, the disclosure includes a motorized, winch apparatus for manipulating staging equipment.
When presenting events such as concerts or theatre productions, winches, pulleys and other equipment are commonly used for support, movement and manipulation of performers and various equipment, such as, lighting, sound, scenery and props. Remotely controlled motorized winches are commonly used to rapidly and reliably move performers and equipment during such productions. There currently remains a need in the staging industry to provide a more compact winch assembly that includes a zero fleet angle, high torque, an effective free-wheeling design, and a cable tensioning device that provides smooth movement and manipulation of loads.
What is needed is a method and apparatus that addresses the above-referenced issues and concerns. The present device addresses the issues listed above.
Aspects of embodiments of the present disclosure include at least the following:
An aspect of embodiments of the present disclosure includes a system that provides a winch apparatus for manipulating loads associated with public performances, such as performers and staging equipment.
In an exemplary embodiment, a tensioning device for a winch assembly includes a pair of wheels operatively connected to a winch assembly and is configured to grippingly receive a cable extending therebetween from a rotatably movable drum configured to extend/retract the cable with respect to the winch assembly. The pair of wheels continuously maintains a predetermined tension to the cable extending between the pair of wheels and the drum during operation of the winch assembly.
In a further exemplary embodiment, a winch assembly includes a housing, and a rotatably movable drum configured to extend/retract cable with respect to the housing at a zero fleet angle. A motor rotatably moves the drum, and a controller controls the motor. A tensioning device is operatively connected to the housing and configured to continuously maintain a predetermined tension to cable extending between the tensioning device and the drum during operation of the winch assembly.
In a further exemplary embodiment, a method of supporting a load includes providing a winch assembly having a housing, and a rotatably movable drum configured to extend/retract cable with respect to the housing at a zero fleet angle. The method further includes providing a motor for rotatably moving the drum and a controller for controlling the motor. The method further includes a tensioning device operatively connected to the housing and configured to continuously maintain a predetermined tension to cable extending between the tensioning device and the drum during operation of the winch assembly. The method further includes moving the load supported by the cable extending from the housing.
Another aspect includes providing a winch apparatus with a tensioning device and cable guides to maintain a zero fleet angle of the cable relative to the drums for ease of manipulating staging equipment.
An additional aspect includes a motorized tensioning device for actively maintaining a predetermined cable tension between the drums and the tensioning device.
Still another aspect is to provide a winch apparatus with a high speed servomotor and dual drum arrangement with compact integral gear box that provides high torque.
A further aspect is to provide a winch apparatus with bearing assembly and mounting bracket pivot that enable the winch to rotate horizontally and pivot vertically in response to load element changes in angle and rotation.
It is to be understood that an embodiment of a winch apparatus may include one or more of the above-described aspects.
Further aspects of the method and system are disclosed herein. The features as discussed above, as well as other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description and drawings.
Provided is an apparatus to rapidly extend and retract cable with respect to a winch assembly in order to move or manipulate a load, such as performers or staging equipment associated with a performance. What follows are exemplary embodiments.
Base 110 includes a controller 114 disposed within the base, which controller may include microprocessors or a CPU for control of the winch assembly 100. The controller 114 electrically connects to a cable (not shown) or other source of power and control wiring for operating the winch assembly 100. The cable may be routed from the controller 114 through an opening formed in the mounting bracket 120 and continued through an adjacent portion of the winch housing 140. In one embodiment, controller 114 may also be integrated into or operate as a larger control system that can provide additional control operations or instructions to other components, e.g., lights, sound, video, that may be used in conjunction with a performance.
In one embodiment, the mounting bracket 120 includes a mounting plate 122, a first arm 124 and a second arm 126. Mounting plate 122 is configured to operatively connect portion 116 of base 110. As shown in
As further shown in
As shown in
The primary or first drum 146 and secondary or second drum 148 may be mounted in a parallel stacked relation on opposite sides of the servomotor 160, and may be supported by the inner support frames 144. The drums 146, 148 may be helically grooved to allow for a single layer of the cable 150 to be wound around the drums. Cable 150 may be synthetic or wire material, and is of predetermined strength, as required by the application. The cable 150 may be configured to travel around both drums prior to extending exterior of the winch housing 140 from one end of the winch housing. When winch housing 140 is pivoting in response to the load or load elements, e.g., during positional shifting of the load or load elements, the cable keepers or guides 166 serve to maintain the cable 150 in position, i.e., maintain the cable in contact with the drum grooves, as the cable is traveling around the drums. Grip pulleys 164 may be disposed near one end of the winch housing, and may be spring loaded in order to help maintain tension and position of cable 150 at a fixed angle relative to the drums as the cable is extended or retracted with respect to the winch housing. In other words, grip pulleys 164 permit the winch assembly to operate at a zero fleet angle.
Cable 150 includes a feed, feed line, dead end line, or feed portion 152, or a similar term, and an opposed load line, live end line, load portion or load carrying portion 154, or a similar term. In other words, cable 150 is composed of a single, continuous length of material, with one end defining feed portion 152 and the other end defining load carrying portion 154. The feed portion 152 of cable 150 may be anchored or may be wound about a separate storage spool 170 secured in a housing 172, such as shown in
As shown collectively shown in
Motors 224, 232 are high-speed, low torque motors, such as servomotors, and are configured to continuously maintain a predetermined level of tension on cable 150 between the pair of wheels 264 and the drum, such as first drum 146 and second drum 148 previously discussed, the cable 150 extending between the particular drum and the pair of wheels 264 during operation of winch assembly 340. In one embodiment, at least one of motors 224, 232 is configured to continuously maintain a predetermined level of tension on cable 150 between the pair of wheels 264 and the drum during non-operation of winch assembly 340. In one operating mode of motors 224, 232, the corresponding pair of wheels 264 are urged to rotate in a direction that would extend cable 150 from the housing of winch assembly 340. During operation of winch assembly 340 in which the drum (first drum 146 or second drum 148) is urged to rotate such that cable 150 is retracted into the housing, the high torque motor 160 rotatably driving the drum easily overcomes or overpowers the motor 224, 232 driving the pair of wheels 264, with the counter-torque generated by motor 224, 232 achieving a predetermined tension in the cable 150.
However, during operation of winch assembly 340 in which the drum (first drum 146 or second drum 148) is urged to rotate such that cable 150 is extended from the housing, i.e., the motor 224, 232 and the high torque motor 160 are rotatably driving the cable in the same direction, motor 224, 232 is configured to “attempt to” accelerate more quickly and continuously “attempt” to produce a higher cable feed rate by pair of wheels 264 than achieved by motor 160 rotably driving the drum. In other words, while the high torque motor rotatably driving the drum easily overcomes or overpowers the motor 224, 232, the torque generated by motor 224, 232 as a result of motor 224, 232 attempting to produce a greater cable extention rate between the pair of wheels 264 than the cable extention rate produced by drum motor 160 results in achieving and continuously maintaining a predetermined tension in the cable 150.
It is to be understood that motor 224, 232 can be configured to operate and achieve the results as described above over the entire operating range of drum motor 160.
In summary, the continuous difference in feed direction and/or the continuous difference in speed of the drum motor 160 as compared to that of motor 224, 232 as described above, results in achieving and continuously maintaining a predetermined tension in the cable 150 between the drum and the pair of wheels 264.
In one embodiment, motor 224, 232 continuously maintains a predetermined tension of cable 150 between a drum (first drum 146 or second drum 148) and the pair of wheels 264 during non-operation of winch assembly 340. In one embodiment, motor 224, 232 includes an anti-rotation device 226 that can be actuated immediately prior to non-operation of winch assembly 340 such that motor 224, 232 cannot rotate when winch assembly 340 is non-operational, thereby maintaining a predetermined tension in the cable 150 between the drum and the pair of wheels 264.
In one embodiment, service personnel may be required to work on winch assembly 340. As a result, an override feature, such as manually actuatable override feature 228 can be provided so that cable 150 can be extended/retracted through pairs of wheels 264.
It is to be understood that at least one of the pair of wheels 264 and motor 224, 232 can be positioned interior of a housing of the winch assembly, protecting these components or personnel from inadvertent contact with these components.
It is to be understood that the pair of wheels 264 are configured to maintain cable 150 at a zero fleet angle relative to the drum (first drum 146 or second drum 148).
In one embodiment, controller 114 (
The cable 150 is electrically coupled (not shown) to servomotor 160, and may serve to relay the feedback signal from the position encoder 162. Remote controls (not shown), such as a computer or other user interface, may be operatively connected to the cable to allow for operation of servomotor 160, and to provide control for variable speed, acceleration and deceleration of the motor. A drive shaft 168 on the servomotor 160 is mechanically coupled to the gear assembly 190. The gear assembly 190 may be composed of a set of meshing gears, including helical, spur or other suitable type of gear that may be mechanically coupled to the primary or first drum 146 and secondary or second drum 148, or may be coupled to only one of the two drums. The gear casing 142 may be configured to substantially enclose the gear assembly 190, providing protection and safety. The gear assembly 190 provides a speed reducing mechanism to reduce the rotational speed of the motor to an output speed suitable for driving rotation of the drums.
The primary brake system (not shown) may be configured to retard or prevent rotation of the gear assembly adjacent the servomotor drive shaft 168. In one embodiment, the primary brake system is a double spring applied brake, and remotely controlled. As shown in the figures, the secondary brake system 180 may be operatively connected to the secondary or second drum 148, and operates to retard or prevent rotation of the drum.
It is important to note that the construction and arrangement of the present application as shown in the various exemplary embodiments is illustrative only. Only certain features and embodiments of the invention have been shown and described in the application and many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the invention, or those unrelated to enabling the claimed invention). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.
Number | Date | Country | |
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Parent | 13302536 | Nov 2011 | US |
Child | 13800972 | US |