Patent Publication Number: US-2013230378-A1

Title: Winch apparatus

Description:
FIELD 
     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. 
     BACKGROUND 
     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. 
     SUMMARY 
     Aspects of embodiments of the present disclosure include at least the following:
         Zero Fleet Angle Winch—Providing a winch with cables that extend and retract cables with respect to the winch housing at fixed angles relative to the drum head.   Compact high torque drive assembly—Providing an arrangement of a high speed servomotor with integral gear box and multiple drums; equipment spaced more efficiently, yet capable of delivering high torque.   Effective free-wheeling design—Providing a winch assembly that can rotate relative to its base, both freely about a vertical axis and freely about a horizontal axis in response to changes in position of the load element.   Cable tensioning device—Providing a device for maintaining cable tension between the drum and the device, maintaining proper cable alignment along the drum, promoting proper operation of the winch assembly, as well as providing precise control of cable extension/retraction.       

     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view of a winch assembly according to an exemplary embodiment of the disclosure. 
         FIG. 2  shows a top cutaway of the winch housing of  FIG. 1  according to an exemplary embodiment of the disclosure. 
         FIG. 3  shows a side cutaway view of the winch housing of  FIG. 1  according to an exemplary embodiment of the disclosure. 
         FIG. 4  shows a perspective view of the winch housing of  FIG. 1  according to an exemplary embodiment of the disclosure. 
         FIG. 5  shows an exposed perspective view of the winch housing components of  FIG. 4  according to an exemplary embodiment of the disclosure. 
         FIG. 6  shows an exposed top view of the winch housing components of  FIG. 4  according to an exemplary embodiment of the disclosure. 
         FIG. 7  shows an exposed side view of the winch housing components of  FIG. 4  according to an exemplary embodiment of the disclosure. 
         FIG. 8  shows an exposed perspective view of the winch housing components of  FIG. 4  according to an exemplary embodiment of the disclosure. 
         FIG. 9  shows an exposed end view of the winch housing components of  FIG. 4  according to an exemplary embodiment of the disclosure. 
         FIG. 10  shows a perspective view of a winch assembly according to an alternate embodiment of the disclosure. 
         FIG. 11  shows a cross section taken along line  11 - 11  of  FIG. 10  of an embodiment of a rotation device of the disclosure. 
         FIG. 12  shows a perspective view of a securing device of a winch assembly according to an alternate embodiment of the disclosure. 
         FIG. 13  shows a top cutaway of the winch housing of  FIG. 1  according to an exemplary embodiment of the disclosure. 
         FIG. 14  shows a perspective view of the winch housing of  FIG. 1  according to an exemplary embodiment of the disclosure. 
         FIG. 15  shows an exposed perspective view of the winch housing components of  FIG. 4  according to an exemplary embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     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. 
       FIG. 1  shows a perspective view of a winch assembly  100  according to an embodiment. The winch assembly  100  includes a base  110 , a mounting bracket  120 , and a winch housing  140 . Base  110  includes a plurality of securing devices  112  that may be clamps or clips used to connect the base  110  to adjacent support structural (not shown) such as beams, trusses or racks. In one embodiment, securing device  112  may be configured to secure base  110  to support structure that is movable during operation of winch assembly  100 . In another embodiment, securing device  112  may be configured to movably secure base  110  along support structure during operation of winch assembly  100 . In yet another embodiment, securing device  112  may both movably secure base  110  along support structure, as well as be secured to support structure that is movable during operation of winch assembly  100 . In another embodiment, base  110  may be attached to the structure so as to be mounted in a substantially horizontal position, allowing mounting bracket  120  and winch housing  140  to be operatively connected to a portion  116 , such as a panel of base  110 . In another embodiment securing device(s)  112  of base  110  may be operatively connected to support structure in a non-horizontal angle or orientation. 
     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  FIG. 1  prior to installation, a rotation device  118 , such as a bearing assembly or other means for facilitating rotation may be disposed in a central portion of mounting plate  122  located within base  110 . In other embodiments, the rotation device may be located in a non-central portion of the mounting plate. In another embodiment, rotation device  118  may be configured for manual control to restrict freedom of rotation of winch housing  140 , including variable resistance to rotational movement, such as by adjustment of friction between contacting surfaces between base  110  and mounting plate  122 , if desired. A fastener, lever, other suitable mechanical device or arrangement, including an automated control that is controllable such as by controller  114  may be used to achieve the friction adjustment. Rotational device  118  operates such that the mounting bracket  120  may rotate about axis  119  with respect to base  110 . In one embodiment, axis  119  may be placed in a substantially vertical position. In other embodiments, axis  119  may be placed in a non-vertical position. In a further embodiment, rotation device  118  may be a spherical bearing, permitting angular rotation about a central point in two orthogonal directions. For example, as shown in  FIG. 1 , spherical bearing  118  has a center point  106 , permitting rotation about axis  119  and axis  108 , which is orthogonal to axis  119 . In an embodiment that includes spherical bearing  118 , base  110  may incorporate sufficient rotational movement about axes  108 ,  119 , such that winch housing  140  may be affixed to one portion of the spherical bearing, such as a spherical ball portion (not shown) with base  110  affixed to another portion of the spherical bearing, such as a raceway (not shown) configured to rotatably receive the spherical ball portion of the spherical bearing. In other words, in such an embodiment, mounting bracket  120  may not be required. In yet another embodiment, the portions of the spherical bearings affixed to respective base and winch housing may be reversed. 
     As further shown in  FIG. 1 , first arm  124  and second arm  126  of mounting bracket  120  may extend generally outward from the mounting plate  122 . Ends of first arm  124  and second arm  126  opposite base  110  include pivot  130  and pivot  132  respectively, which are pivotably connected to opposing sides of winch housing  140 . Pivots  130  and  132  operate to allow the winch housing  140  to pivot relative to the mounting bracket  120  about an axis  128 , which as shown in  FIG. 1 , is a horizontal axis. Pivot  132  (opposite pivot  130 ) may be configured to allow the winch housing  140  to be free-rotating about axis  128 , except that limit stops may be provided at predetermined maximum angles of rotation. In one embodiment, there may be multiple limit stops, providing adjustment, depending upon the application or special restrictions associated with the supporting structure or performance, or other reasons. Pivot  130  may be configured for manual control to restrict the degree of freedom of rotation of winch housing  140 , including variable resistance to rotational movement, such as by adjustment of friction between contacting surfaces of first arm  124  and winch housing  140 , or by springs (not shown) operatively connected to pivot  130  and may also include limit stops provided at predetermined maximum angles of rotation. As shown in  FIG. 1 , lever  134  is disposed on first arm  124  adjacent to pivot  130 , and may be configured to provide either locking or free operation of pivot  130 . As further shown in  FIG. 1 , adjustment knob  136  is disposed on first arm  124  adjacent to pivot  130 , and may be configured to adjust the degree of freedom of rotational movement available in pivot  130 . Pivots  130 ,  132  in combination with rotation device  118 , provides a substantially free-wheeling arrangement. In one embodiment in which rotation device  118  is a spherical bearing, a substantially free-wheeling arrangement may be achieved without the addition of pivots  130 ,  132 . 
     As shown in  FIGS. 10-11 , an alternate embodiment of winch assembly  200  is now discussed. Winch assembly  200  includes a multiple-axis rotation device  206 , such as a universal joint, including an “X-shaped” frame  208 . As further shown in  FIG. 10 , a first set of opposed ends of frame  208  is rotatably connected to respective pivots  130 ,  132  of arms  124 ,  126 . As yet further shown in  FIG. 10 , a second set of opposed ends of frame  208  is rotatably connected about an axis  210  to respective opposed sides  202 ,  204  of winch housing  240 . In one embodiment, winch assembly  200  may be generally arranged such that rotation axes  119 ,  128 ,  210  are orthogonal or mutually perpendicular to each other. As further shown in  FIG. 11 , rotation device  118  is a cross section taken along line  11 - 11  of  FIG. 10  of an embodiment of a spherical bearing having an outer race  156  and including a concave peripheral surface  157  that corresponds to a convex peripheral surface  159  of an inner sleeve  158 . It is to be understood that base  110  can be configured to support outer race  156  and mounting bracket  120  can be supported by sleeve  158  in one embodiment, although the arrangement could be reversed in another embodiment. In yet another embodiment, rotation device  118  may be a bearing assembly that is not a spherical bearing, and confined to provide rotational movement about a single rotational axis. 
       FIG. 12  shows an exemplary embodiment of securing devices  212  configured for supporting a winch assembly  300 . As further shown in  FIG. 12 , securing devices  212  include a plurality of brackets  216  having a roller  214  to movably contact support structure  220  for supporting winch assembly  300 . Motors  218  may be provided to controllably rotate roller  214  along a surface of support structure  220 , which motors are controllable such as by controller  114  ( FIG. 1 ). In other words, securing devices  212  permit winch assembly  300  to be movable with respect to support structure  220 . 
       FIGS. 2-9  show views of the winch housing  140  according to an embodiment. The winch housing  140  includes gear casing  142 , support frames or plates  144 , primary or first drum  146 , secondary or second drum  148 , cable  150 , servomotor  160 , position encoder  162 , grip pulleys  164 , cable guides  166 , primary brake system (not shown), secondary brake system  180 , and gear assembly  190 . The support frames  144 , such as plates may be aligned generally parallel with each other and may be interconnected at a predetermined spacing by a plurality of support members  145 . 
     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  FIG. 10 . In one embodiment, housing  172  is configured to be connected to a side of winch assembly  240 . Alternately, feed portion  152  may loosely extend exterior of the housing of winch assembly  240 . The load carrying portion  154  may be operatively secured to a load, such as a performer, lights, speakers, scenery or other elements (not shown). As the load changes position relative to the winch assembly  100 , the winch housing  140  may react by rotating or pivoting relative to the base  110 . In one embodiment, in which securing devices  112  are secured to movable structure or permit movement of the winch assembly with respect to supporting structure (e.g., controlled movement along flanges of an I-beam) winch housing  140  may move in combination with rotational or pivoting movement of the winch housing relative to base  110 . 
       FIGS. 13-15  collectively show an exemplary embodiment of a winch assembly  340  including tensioning devices  222 ,  230  for continuously maintaining a predetermined tension or a predetermined tensile force to cable  150  extending between either or both of drums  146 ,  148  and tensioning devices  222 ,  230 , prior to cable  150  extending exterior of the housing of winch assembly  340 . Such continuous maintenance of cable tension is not possible by use of springs associated with wheels  264  throughout the full range of operating conditions of winch assembly  340 . As further shown in  FIGS. 13-15 , tensioning devices  222 ,  230  each include a pair of wheels  264  configured to grippingly receive cable  150  extending between at least one of rotatably movable drums  146 ,  148  associated with extention/retraction of cable  150  with respect to the winch assembly  340 . Wheels  264  are composed of a suitable material having a high coefficient of the static friction between the contacting wheel surface and the surface of the cable. In one embodiment, a coding having a high coefficient of static friction may be applied to the surface of wheels  264 . In one embodiment, wheels  264  have an inwardly cupped peripheral surface, such as is associated with pulleys, permitting improved conformal contact between the wheel surface and the surface of the cable  150 . 
     As shown collectively shown in  FIGS. 13-15 , a motor  224  is operatively connected to a wheel  264  for urging the wheel  264  or pair of wheels  264  to rotatably move as part of tensioning device  222 . A motor  232  is operatively connected to a wheel  264  for urging the wheel  264  or pair of wheels  264  to rotatably move has part of tensioning device  230 . In one embodiment, the arrangement of the pair of wheels  264  achieves mutual contact along a tangent of each of the wheels. In another embodiment, the pair of wheels  264  are maintained in sufficiently close proximity to one another such that when cable  150  is directed to extend between the pair of wheels  264 , opposed portions of the surface of cable  150  are brought into conformal contact with a corresponding surface of each of the pair of wheels  264 . In another embodiment, the arrangement of the pair of wheels  264  is a combination of the two previous embodiments. As a result, activation of motor  224  operatively connected to wheel  264  of tensioning device  222  directly urges rotational movement of the wheel  264 , with the other wheel  264  of the wheel pair being urged to rotate in opposite rotational movement as a result of the conformal contact between one or more of the proximate surfaces of the pair of wheels  264  or the mutual conformal contact between opposed surfaces of the cable and the corresponding surfaces of each of the pair of wheels  264 . In other words, one wheel  264  would be considered the drive wheel, while the other wheel  264  of the pair of wheels would be considered an idler wheel. In one embodiment, each wheel  264  of a pair of wheels can be operatively connected to separate motors  224  and configured to rotate in opposed rotational directions. 
     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  ( FIG. 1 ) controls each of servomotor or motor  160  and motor  224 ,  232 . 
     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.