Design of Winch System with Automated Cable Winding Mechanism

Winch mechanism is employed to wi$n$d/unwind a cable and the resulting tension is used to lift or deploy the load being powered manually or by an automated system. In the past, people have been manually lifting loads, powered, by a crank used to wind up or out a line. Research and technical advancements in winch systems have made the winching process more efficient, and the required time for retrieval and deployment is also reduced. In recent years, technology has evolved exponentially, allowing designers to create better, more compact systems to meet required functional needs. This research study explores the different design considerations of an automated cable winding winch mechanism which includes the selection of motors, gears and gear ratios, shafts, shaft keys, cable diameter, and winding speed. The selection of these was based on design calculations optimized through multiple iterations. The resulting model was analyzed for structural stability under dynamic and static loading. The stress and strain generated under the applied loads were within the yield stress and strain of the design. Results were further verified by developing a scaled-down prototype of the model and testing it by applying various loading conditions. However, the scope of our research does not end here. It contributes to assisting the research on more compact and lighter designs that could be achieved by using variable frequency drive (VFD) technology.