Abstract:
Provided is a winch apparatus including two exchangeable and interchangeable gears connecting a motor to a drum, the drum being operative to extend and retract a flexible line. By exchanging and interchanging the gears to effect a change in the ratio of the diameters of the first gear to the second gear, the torque and the linear speed of the flexible line are adjustable, permitting the same winch apparatus to move heavier loads at lower speeds, or lighter loads at higher speeds

Description:
FIELD 
       [0001]    The disclosure is generally related to a motorized winch apparatus for positioning a load. More particularly, the disclosure includes a motorized winch apparatus capable of variable torque/speed configurations for manipulating staging equipment. 
       BACKGROUND 
       [0002]    At events such as concerts or theatre productions, winches are commonly used for support, movement and manipulation of performers and various equipment, such as, lighting, sound, scenery and props. Winches are selected based on specifications such as the weight of a load to be moved and the speed at which the load must be moved. Winches with higher torque are needed for heavier loads; however, higher torque winches have lower speeds at which the load may be moved in order to provide the higher torque. Winches with higher speeds are needed for loads which must be moved quickly; however, high speed winches sacrifice torque in order to provide the higher speed. Winches are generally only suitable to provide a particular combination of torque and speed (high torque/low speed, intermediate torque/intermediate speed, or high speed/low torque). As such, additional winches must be kept on hand in the event that a different torque/speed profile is needed. Keeping additional winches on hand is an expensive proposition, as the cost of the spare winches must be considered as well as the cost of maintenance of the spare winches. 
         [0003]    What is needed is a winch apparatus and method of adjusting a winch apparatus that do not suffer from one or more of the above drawbacks in the art. 
       SUMMARY 
       [0004]    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. 
         [0005]    In an exemplary embodiment, a winch apparatus is provided. The winch apparatus includes a gear set and a motor. The gear set includes a first gear having a first diameter and a second gear having a second diameter. The first diameter and the second diameter have a ratio. The motor is operative through a drive belt to provide a torque that translates a length of at least one flexible line at a linear speed. The torque and the linear speed are adjustable by altering the ratio of the first diameter to the second diameter. 
         [0006]    In a further exemplary embodiment, a method for adjusting torque and speed of a winch apparatus is provided. The method includes providing the winch apparatus, removing at least one of the first gear and the second gear from the winch, and replacing the removed first or second gear with a replacement gear. The winch apparatus includes a gear set and a motor. The gear set includes a first gear having a first diameter and a second gear having a second diameter, the first diameter and the second diameter having a ratio and a motor. The motor is operative through a drive belt to provide a torque that translates a length of at least one flexible line at a linear speed. The torque and the linear speed are adjustable by altering the ratio of the first diameter to the second diameter removing at least one of the first gear and the second gear from the winch. The step of replacing the removed first or second gear with the replacement gear alters the ratio of the first diameter to the second diameter. 
         [0007]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a front left perspective view of a winch apparatus according to an exemplary embodiment of the disclosure. 
           [0009]      FIG. 2  is back right perspective view of the winch apparatus of  FIG. 1  according to an exemplary embodiment of the disclosure. 
           [0010]      FIG. 3  shows the drive belt sight window of the winch apparatus of  FIG. 1  according to an exemplary embodiment of the disclosure. 
           [0011]      FIG. 4  shows the exposed gear set and drive belt of the winch apparatus of  FIG. 1  where the ratio of the diameter of the first gear to the diameter of the second gear is about 2:1 according to an exemplary embodiment of the disclosure. 
           [0012]      FIG. 5  shows gear set and drive belt of the winch apparatus of  FIG. 1  where the ratio of the diameter of the first gear to the diameter of the second gear is about 1:1 according to an exemplary embodiment of the disclosure. 
           [0013]      FIG. 6  shows gear set and drive belt of the winch apparatus of  FIG. 1  where the ratio of the diameter of the first gear to the diameter of the second gear is about 1:2 according to an exemplary embodiment of the disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Winches are used to create a variety of effects in the entertainment industry, such as, but not limited to, flying cameras, flying people or objects, lifting people or objects, suspending and moving lighting or other staging equipment. 
         [0015]      FIG. 1  shows a front left perspective view of a winch apparatus  100  according to an exemplary embodiment of the disclosure. A winch frame  102  encloses winch apparatus  100 . Enclosed within winch frame  102  is a motor  104  which causes a drum  106  to rotate to spool or unspool at least one flexible line  108  wrapped about drum  106 . In one embodiment, flexible line  108  is, but not limited to, wire, wire rope, wire cable, filament, string, cord, rope, or combinations thereof. A pinch roller  110  is held in close proximity to drum  106  to ensure that flexible line  108  spools and unspools onto or off of drum  106  smoothly, with the aid of a fairlead  112  moving along a fairlead screw  114 . Flexible line  108  is drawn into or extended from winch frame  102  through a plurality of flexible line pass through locations  116 . During operation of winch apparatus  100 , flexible line  108  passes through fairlead  112  turning at an approximate right angle so as to spool or unspool smoothly onto or off of drum  106 . As flexible line  108  spools or unspools, fairlead screw  114  turns, moving fairlead  112  adjacent to drum  106  such that flexible line  108  is always being drawn onto or off of the drum  106  at near to a right angle, preventing flexible line  108  from slipping or becoming tangled. 
         [0016]      FIG. 2  is a back right perspective view of winch apparatus  100  of  FIG. 1  according to an exemplary embodiment of the disclosure. A gear set cover plate  200  and drive belt sight window  202  form the exterior of one end of winch frame  102 . 
         [0017]      FIG. 3  illustrates drive belt sight window  202  of winch apparatus  100 . A drive belt  300  is visible through drive belt sight window  202 , which permits the angle of the path of drive belt  300  to be observed without removing gear set cover plate  200 . Drive belt  300  connects motor  104  to drum  106 . 
         [0018]      FIG. 4  shows gear set  400  and drive belt  300  of winch apparatus  100  when gear set cover plate  200  is removed from winch frame  102 . Removably attached to motor  104  is a first gear  402 , which is secured by a first retainer bushing  404 . Between motor  104  and first gear  402  is a first washer  406 , and this assemblage is held in place by a plurality of bolts  408 . Drive belt  300  is engaged around first gear  402  and a second gear  410 . Second gear  410  is secured to drum  106  by a second retainer bushing  412 . Between drum  106  and second gear  410  is a second washer  414 , and this assemblage is held in place with a plurality of bolts  408 . Motor  104 , through gear set  400 , operates to rotate drum  106 , thereby extending or withdrawing at least one flexible line  108  from winch apparatus  100 . First gear  402  and second gear  410  are removable by an end-user of winch apparatus  100 . First gear  402  has a first diameter  416 , and second gear  410  has a second diameter  418 . In one embodiment, first gear  402  and second gear  410  may be interchanged with one another or exchanged with an additional gear or gears (not shown). By interchanging or exchanging first gear  402  and second gear  410  with each other or with an additional gear or gears, the ratio of first diameter  416  to second diameter  418  may be altered. 
         [0019]    When first gear  402  and second gear  410  are selected such that first diameter  416  and second diameter  418  are about the same (i.e., the ratio of first diameter  416  to second diameter  418  is about 1:1) (see  FIG. 5 ), an intermediate torque is effected on drum  106  by motor  104 , producing an intermediate linear speed of flexible line  108 . By way of example only, in this exemplary embodiment of the disclosure, with a ratio of first diameter  416  to second diameter  418  of about 1:1, winch apparatus  100  produces a torque operative to move a load weighing in the range of about 250 pounds to about 300 pounds at a linear speed of up to about 5 feet per second to about 10 feet per second. In a preferred embodiment of the disclosure, wherein 3/16 inch wire rope is used for flexible line  108 , and with a ratio of first diameter  416  to second diameter  418  of about 1:1, winch apparatus  100  produces a torque operative to move a load of up to about 300 pounds at a linear speed of up to about 10 feet per second. 
         [0020]    When first gear  402  and second gear  410  are selected such that first diameter  416  is about one-half of second diameter  418  (i.e., the ratio of first diameter  416  to second diameter  418  is about 1:2) (see  FIG. 6 ), a higher torque is effected on drum  106  by motor  104 , producing a lower linear speed of flexible line  108 . By way of example only, in this exemplary embodiment of the disclosure, with a ratio of first diameter  416  to second diameter  418  of about 1:2, winch apparatus  100  produces a torque operative to move a load weighing in the range of about 500 pounds to about 600 pounds at a linear speed of up to about 3 feet per second to about 8 feet per second. In a preferred embodiment of the disclosure, wherein 3/16 inch wire rope is used for flexible line  108 , and with a ratio of first diameter  416  to second diameter  418  of about 1:2, winch apparatus  100  produces a torque operative to move a load of up to about 600 pounds at a linear speed of up to about 5 feet per second wherein a single flexible line  108  is employed, or a load of up to about 540 pounds at a linear speed of up to about 5 feet per second wherein two flexible lines  108  are employed or a single flexible line  108  is employed in a push/pull configuration. 
         [0021]    When first gear  402  and second gear  410  are selected such that first diameter  416  is about double second diameter  418  (i.e., the ratio of first diameter  416  to second diameter  418  is about 2:1) (see  FIG. 4 ), a lower torque is effected on drum  106  by motor  104 , producing a higher linear speed of flexible line  108 . By way of example only, in this exemplary embodiment of the disclosure, with a ratio of first diameter  416  to second diameter  418  of about 2:1, winch apparatus  100  produces a torque operative to move a load weighing in the range of about 100 pounds to about 200 pounds at a linear speed of up to about 15 feet per second to about 25 feet per second. In a preferred embodiment of the disclosure, wherein 3/16 inch wire rope is used for flexible line  108 , and with a ratio of first diameter  416  to second diameter  418  of about 1:2, winch apparatus  100  produces a torque operative to move a load of up to about 150 pounds at a linear speed of up to about 20 feet per second. 
         [0022]    The foregoing embodiments and preferred embodiments present load weights and linear speeds based on motor  104  operating at 100% rated current and speed as well as a safety factor for flexible line  108 . Greater load weights and linear speeds are enabled by improving the material characteristics of flexible line  108  and rated power of motor  104 , as well as by providing greater than 100% of the rated current for motor  104  or exceeding 100% of the rated speed, which is possible for some periods of time. However, exceeding normal operating parameters must be at the discretion of the operator with a view to governing safety regulations. 
         [0023]    By selecting first gear  402  and second gear  410  to result in different ratios of first diameter  416  to second diameter  418 , the torque/speed profile is adjustable to fine-tune winch apparatus  100  for a wide variety of specific needs, including ensuring that the maximum speed is available for moving a particular load with a particular weight. Ratio of diameters between first gear  402  and second gear  410  is varied by substituting either first gear  402  or second gear  410  with a replacement gear having a predetermined diameter. The predetermined diameter is greater than or less than that of the removed first gear  402  or second gear  410 , depending on the desired torque/speed profile. 
         [0024]    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.