Patent Description:
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 fit tightly within the housing and are 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.

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.

JPS60-<NUM> discloses a winch apparatus according to the pre-characterising portion of claim <NUM>.

<CIT> discloses a winch apparatus capable of hauling and supporting a heavy load on a cable, comprising: a horizontal winch drum for storing cable comprising two axial ends and a flange on at least one axial end; a drive means; a bearing means; and a base. <CIT> discloses a winch comprising a motor and gearbox.

The invention provides a winch apparatus capable of hauling and supporting a heavy load on a cable as specified in claim <NUM>.

Embodiments of the winch apparatus may provide 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.

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 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.

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.

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 mean " includes," "including," and the like; "consisting essentially of" or "consists essentially" likewise 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 invention is a winch apparatus <NUM> capable of hauling and supporting a heavy load from a cable and may comprise a lightweight, industrial winch design for use in a plurality of configurations and applications, particularly in the marine environment. While the winch apparatus <NUM> may be used in any suitable capacity, overall, the winch apparatus <NUM> 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 <FIG>, the winch apparatus <NUM> described herein provides a compact design which involves a disengagable motor assembly comprising a motor assembly <NUM> and housing <NUM>, wherein the motor assembly <NUM> is disposed evenly within the internal space of the winch drum <NUM> by the housing <NUM> connected to and centered by the winch base <NUM> of the winch apparatus <NUM>. Coupled to the winch drum <NUM> is a narrow profile bearing means <NUM> which reduces the side clearance of the overall system while providing a reliable, smooth rotation about the longitudinal axis of the drum and managing the heavy torque cabled load. The bearing means <NUM> is secured to a fixed winch base <NUM> designed to support the winch drum <NUM> and other internal elements using an amount of material for reduced weight and size considerations.

The winch apparatus <NUM> comprises a disengagable motor assembly comprising a motor assembly <NUM> and the housing <NUM>, the motor assembly <NUM> at least partially residing within the housing <NUM> which disengagably (e.g., removably) slides into an axial end of the winch drum <NUM>. The removable installation of the motor assembly <NUM> is aided, in some embodiments, by the self-centering feature of the compact housing <NUM>, as shown in <FIG>. Another particular feature of this assembly method is the ease of accessibility to the motor assembly <NUM> for replacement or maintenance, an ability which is often made difficult by the bulky frame or inconvenient access points of conventional winches. The motor assembly <NUM> may be removed or at least easily accessed by one side end of the stationary housing <NUM>, as illustrated in the side view of <FIG>.

As the depicted embodiment of the present invention uses a winch drum <NUM> open (i.e., unsealed) on at least one axial end, passive air is allowed to flow through and around the motor assembly <NUM> to dissipate heat without hindering access to the motor assembly <NUM> or requiring added cooling components. In additional embodiments, the winch drum <NUM> is open on one end, while in alternate embodiments it is open on both ends. In yet alternate embodiments, the winch drum <NUM> has apertures to allow air to pass into it. Furthermore, centering the motor assembly <NUM> via a housing <NUM> within the winch drum <NUM> allows more surface area of the motor assembly <NUM> to be air-cooled.

As shown in <FIG>, the integration of the motor assembly <NUM> reduces the overall height profile of the winch apparatus <NUM> unit as compared to a conventional winch which typically disposes its motor assembly in a case adjacent to, or at a raised position around, the winch drum <NUM>. Moreover, the integration of the motor assembly <NUM> into the winch drum <NUM> frees additional area above and around the winch drum <NUM> to permit the rearrangement of the levelwind mechanism <NUM>. The reduction in height clearance also allows the winch apparatus <NUM> to fit and operate within areas of lower clearance previously inaccessible to conventional winch models.

The overall footprint of the winch apparatus <NUM> 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 winch apparatus <NUM>, as illustrated in <FIG>, is largely defined by the size of the winch drum <NUM> when the winch apparatus <NUM> is mounted directly onto a platform by the winch base <NUM>. In various embodiments such as the one as shown in <FIG>, the winch apparatus <NUM> may also be utilized with a low profile turntable <NUM> or other suitable mounting base as would be readily identified by one having ordinary skill in the art in light of this disclosure, which redefines the footprint of the winch apparatus <NUM> to the size of the turntable <NUM>. Even in such embodiments, the winch apparatus <NUM> still consumes less deck space for operation than conventional winch constructions and may also be rotationally adjusted.

The side clearances of the winch apparatus <NUM> are also condensed by replacing the conventional pillow blocks typically used in winch constructions for rotation with a slimmer bearing means <NUM>, 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 apparatus <NUM> requires no additional housing or framing; however, the winch apparatus <NUM> may be integrated into an existing housing or frame to mount to a desired position on a platform. In many cases, the winch <NUM> may be easily manually adjusted due to the reduction in weight and/or size.

The winch apparatus <NUM> also includes an improved lightweight levelwind mechanism <NUM> which further reduces the winch apparatus' <NUM> size clearance and weight. Conventional winch constructions spool the cable through the levelwind mechanism <NUM> disposed at a frontal position level with the winch drum <NUM>. At this position, the levelwind 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 winch apparatus <NUM> reduces the levelwind mechanism <NUM> to a single lightweight beam <NUM> arranged above the winch drum <NUM> to remove any substantial torque forces from bearing upon the levelwind mechanism <NUM> during operation. Alternate embodiments may move the single lightweight beam <NUM> to other suitable non-load bearing positions. The levelwind motor assembly <NUM> is often mounted to the winch base <NUM> keeping the profile of the winch apparatus <NUM> as compact as possible.

As previously mentioned, the motor assembly <NUM> may be easily accessed and disengaged from the winch drum <NUM> 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 winch apparatus <NUM> to suit a specific load. Likewise, it is an object of at least one embodiment of this invention to provide a winch apparatus 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 <FIG> and <FIG>, the motor assembly <NUM> comprises a motor <NUM> and gearbox <NUM> and is disposed within the winch drum <NUM>, wherein the motor assembly <NUM> engages a drive means <NUM> to translate the power generated from the motor <NUM> into rotational force, driving the forward or reverse turning motion of the winch drum <NUM> during operation. At one end, the drive means <NUM> engages the motor assembly <NUM> while at the other end the drive means <NUM> is attached to the drum engagement means <NUM>. The drum engagement means <NUM> connects to a portion of the winch drum <NUM> to provide drum rotation.

Rotation of the winch drum <NUM> is further facilitated by the bearing means <NUM> which is generally disposed on one or both adjacent axial ends of the winch drum <NUM>. The winch drum <NUM> is attached to the rotatable inner surface of the bearing means <NUM>, while the fixed outer surface of the bearing means <NUM> connects to the winch base <NUM> (which comprises the winch frame and drum mount). In some instances, the winch base <NUM> is directly mounted to the platform but is often attached to a turntable <NUM> which is attached to the platform.

The system comprises additional components such as the levelwind mechanism <NUM> which is attached to the winch base <NUM> and in contact with the cable being wound about the winch drum <NUM>. The levelwind mechanism <NUM> is powered by the levelwind motor assembly <NUM> to drive rotation of the lead screw <NUM> and screw nut <NUM> which is attached to the carriage <NUM> engaged with the sheave <NUM>. The cable wound about the winch drum <NUM> passes over the sheave <NUM> 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 <NUM> 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 <NUM> to signal control of motor speed and rotation direction.

The winch apparatus <NUM> comprises a horizontal winch drum <NUM> for storing cable and withstanding distortion under applied torque and tension forces. As illustrated in <FIG>, the winch drum <NUM> holds the motor assembly <NUM>, stores the cable wrapped around the winch drum <NUM> in successive layers, and is rotatable in a forward and/or reverse direction. In order to provide a compact and heavy load-bearing winch, the winch drum <NUM> maintains adequate load-bearing abilities to transfer and manage the load forces off of the flanges <NUM> which are often a weak link in winch design. Thus, the flanges <NUM> may be constructed to be non-load bearing flanges. The cable attaches to the winch drum <NUM> or other portion of the winch apparatus <NUM> and is wound around the longitudinal axis of rotation preferably in an even distribution along the length of the winch drum <NUM>. The winch drum <NUM> may be any suitable drum, reel, spindle, or body to wind and reel out cable for the intended hauling purposes. In some embodiments, the winch drum <NUM> is interchangeable with another winch drum appropriate for the task.

The winch drum <NUM> 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 <FIG>) to further eliminate excess material and to provide air cooling to the motor assembly <NUM> disposed within the winch drum <NUM>. In specific cases where the winch apparatus <NUM> may be submerged, heavily splashed with fluid, or exposed to damaging environmental conditions, the winch drum <NUM> is partially sealed or completely sealed. Disposed on at least one and preferably each axial end of the winch drum <NUM> is a flange <NUM>.

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 winch apparatus <NUM> shifts the torsional forces off of the flanges <NUM> and onto the winch drum <NUM> to lessen the need for reinforced additions and reduce material and weight while providing comparable hauling capacity for industrial purposes.

The flanges <NUM> are secured (e.g., welded, bolted, adhered, mechanically attached) at each axial end of the winch drum <NUM> to prevent overspill of cable off of the drum <NUM>. Overspill of the cable occurs when the cable jumps out of its designated position on the winch drum <NUM> 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 <NUM>, the winch apparatus <NUM>, particularly the winch drum <NUM>, is capable of bearing more force (e.g., heavy load) to reduce the strain on the flanges <NUM>. Thus, the flanges <NUM> 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 <NUM>¼" (approximately <NUM>) thick steel whereas the winch apparatus <NUM> may be made of a material less than <NUM>¼" thickness, be it steel or a lower strength, more cost-effective material. In some embodiments, the flanges <NUM> are less than ¼ inch (approximately <NUM>), less than ½ inch (approximately <NUM>), less than <NUM> inch (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), or equal or greater than 3¼ inches (approximately <NUM>) thick. However, the flanges <NUM> are preferably constructed from an appropriate material and set of specifications to maintain proper form and resist shearing. The diameter of the flange <NUM> is most often determined by the diameter of the winch drum <NUM> and the amount of flange <NUM> exposed radially past the top layer of the wrapped cable (i.e., freeboard).

In some embodiments, one or more additional flanges <NUM> is provided at a vertical middle position on the winch drum <NUM> (e.g., split drum) to allow more than one cable to wrap around the winch drum <NUM> without entanglement (e.g., interaction).

The winch drum <NUM> may be any suitable size for the desired application. In general, the winch drum <NUM> is kept to a compact size to house the motor assembly <NUM> 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 <NUM> is the same size as a conventional winch drum. In other embodiments, the drum <NUM> is larger in diameter than conventional drums. When a larger winch drum <NUM> is selected, greater torque is generated, and the winch drum <NUM> rotates at a slower speed in comparison to a smaller diameter winch drum <NUM>. 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 apparatus <NUM> to extend the lifespan. In some embodiments, a larger winch drum <NUM> is used for the above reasons which may be accommodated by the reduction in winch size by the narrow bearing means <NUM>, the levelwind mechanism <NUM> arrangement, the internally disposed motor assembly <NUM>, and/or a combination of the aforementioned components.

The winch drum <NUM> 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, the levelwind 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 winch apparatus <NUM> utilize the disclosed levelwind mechanism <NUM>, the winch drum <NUM> bears most and in some cases, all of the applied forces. In other embodiments, the winch drum <NUM> 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 <NUM> is measured as the distance of material between the inner face of the winch drum <NUM> to the outer face of the winch drum <NUM> which can vary depending on the needed weightbearing capacity. In some embodiments, the winch drum <NUM> is less than <NUM>/<NUM> inch (approximately <NUM>), about <NUM>/<NUM> to <NUM>/<NUM> inch (approximately <NUM> to <NUM>), about <NUM>/<NUM> to <NUM> inches (approximately <NUM> to <NUM>), about <NUM> inches to <NUM> inches (approximately <NUM> to <NUM>), or greater than <NUM> inches (approximately <NUM>) thick.

In one or more embodiments, the winch drum <NUM> is substantially smooth or at least grooveless to accommodate different types and sizes of cable and may rely on the levelwind mechanism <NUM> or other suitable method to evenly distribute the cable on the winch drum <NUM> during operation. In other embodiments, the winch drum <NUM> is grooved to assist with symmetrical cable loading/winding. The grooves can be cast on the winch drum <NUM> or machined as separate pieces that are mechanically affixed to the winch drum <NUM>. 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 <NUM>, although this would not be necessary for every embodiment to function.

In yet some alternate embodiments, the winch apparatus <NUM> utilizes a split winch drum <NUM> for providing one or more cables on the same winch drum <NUM>.

The motor assembly <NUM> of the disengagable motor assembly provides the power and control of rotation to turn the winch drum <NUM> for extending and retrieving the cable and the attached load. As further depicted, the motor assembly <NUM> is disposed at least partially, if not entirely, within the housing <NUM>. For example, in alternate embodiments, this may mean that only the gearbox <NUM> is disposed internally, half of the motor assembly <NUM> is disposed internally, three quarters of the motor assembly <NUM> is disposed internally, or the like. In many embodiments such as the one shown in <FIG>, the motor assembly <NUM> may be mounted within the housing <NUM> with the motor axis parallel to the winch drum <NUM> axis of rotation. The motor assembly <NUM> is engaged with the winch drum <NUM> by means of the drive means <NUM> at one axial end.

The disengagable motor assembly comprises the motor <NUM>, the gearbox <NUM>, the housing <NUM>, a motor brake, and a controller. A feature of the present invention is the flexibility to integrate numerous suitable motor assemblies <NUM> within the housing <NUM> which can then be easily removed without the complete dismantlement of the winch apparatus <NUM> through the quick removal means. While most constructions integrate a single motor assembly <NUM> into the winch drum <NUM>, additional embodiments are envisioned to include multiple motors (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> motors or more) within the internal space of the winch drum <NUM>, of the housing <NUM>, 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 <NUM> within the winch drum <NUM> or may be arranged together within a single housing <NUM> in the winch drum <NUM>.

The motor <NUM> is generally an electric motor. However, the winch apparatus <NUM> and the motor assembly <NUM> 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 <NUM> 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 <NUM> is a variable speed DC electric motor.

The gearbox <NUM> transmits the force generated by the motor <NUM> to a plurality of gears arranged in an assembly which revolve and rotate the drive means <NUM>. The gearbox <NUM> is generally matched to the motor <NUM> to mechanically fit and provide adequate rotation of the drive means <NUM>. In many cases, the gearbox <NUM> is a helical gear assembly engaged with the motor <NUM> and the drive means <NUM>, although other gears such as planetary gears, worm gears, or the like may be used. In many embodiments, the gearbox <NUM> is a compact arrangement of gears disposed in a closed housing <NUM> to protect the gears from environmental factors such as water, salt, or dust. In some constructions, the gearbox <NUM> is filled with oil or other fluid like lubrication, mineral oil, synthetic oil. In other cases, the gearbox <NUM> is not filled with fluid or may comprise openings.

The motor assembly <NUM> includes a motor braking system to slow down, stop, and prevent rotation of the winch drum <NUM> such as when a load is held in midair or disposed off of the platform or the winch apparatus <NUM> is not in operation. Suitable motor brakes depend on the type of motor <NUM> in use with the winch apparatus <NUM>. In general, the motor brake acts in an On/Off manner, allowing or preventing rotation of the winch drum <NUM>. In some embodiments, the motor brake is used to regulate or limit the speed of the winch apparatus <NUM>. Suitable braking systems for the motor assembly <NUM> include an electrical dynamic brake, a hydraulic brake (which may comprise a wet disc, dry disc, and/or band), electric brake, a failsafe 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 <NUM> or other appropriate motor component. In some embodiments, the inner or outer surface of flange <NUM> provides a surface for a motor brake (i.e., the brake disc) to press against to prevent rotation of the winch drum <NUM>. In other embodiments, the motor brake is fitted to act upon the winch drum <NUM>.

The motor assembly <NUM> 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 <NUM> 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 apparatus <NUM> 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 <FIG>, the housing <NUM> accommodates and secures the motor assembly <NUM> in a steady and immobile manner relative to the rotatable winch drum <NUM>. The motor <NUM> and the gearbox <NUM> are supported within the housing <NUM> wherein the gearbox <NUM> projects through the housing <NUM> to engage the drive means <NUM>. In some embodiments, the motor assembly <NUM> is supported in the housing <NUM> by attaching to a portion of the housing <NUM> which may be to the end of the housing <NUM> disposed in the winch drum <NUM>, to the middle inside of the housing <NUM>, to the end of the housing <NUM> connected to the winch base <NUM>, and/or any other suitable position in or on the housing <NUM>. The housing <NUM> and the motor assembly <NUM> it houses ares supported (e.g., connected, mounted) by the connection to the drum engagement means <NUM> and to the winch base <NUM>.

In the depicted embodiment, the housing <NUM> is capable of sliding into the winch drum <NUM> wherein one end of the housing <NUM> of the disengagable motor assembly is disposed within the winch drum <NUM> with a gap or space between the outer face of the housing <NUM> and the inner face of the winch drum <NUM> and the second end of the housing <NUM> is connected to the winch base <NUM>. The motor assembly <NUM> is self-centered within the housing <NUM>. The self-centering feature of the winch apparatus <NUM> is provided by securely attaching the housing <NUM> (disposed within the winch drum <NUM> and housing the motor assembly <NUM>) to the winch base <NUM>. When the housing <NUM> is attached in stationary position to the winch base <NUM>, the winch drum <NUM> and the bearing means <NUM> are free to move independently relative to the housing <NUM>. In some embodiments, the gap between the outer face of the housing <NUM> and the inner face of the winch drum <NUM> may be less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately203. <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inch (approximately <NUM>), less than <NUM> inch (approximately <NUM>), or less than <NUM>/<NUM> inch (approximately <NUM>), while in other embodiments it may be greater.

The housing <NUM> enters one axial end of the winch drum <NUM> by sliding through an open portion on the side of the winch base <NUM> which is aligned with the center of the bearing means <NUM>, as shown in <FIG>. The housing <NUM> attaches to the outer surface of the base <NUM> (or any other suitable portion of the winch) using attachment means <NUM> (which may comprise nuts bolts, pins, grooves, welds, rivets, threaded fasteners, and/or other suitable fittings) to center the housing <NUM> within the winch drum <NUM>. When the housing <NUM> is disposed within the winch drum <NUM> and secured to the winch base <NUM>, the housing <NUM> is stationary with respect to the rotatable winch drum <NUM>, and the space between the inner face of the winch drum <NUM> and the outer surface of the housing <NUM> does not vary when the winch apparatus <NUM> is in operation. Furthermore, in many embodiments, the outer diameter of the housing <NUM> remains equal distance from the inner face of the winch drum <NUM> along the longitudinal length of the housing <NUM>. In many embodiments, the attachment means <NUM> securing the housing <NUM> to the winch base <NUM> are evenly distributed about the circumference of the housing <NUM>, as shown in <FIG>.

The motor assembly <NUM> is disposed within the housing <NUM> with a space between the inner surface of the housing <NUM> and the internally disposed motor assembly <NUM> to allow air to pass by and cool the motor assembly <NUM> components. The housing <NUM> incorporates this ventilation to easily exchange the hot air for ambient or cool(er) air. Furthermore, the housing <NUM> resides in the winch drum <NUM> evenly disposed from the inner face of the winch drum <NUM> as to least hinder airflow through the winch drum <NUM>.

In accordance with a feature of this invention, this compact motor assembly housing <NUM> may be greatly reduced in size and weight from the standard motor housings or cases. In general, the diameter and length of the housing <NUM> is dependent upon the size of the motor assembly <NUM>, the diameter of the winch drum <NUM>, and/or the desired gap distance between the outer diameter of the housing <NUM> and the inner face of the winch drum <NUM>. In some embodiments, the gap is less than <NUM>/<NUM> inch (approximately <NUM>), less than <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> to <NUM> inch (approximately <NUM> to <NUM>), <NUM> inch to <NUM> inches (approximately <NUM> to <NUM>), <NUM> inches to <NUM> inches (approximately <NUM> to <NUM>), <NUM> to <NUM> inches (approximately <NUM> to <NUM>), or greater than <NUM> inches (approximately mm). In other embodiments, there is no gap between the outer face of the housing <NUM> and the inner face of the winch drum <NUM>. Additionally, the housing <NUM> facilitates the connection of the motor assembly <NUM> with the controller and the power source.

The housing <NUM> is generally cylindrical in shape with an outer diameter less than the inner diameter of the winch drum <NUM> to center the housing <NUM> within the winch drum <NUM>. Other shapes, such as a box, may be used as well so long as the motor assembly <NUM> is capable of being secured and mounted within the winch drum <NUM>. In some embodiments, the housing <NUM> is a platform (e.g., plank, slab, support, board) which supports the motor assembly <NUM> within the winch drum <NUM>. Further embodiments provide a platform which slides in and out of the winch drum <NUM>.

The housing <NUM> 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 <NUM>. 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 <NUM>.

In many instances, the housing <NUM> is open on at least one axial end of the winch drum <NUM>, preferably both axial ends, to provide adequate passive air flow through and around the motor assembly <NUM> to dissipate heat and allow easy access to the motor assembly <NUM>. The housing <NUM> centers the motor assembly <NUM> within the winch drum <NUM> to allow more surface area of the motor assembly <NUM> to be cooled. Air flow may be permitted through both ends of the housing <NUM> 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 <NUM> is partially closed on one or more ends or is completely enclosed (e.g., waterproof, liquid-tight).

The drive means <NUM> directly engages the gearbox <NUM> of the motor assembly <NUM> and connects to the winch drum <NUM> to translate the torque and power generated by the motor <NUM> into rotation of the winch drum <NUM>.

The drive means <NUM> comprises a drive shaft <NUM> and a drum engagement means <NUM>. In general, the drive shaft <NUM> is a mechanical part such as a rod, shaft, bar, element, or connection device capable of connecting the motor assembly <NUM> (most often the gearbox <NUM>) with the drum engagement means <NUM>. When engaged with the drum engagement means <NUM>, the rotation of the drive shaft <NUM> is transmitted to the winch drum <NUM>. The drum engagement means <NUM> comprises a suitable connection between the drive shaft <NUM> and the winch drum <NUM> to provide rotation of the winch drum <NUM> by way of the turning of the drive shaft <NUM>. Specifically, the drum engagement means <NUM> is engaged with the inner face of the winch drum <NUM>. The drum engagement means <NUM> 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 <NUM> is a metal drive plate which is attached to the inner face of the winch drum <NUM>.

The drive shaft <NUM> projects from its engagement with the motor assembly <NUM> gearbox <NUM> residing in the housing <NUM> through the hollow center region of the winch drum <NUM> to connect to the drum engagement means <NUM>. The drive shaft <NUM> transmits the movement of the gearbox <NUM> components (i.e., the gears therein) into rotation of the winch drum <NUM> wherein the drive shaft <NUM> is rotated about a longitudinal axis by the turning of the gearbox <NUM> which thereby turns the drum engagement means <NUM>. During the operation of the winch apparatus <NUM>, the drive shaft <NUM> rotates and turns the drum engagement means <NUM>, rotating the winch drum <NUM> in the forward or the reverse direction. When the winch apparatus <NUM> is stationary, the drive shaft <NUM> does not rotate.

The drive shaft <NUM> 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 j oint, a jaw coupling, a splined j oint, a key j oint, a Hirth j oint, a prismatic joint, or other attachment to align and complete the distance between the motor assembly <NUM> and the drum engagement means <NUM> and translate the relative movement of the gearbox <NUM> to the axial rotation of the drive shaft <NUM>.

The winch base <NUM> 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 apparatus <NUM> assembly. The winch drum <NUM> is mounted across the winch base <NUM>, as shown in <FIG>; the winch base <NUM> is connected to one side of the bearing means <NUM>, and the bearing means <NUM> supports the winch drum <NUM> by attachment to the flanges <NUM>. The winch base <NUM> supports the attachment of the levelwind mechanism <NUM>, allowing the levelwind mechanism <NUM> to transverse the length of the winch drum <NUM>. In many embodiments, the winch base <NUM> is capable of mounting to a turntable <NUM> for rotating the winch apparatus <NUM> about a vertical axis.

The winch base <NUM> most often comprises a flat mounting surface, however this portion of the winch base <NUM> may be any appropriate design or shape (e.g., rectangular, square, free form, round) capable of supporting the winch drum <NUM> 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 <FIG>). The mounting surface may comprise attachment points or holes to attach to a turntable <NUM> or directly to the underlying platform. In other embodiments, the mounting surface is reduced to a size about the footprint of the winch drum <NUM>.

In several embodiments, the winch apparatus <NUM> comprises a low level winch base <NUM> wherein the low level winch base <NUM> allows the winch drum <NUM> to be mounted substantially close (e.g., low) to the platform to which it is mounted. In some embodiments, the low-level winch base <NUM> supports the winch drum <NUM> with a substantially close distance <NUM> between the flange <NUM> and the mounting surface. Said close distance <NUM> may be less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), or less than <NUM> inch (approximately <NUM>). In other embodiments, the low level winch base <NUM> supports the winch drum <NUM> at a space <NUM> between the bottom of the winch drum <NUM> and the mounting surface wherein the space <NUM> is less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), or less than <NUM> inches (approximately <NUM>).

Furthermore, the distance between the mounting surface of the winch base <NUM> and the platform when the winch apparatus <NUM> is mounted on a turntable <NUM> may be less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), less than <NUM> inches (approximately <NUM>), or less than <NUM> inch (approximately <NUM>). Obviously, embodiments may be made at greater distances.

From the mounting surface, two side portions project vertically to support the winch drum <NUM>. Each side portion may comprise a plurality of attachment points for securing other winch apparatus <NUM> components such as the bearing means <NUM> and/or the levelwind mechanism <NUM> with the attachment means <NUM>. The side portions are generally symmetrical, but may individually vary in size and shape.

Depending on the maximum weight rating for the winch apparatus <NUM>, the winch base <NUM> is formed from a high strength material of an appropriate thickness; in some embodiments, the winch base <NUM> is made from steel or a steel alloy material of a thickness of less or equal to ¼ inch (approximately <NUM>), less than ½ inch (approximately <NUM>), less than <NUM> inch (approximately <NUM> ), <NUM> to <NUM> inches (approximately <NUM> to <NUM>), <NUM> to <NUM> inches (approximately <NUM> to <NUM>), or in some cases, greater than <NUM> inches (approximately <NUM>) up to <NUM> inches (approximately <NUM>) in thickness. Furthermore, some embodiments include a winch base <NUM> which has certain portions of the winch base <NUM> at a select thickness and other portions at a different thickness.

The bearing means <NUM> is a load-bearing assembly and provides for the rotatable interface between the winch base <NUM> and the rotatable winch drum <NUM>, allowing the winch drum <NUM> to move independently of the winch base <NUM> when the motor assembly <NUM> provides the means for rotation or when manipulated manually. The bearing means <NUM> supports the winch drum <NUM>, and reduces the load bearing on the flanges <NUM>.

The bearing means <NUM> is generally a bearing comprising a rotatable surface and a fixed surface. The rotatable surface most often attaches to the winch drum <NUM>, and the fixed surface attaches to the winch base <NUM>; in some embodiments, the rotatable surface attaches to the winch base <NUM>, and the fixed surface attaches to the winch drum <NUM>. In many embodiments, the bearing means <NUM> is attached to an axial end of the winch drum <NUM> by the flange <NUM>. In other embodiments, the bearing means <NUM> is attached to an axial end of the winch drum <NUM> at another suitable position such as any point along the circumference of the winch drum <NUM> end.

Suitable bearings generally have a diameter capable of interfacing with the winch base <NUM> and the winch drum <NUM>, 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 <NUM> and the motor assembly <NUM> through the center of the bearing into the winch drum <NUM>. 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 <NUM> uses one or more rolling element bearings such as ball bearings, and in particular slewing bearings. In further embodiments, the bearing means <NUM> 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 apparatus <NUM> comprises a bearing means <NUM> disposed on each axial end of the winch drum <NUM>. In some embodiments, the winch apparatus <NUM> comprises one bearing means <NUM> disposed on one axial end of the winch drum <NUM>.

The bearing means <NUM> is attached to the winch base <NUM> and to the winch drum <NUM> using bolts to allow secure attachment that can be removed for inspection or maintenance. In some embodiments, the bearing means <NUM> 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 apparatus <NUM> may also comprise a levelwind mechanism <NUM> 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 <NUM> to carefully lay down the cable during retrieval or to unwind cable during deployment. In the absence of a levelwind, the cable is more prone to bunch or cluster in uneven mounds along the length of the winch drum <NUM>, creating tangles in the cable and hindering the hauling activities. In general, the winch apparatus <NUM> may utilize any levelwind (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 <NUM>. In some embodiments, the winch apparatus <NUM> comprises the improved levelwind mechanism <NUM>, shown in <FIG>.

One major aspect of the levelwind mechanism <NUM> is the lightweight design due to the reduction in material. In conventional levelwind constructions, a high strength beam assembly, employed at a frontal level position with the winch drum <NUM>, is necessary in order to maintain cable organization under the torsional forces applied by the cable under load. The improved levelwind mechanism <NUM> is reduced from two high strength bars down to a single lightweight beam <NUM>, as shown in <FIG>. The levelwind mechanism <NUM> may be arranged to any appropriate position on the winch apparatus <NUM> to provide reliable cable spooling. In certain embodiments, the levelwind mechanism <NUM> is positioned above the winch drum <NUM> and directs the wind of the cable from above the winch drum <NUM>. In other embodiments, the levelwind mechanism <NUM> is placed in a non-load bearing position on the winch apparatus <NUM>. In another embodiment, the winch apparatus <NUM> does not comprise a levelwind mechanism <NUM> and may use an alternative method for distributing cable.

The levelwind mechanism <NUM> comprises a sheave <NUM>, a carriage <NUM>, a screw nut <NUM>, a lead screw <NUM>, a beam <NUM>, a levelwind motor assembly <NUM>, and a levelwind frame <NUM>. As illustrated in <FIG>, the beam <NUM> extends the length of the winch drum <NUM> and is supported by the levelwind frame <NUM>. The levelwind frame <NUM> may be any structure capable of lending support for the rotating action of the sheave <NUM> and its levelwind motor assembly <NUM>. The sheave <NUM> is usually an open groove guide for the cable to sit in, supported on the carriage <NUM> with the carriage <NUM> disposed on the beam <NUM>. The carriage <NUM>, attached to the lead screw <NUM> by a screw nut <NUM> or other attachment means, is shiftably guided along the length of the beam <NUM> and driven by the lead screw <NUM>.

The sliding motion of the carriage <NUM> and attached assembly is provided by the levelwind motor assembly <NUM> rotating the guide beam <NUM>. The levelwind motor assembly <NUM> 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 <NUM> revolves the lead screw <NUM>, resulting in the axial movement of the carriage <NUM> and sheave <NUM> assembly along the length of the winch drum <NUM>.

The levelwind mechanism <NUM> is typically comprised of metal or mechanical grade plastic, but may also be constructed from other suitable materials or composites. Furthermore, the levelwind components may be formed of any shape and size such as the sheave <NUM> to accommodate various cable types. In some embodiments, one or more of the components of the levelwind mechanism <NUM> is coated in a protective coating (such as one described below) for increased resistance to the environment.

The levelwind mechanism <NUM> may be operated by the controller or by a separate means of operation. Additional sensors may be added to the levelwind mechanism <NUM> to assist guidance of the sheave <NUM> 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 apparatus <NUM> by regulation of the motor assembly <NUM> 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 apparatus <NUM> power supply and provides a signal(s) to the motor assembly <NUM> to activate the motor <NUM> and provides the motor assembly <NUM> with power to rotate the winch drum <NUM> in the desired direction to raise or lower the cabled load. In other embodiments, the controller is engaged with the winch motor assembly <NUM> 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 apparatus <NUM> 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 apparatus <NUM> 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 <NUM> 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 <NUM> turns. The controller may comprise additional features including an emergency stop function or monitoring of parameters such as cable position, cable overspill, cable slack, levelwind control, etc..

The controller may be affixed to the winch apparatus <NUM> ("at winch" controller) or may be plugged into the winch apparatus <NUM> ("local" controller) to allow the operator to stand at a nearby location. In some embodiments, the winch apparatus <NUM> 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 apparatus <NUM>.

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 apparatus <NUM> components are laid out in a special arrangement that provides for the means to easily access, remove, and exchange the motor assembly <NUM> and drive means <NUM> disposed within the winch drum <NUM>. As applied in the instant invention, such an arrangement is termed the "quick removal means. " The quick removal means allows drive means <NUM> and disengageable motor assembly (housing <NUM> and motor assembly <NUM>) disposed within the winch drum <NUM> to be disengaged by any suitable manner without dismantling the entirety (e.g., removing the winch drum <NUM> from the winch base <NUM>, removing the levelwind <NUM>, detaching the winch apparatus <NUM> from the platform or turntable <NUM>, disconnecting the bearing means <NUM>, etc.) of the winch apparatus <NUM>. The quick removal means involves detaching the drum engagement means <NUM> from the winch drum <NUM>, allowing the entire assembly comprising the drive means <NUM>, the motor assembly <NUM> and the housing <NUM> to exit the winch drum <NUM>.

In instances where the winch apparatus <NUM> is made for operation in the marine or an otherwise wet environment, the winch apparatus <NUM> 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 apparatus <NUM>, including components such as the winch drum <NUM>, the winch base <NUM>, the levelwind mechanism <NUM>, the housing <NUM>, 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 apparatus <NUM> 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 <NUM>, the winch base <NUM>, and the housing <NUM> 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 apparatus <NUM> components are built using aluminum or aluminum alloy to greatly reduce the weight of the winch apparatus <NUM> and provide a more portable version suitable for lighter hauling tasks.

Various components of the winch apparatus, including the winch drum <NUM>, the winch base <NUM>, the attachment means <NUM>, the housing <NUM>, 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 apparatus <NUM> 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 apparatus <NUM> are composed of materials which have been galvanized (e.g., hot-dipped galvanized, electrogalvanized) or chrome plated.

In general, the winch apparatus components are assembled and attached using attachment means <NUM> (as illustrated in <FIG>) such as fasteners including but not limited to nuts and bolts, pins, grooves, welds, rivets, threaded fasteners, or other suitable fittings. In some embodiments, such attachments means <NUM> are also coated with a corrosion-resistant coating or galvanized. The size or length of the attachment means <NUM> varies depending on the thickness of the material and washers, if needed, for assembly. In yet other alternate embodiments, certain components may be welded together when they do not require independent motion from each other.

The winch apparatus <NUM> 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), <NUM>" (approximately <NUM>) CTD cable, or any other appropriate cable for use with winches or for hauling purposes. In one embodiment, the winch apparatus <NUM> employs a <NUM> x <NUM> (<NUM> strands, <NUM> 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 apparatus <NUM> which is dependent on the diameter and length of the winch drum <NUM> up to <NUM>,<NUM> feet or more. In certain embodiments, the winch apparatus <NUM> comprises <NUM> feet (approximately <NUM>), up to <NUM> feet (approximately <NUM>), up to <NUM>,<NUM> feet (approximately <NUM>), <NUM>,<NUM> to <NUM>,<NUM> feet (approximately <NUM> to <NUM>), <NUM>,<NUM> to <NUM>,<NUM> feet (approximately <NUM> to <NUM>), <NUM>,<NUM> feet (approximately <NUM>), <NUM>,<NUM> feet (approximately <NUM>) , or more of cable wrapped on the winch drum <NUM>. In some embodiments, the cable is rated for ocean bottom exploration and made of wire rated for about <NUM>,<NUM> psi (approximately <NUM> kN/m<NUM>), <NUM>,000psi (approximately <NUM> kN/m<NUM>), or <NUM>,<NUM> psi (approximately <NUM> kN/m<NUM>)or more.

Cable sizes include less than <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch (approximately <NUM>), <NUM>/<NUM> inch , <NUM>/<NUM> inch (approximately <NUM>), <NUM> inch (approximately <NUM>), <NUM><NUM>/<NUM> inches (approximately <NUM>), <NUM><NUM>/<NUM> inches (approximately <NUM>), <NUM><NUM>/<NUM> inches diameter (approximately <NUM>), <NUM> inch (approximately <NUM>)or more, or any suitable cable capable of winding about the winch drum <NUM>. Cables may be rated for working loads less than <NUM> lbs (approximately <NUM>), up to <NUM>,<NUM> lbs (approximately <NUM>), up to <NUM>,<NUM> lbs (approximately <NUM>. kg), up to <NUM>,<NUM> lbs (approximately <NUM>), up to <NUM>,<NUM> lbs (approximately <NUM> tonne), and up to <NUM>,<NUM> lbs (approximately <NUM> tonne), to or greater than <NUM>,<NUM> lbs (approximately <NUM> tonne) or more.

The winch apparatus <NUM> 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 <NUM>. An exemplary turntable <NUM> is found in the <CIT> "Portable Turntable and Winch" (see <CIT>) which allows the winch apparatus <NUM> to be easily manually rotated in any direction or locked to a fixed position. As shown in <FIG> and <FIG>, the light weight, compact winch apparatus <NUM> is easily mounted on the turntable <NUM> using suitable attachment means <NUM> to provide precise angular position for hauling purposes; the winch apparatus <NUM> and turntable <NUM> can also be easily removed for repositioning to another area on the platform. The winch apparatus <NUM> may be designed for compatibility with a plurality of other mounting plates, structures, or turntables <NUM> known to those skilled in the art.

The winch apparatus <NUM> is generally operated as follows. The winch apparatus <NUM> is secured to a platform (e.g., deck), directly or to a turntable <NUM> mounting base by attachment means <NUM> 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 apparatus <NUM> 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 <NUM> (or other suitable component) to actuate the winching mechanism for hauling, deploying, supporting etc. (depending on the application), causing the winch drum <NUM> to rotate in a forward or reverse direction as determined by the operator. Power is provided to the motor assembly <NUM> which is translated into rotational motion via the drive means <NUM> coupling the drum engagement means <NUM> to turn the winch drum <NUM>. The turning of the winch drum <NUM> winds the cable on or off of the winch drum <NUM> 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 <NUM> for retrieval winds the cable back onto the winch drum <NUM> in an evenly distributed manner via the levelwind mechanism <NUM> (or other method), returning the cable back to its storage position.

The levelwind mechanism <NUM> guides the cable onto the winch drum <NUM> through the sheave <NUM> to evenly spool the cable about the revolving axis and equally across the axial length of the winch drum <NUM>. The levelwind mechanism <NUM> may also lead the cable from the winch drum <NUM> over to additional sheaves <NUM> or other rigging components set up on the platform for the deployment of the attached load.

When the winch apparatus <NUM> in not in operation, the motor brake or similar means prevents the unnecessary rotation of the winch drum <NUM>.

In instances where the winch apparatus <NUM> is desired at another position on the platform, the winch apparatus <NUM> may be uninstalled by removing the attachment means <NUM> from the winch base <NUM> or from the turntable <NUM>. The lightweight winch apparatus <NUM> may then be moved and re-bolted to another selected position on the platform. In some embodiments, the winch apparatus <NUM> is repositioned by rotation on the turntable <NUM>.

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 scope of the invention as specified in the claims hereof. The 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 winch apparatus, references are made in the text to exemplary embodiments of a compact winch apparatus, 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.

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.

Claim 1:
A winch apparatus capable of hauling and supporting a heavy load on a cable, said winch apparatus comprising:
a horizontal winch drum (<NUM>) for storing cable comprising two axial ends and a flange (<NUM>) on at least one axial end;
a drive means (<NUM>); a base (<NUM>); and
a bearing means (<NUM>) that supports the winch drum (<NUM>), the bearing means being attached to one said axial end of the winch drum and attached to the base (<NUM>);
characterised by a motor assembly quick removal means to allow for the removal of an assembly comprising said drive means (<NUM>) and a disengagable motor assembly comprising a housing (<NUM>) and a motor assembly (<NUM>) that comprises a motor (<NUM>) and a gearbox (<NUM>) without dismantling the entirety of the winch apparatus,
wherein:
at least a part of the motor assembly (<NUM>) is centred within the housing (<NUM>), the housing (<NUM>) is at least partially disposed within the winch drum (<NUM>) with a gap between the outer face of the housing (<NUM>) and the inner face of the winch drum and the housing (<NUM>) is connected to the base (<NUM>);
the disengagable motor assembly (<NUM>, <NUM>) is engaged with the winch drum (<NUM>) by means of the drive means (<NUM>), wherein the drive means (<NUM>) comprises a drum engagement means (<NUM>) that is engaged with the inner face of the winch drum (<NUM>) at a first of said axial ends of the winch drum and a drive shaft (<NUM>) that connects the drum engagement means (<NUM>) with the motor assembly (<NUM>) so that, in use, rotation of the motor (<NUM>) is transmitted to said winch drum (<NUM>);
the drum engagement means (<NUM>) is accessible from said first axial end of the winch drum (<NUM>) to permit disengagement from said inner face of the winch drum so that said entire assembly comprising the drive means (<NUM>) and disengageable motor assembly (<NUM>, <NUM>) can be removed from the winch apparatus by exiting the second of said axial ends of the winch drum (<NUM>);
and
the motor (<NUM>) is capable of controllably rotating the winch drum (<NUM>).