Purpose and principle of operation of the winch
The winch is used in many branches of human activity.
This is a special mechanism designed to lift a load vertically or move it horizontally by transmitting force from the drum drive to a flexible traction element, for example, a cable or chain.
Depending on the type of winch, it can be used to perform the following tasks:
- Move the car. Here the mechanism is most often used to pull a vehicle to some static object, in cases where the car is not able to move independently, for example, “sat down” in the sand. Using a winch, the vehicle can pull itself up or pull up other vehicles. In general, a winch installed on any vehicle, especially one designed for off-road driving, including a snowmobile and ATV, is used to free stuck equipment.
- Lifting a load is the most obvious way to use the mechanism. So winches are the basis of lifting systems of various cranes, including truck and tower ones. Car enthusiasts and craftsmen also buy special hand winches for garages as an alternative to hoists. By the way, the hoists themselves, as well as the crane beams, which are found in almost every large workshop, are also built on the basis of a winch mechanism.
- On the water, winches are used as part of the anchoring and mooring devices of both small boats and huge ships.
It should immediately be noted that despite the similar principle of operation, each type of winch is designed to perform a very specific, limited job.
The simplest version is installed on a well to lower and raise a bucket of water.
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Features of the design of cargo and lifting winches
The design and structure of a cargo winch have general operating principles, but may differ in implementation mechanism, purpose, force and efficiency. The main parts of the machine for lifting and moving loads with the application of traction force to the rope (cable, chain):
- drive unit, gearbox, receives mechanical force from an external source and converts it into torque of a drum with a cable;
- the drum, when rotating, winds the cable or chain with force, forcing the load to move in the horizontal or vertical direction;
- the fastening and engagement unit is a hook or mechanical device for capturing the load;
- the working body of a lifting or shunting winch is a cable, chain, rope that directly receives and transmits traction force;
- the base or frame of the winch is a structural basis that ensures stability and fastening of components and mechanisms.
The operation and design of all types of lifting and traction winches is based on the ability of a drum or cam unit to receive and wind a cable (chain) under the influence of force transmitted from the drive through a gearbox or motion converter. A simpler description: a motor or a person creates a force, for example, turns a handle or shaft, the gearbox transmits rotation to the drum, which rotates, winding the cable, while pulling the load towards itself.
Types of winches
Today, the most common are lever and drum hand winches.
Lever winch
This type is most often used by car owners. And this is no coincidence, because a manual lever-type mechanical winch has undeniable advantages - size and the ability to operate even in the absence of a rigid attachment to the support.
The kit with a manual lever winch often comes with other useful accessories:
- extension cable;
- block that increases traction force;
- bark protection sling;
- cable arrester and protective gloves.
The standard design consists of a metal frame with a built-in mechanism and a lever. Another important element of this device is the ratchet - a kind of wheel on which thrust teeth are located. A steel pin rests against each of these teeth, which prevents the wheel from twisting in the opposite direction, thereby ensuring optimal cable tension
In this case, the winch frame takes on the entire load, so it is very important that it is made of high-quality and thick metal
Drum winch
The manual drum winch consists of:
- drums (there are models with one, two and even three drums);
- gearbox (gear or worm);
- lever;
- a band brake, which allows emergency stoppage of work in case of unforeseen situations, which has a positive effect on operational safety.
The principle of operation is as follows: the gear train, followed by the shaft with the drive gear, is driven using a lever. A friction clutch is installed at the end of the gear, and at the end of the drum there is an annular groove, the dimensions of which correspond to the dimensions of the clutch. Due to this, the rope attached to the drum is wound and lifts the load along with it.
You should be aware of the disadvantages of a drum manual winch:
- limited rope length;
- the small circumference of the inside of the drum. When using a steel cable, it forms a strong bend, so it fails very quickly;
- weak cable laying mechanism.
What types of crane winches are there?
There are two main types of winches on a truck crane:
Truck crane cargo winch
- Cargo (main and auxiliary);
- Arrowheads.
The first type of equipment withstands all the mechanical force of the load being lifted and lowered. Such auto winches are equipped with a powerful traction rope (cable or chain), which is connected at one end to a lifting hook. The second end is attached to the drum. The forward movement of the cable to the hook is transmitted through a system of rollers.
Boom winch device
Auxiliary devices, which are, in fact, cargo, are installed on imported models of truck cranes with a combined jib. They allow you not to rearrange the cable or remove the heavy hook, but to use your own separate cable on the jib. This additional equipment greatly simplifies the work if you need to feed the load very high.
Boom winches are not used on models with a telescopic boom design. They are used only on truck cranes where there is no hydraulic control for lifting the arm. In this case, the device replaces the role of a hydraulic cylinder. It is equipped with a cable that must withstand not only the weight of the boom itself, but also the load, since the latter also exerts mechanical force.
Also, boom devices are subject to more intense dynamic loads, because they change the extension of the boom arm when it is loaded, thereby performing both vertical and horizontal displacement of the load.
Types of winches and their applications, operating principle and application of the winch
Lifting equipment is one of the most necessary assistants in work. So, for lifting loads, a winch is considered one of the most convenient devices. A winch is a device for moving loads using a moving flexible element - a rope, chain or cable. The use of a winch was known back in the days of slave-owning Egypt and even then made it possible to significantly speed up the lifting and movement of goods. At that time, they were driven by muscle or horse-drawn power. The development of technology and production made it possible to use a mechanical drive, which greatly facilitated the work with the winch.
Currently, there are two main types of winches in use: manual winches and electric winches.
Manual winches are a universal and cheap solution for lifting loads on construction sites, warehouses, small industries, and are also excellent for auxiliary and installation and dismantling work. The scope of application of hand winches is very wide, since their operation does not require a source of electricity.
Hand winches include lever winches, drum winches and mounting and traction mechanisms. The operating principle of a manual lever winch is based on pulling the rope through the body using clamps that alternately clamp the rope and advance it in the appropriate direction. In a manually driven drum winch, the lifting and lowering of loads is done by manually rotating one or two handles mounted on the drive shaft. To speed up the lifting of light loads, two-speed winches are made. The mounting and traction mechanisms are unique in their own way and are less similar to other hand winches. The principle of their operation is based on pulling the rope through the winch mechanism, which allows the use of ropes of unlimited length.
Electric winches are lifting equipment intended for lifting and transport operations during construction, installation and other works, drilling rigs, for completing various construction lifting devices, mast lifts, cranes, as well as for moving railway cars and tanks.
Traction winches are designed for lifting and transport operations for installation, construction and other works, as well as for completing construction lifting devices. These traction winches are attached to any surface convenient for you, for example: floors, walls, ceilings, using fastening on a horizontal or vertical platform.
Shunting winches are intended for moving railway cars at rail warehouses, and are used at loading and unloading areas, which allows replacing a diesel locomotive. These winches are classified as single-drum and double-drum, and according to the type of energy consumed - electric and pneumatic.
Auxiliary winches and drilling winches are designed for transporting loads and tools from receiving bridges to drilling sites, lifting loads, making up and unscrewing casing pipes.
Scraper winches are designed for delivering rock mass separated from massifs during underground mining. They are also used in open-pit mines and are used as a means of mechanizing the storage of lump and bulk materials. The winch is driven by turning on or off the working and idle drums using a hand brake. The mine winch is intended for the movement of equipment and cargo, installation and loading and unloading work in mine conditions.
The advantages of using winches are low physical effort during use, simplicity of design and control, compact size and reliability, and large traction forces. With the help of a winch you can significantly facilitate the work associated with lifting and moving loads, this will save time and money.
Types of winches - design and principle of operation
Devices are classified by design, method of actuation and other technical features. They are also divided into portable and stationary. Manufacturers often install permanent winches at the front of the car.
There are several designs by type:
- Hand-held, compact size. Usually they are drum-type, where a cable is wound on a reel, and the work is carried out by rotating the handle. The maximum cargo weight for such a device is 1 ton.
- Mechanical, driven by a motor. They do not provide for an independent moving unit. The structure is large and is used primarily in construction.
- Electric with drum. This option is preferred by drivers because a starter can be used for drive. It is capable of pulling out a stuck car weighing up to 4 tons.
Of particular note are the hydraulic devices. They have quiet operation and a large load capacity, but they are unreliable in operation.
Mechanism drive – manual and machine
The scope of use of devices for moving goods is the most extensive. If physical force is used, quite a lot of effort often has to be applied. A homemade winch will help a person if he correctly assesses the severity of the work and the volume. The design necessarily includes a brake and ratchet. Another option is a safe handle, which simultaneously serves to drive and fix the mechanism in a certain position.
Simple hand-held devices have a number of advantages:
- compact sizes, for which they are especially appreciated by car enthusiasts;
- instant readiness for use without special preparation;
- Possibility of use for moving cargo in horizontal and vertical directions;
- ease of maintenance - no complex and regular repairs are required.
The machine drive is used in simple cranes, scrapers, and drilling rigs. This is a winch with a different number of reels - from one to three. Driven by electric motors, diesel, gasoline.
Types of lifting mechanisms using physical force
Among hand winches, there are three types: lever, drum, mounting and traction. The first of them are the simplest: they consist of a cable, a ratchet or ratchet mechanism, and a lever. The advantage of the design is the ability to work without fixation on the base - simply suspended. The lever makes movements that activate the ratchet.
Lever design for 4 tons with locking in two positions
A cable is wound on the drum, which is fixed with cams without unwinding in the opposite direction. Its length is small - up to six meters, and this is a significant drawback. The advantage is the ability to develop a large traction force: 0.750–4000 tons, lift a load 4 meters.
A drum or cable winch includes a support, a handle, and a gearbox. The basis of the design is the drum itself, a gear or worm gear. The first is preferable due to its ability to serve for a long time. For safety, a brake mechanism is provided to prevent the load from suddenly falling. To work, it requires fixation on a reliable base.
When the handle rotates, the force is transferred to a drum with a long cable - up to 40 meters. The developed traction force reaches 5 thousand kg. Various reel sizes allow the use of powerful cable up to 15 mm thick. With such a winch, it is easy to pull a car out of a ditch, lift reinforced concrete blocks, and plow summer cottages if the soil is not clayey.
An assembly traction winch is the same as a lever winch, only it does not have a drum. The body has clamps in the form of cams to create the required force. They are located in parallel, which allows you to evenly distribute the load on the cable and prolong its service. A lever with a shear pin protects the device from overload and locks the cams if necessary. It is used for various purposes and is popular due to its technical excellence. Periodic lubrication is required for ideal operation of the units.
Which device should I choose for my car?
Manufacturers often install winches on vehicles used for off-road driving. This unit helps you get out of a problem area or climb a slope. Domestic cars, such as Niva and UAZ, do not have such a device. After its installation, the SUV will be able to move through the most difficult terrain.
It is important to choose the right winch power. The indicator depends on the weight of the car, and additional equipment increases it. For various modifications of the Niva it is 1150–1400 kg, UAZ-469 and Hunter are heavier - 1770 kg. The force developed when pulling out the machine should be at least 2 times higher.
A hand-cranked device helps in most cases. But if road conditions are particularly difficult, a vehicle electric winch is required. Homemade is made using a vehicle starter.
Watch the video about the ratchet winch from KAMAZ.
The best manual lever winches
The design of a manual lever device is very simple - a steel frame with a mechanism inside. Traction is carried out by a lever attached to the body
Which manual lever winch to choose, and how to determine reliability? First of all, you need to pay attention to the thickness of the frame. Many people do not recommend buying units with frame thickness less than 3 mm
The category presents the best winches that have a reliable frame size.
Bison "Professional"
Cable hand winches Zubr “Professional” are considered the most reliable, affordable mechanisms. The robust metal frame provides a reliable load capacity of up to 4 tons. The main hook is made of special carbon steel that is resistant to breakage. The frame can withstand high loads and is resistant to destruction. A special switch increases safety when winding/unwinding the cable. Double solid forged ratchet provides reliable traction with maximum lifting capacity. The reinforced pawl ensures safety and trouble-free operation. Fastening points made of hardened steel increase product quality, efficiency, and durability. Warranty 6 months, cable length – 3 m, nominal weight 6.73 kg.
Advantages
- Reliability due to hardened steel;
- Light weight, small dimensions;
- Bag included;
- Traction load 4 t;
- Acceptable price.
Flaws
Short cable.
Many users note that the model features a comfortable anatomically shaped handle that provides a comfortable grip. One of the advantages is its compact dimensions and ease of use.
Sparta
Manual winch for lifting cargo Sparta with a single ratchet wheel is suitable for lifting and moving cargo in a vertical, horizontal, inclined plane. It is often used during installation and unloading work at construction sites, where speed is not needed and loads are moved over short distances. To hold loads, the model is equipped with a ratchet brake. A strong 5mm diameter steel sling ensures reliable movement, lifting and holding. Two standard hardened steel hooks securely secure the weight, increasing safety when moving. Traction mechanism with a lifting capacity of 600 kg. Maximum traction load with a block is 1.5 tons. Steel cable length is 1.5 m. Warranty – 3 months, weight – 1.8 kg.
Advantages
- Lightweight model;
- Little weight;
- Strength;
- Budget price.
Flaws
Low load capacity.
The model will be a good choice for carrying out work with small loads. It is worth purchasing for those who do not want to pay more for unnecessary traction characteristics.
Mirax
The Mirax lever cable mechanism will become a universal assistant when work takes you on the road. To operate the hand tool, no power supply is needed at all. Easily copes with moving loads on horizontal and inclined planes. The mechanical device is small in size and does not take up much space in the trunk. Two hardened carbon steel hooks, double ratchet mechanism. The ergonomic plastic handle on the handle makes it easy to grip. A reinforced frame and high-quality components will ensure a long service life. Steel sling with a diameter of 4 mm, length - 1.8 meters. Weight 2.3 kg. Traction force 1.5 t.
Advantages
- Lightweight but durable frame;
- Good traction force;
- Endurance;
- Copes with inclines up to 15 degrees.
Flaws
- No brake;
- Short cable.
Many consumers note that the work will require an additional towing strap, since often the length of 1.8 m is not enough to engage the winch hook with the fulcrum.
Conversion of a Chinese lever winch
The device is short-lived in use due to low-quality materials. To make ratchet wheels, the metal used is too thin. They are assembled from plates with a total thickness of 2 mm. They need to be welded using electric rivet technology. The “dog” is made from a 4 mm steel plate, in the original there were only 2. Now the mechanism is twice as powerful.
The structure is expanded to accommodate more steel rope. For the base of the drum, a water pipe is used, the body is made of 3 mm iron, and corners. All connectors have pins and cotter pins. Includes up to 8 meters of 4 mm thick cable.
Activated by the following operations:
- “dogs” are raised by a flag;
- the lever is moved towards the person;
- the mechanism is fixed.
Now you can pull out the cable and get to work.
Types of winches
During installation, construction or repair work, various equipment is used to lift loads. But very often you have to not just lift the load vertically, but move it horizontally. In such cases, winches come to the rescue - mechanical devices for vertical and horizontal movement of loads. Using this device, you can pull out a car stuck in the mud, pull up a machine, moor a ship, or, for example, move heavy concrete blocks.
Winches are manual and electric. Each type of winch has its own advantages and disadvantages.
A manual lever-type winch is used in everyday life and when performing simple installation work. It has small dimensions and functions without rigid attachment to the surface. Thanks to its small size, the manual lever winch is easy to install in hard-to-reach places.
A manual drum-type winch operates on the principle of winding a cable onto a drum. It consists of a housing, a gear drum, two bearings and a handle. The device is used to perform simple work, allows you to lift loads to the height of a person and provides double traction force.
A manual winch of the worm type has an “Archimedes screw” (worm) in its design. Its advantage is its miniature size, variety of mounting methods and reliability.
The mounting and traction mechanism is one of the types of winches. It works on the principle of a lever and includes “cams” in its design. The cable is pulled in the desired direction and passes through the cams, moving the load. The advantage is that any length of cable can be used.
The small-sized electric winch is lightweight (up to 40 kg), easy to transport and operates on a 220 V network. Depending on the design, it can be installed permanently on a beam or on a moving carriage. The lifting capacity of small-sized winches is limited to one and a half tons.
The small-sized planetary winch has a planetary type gearbox (drive wheel and driven wheels). With small dimensions and weight, it provides sufficient power to lift cars.
An assembly winch, powered by electricity, is an industrial equipment used in construction and installation work. The weight of such devices is from 250 kg.
The traction winch performs lifting and transport functions. The high power of this equipment is designed to provide high tractive effort. For example, they can be used to move trolleys for construction cranes.
A reliable and powerful electric winch ensures high speed of moving the load, and its use does not require physical strength.
Classification of winches by area of application
The purpose and design of the winch depend on the tasks that will be solved with its help. The variety of equipment allows the design of the mechanism to take into account all the features and requirements associated with the specifics of the work.
The construction winch is designed for maximum simplicity, high lifting speed, limited load weight and equipment mobility. Attention is paid to safety - the load must be fixed, lowered smoothly, and begin and end movement with minimal jerks.
The design of the elevator and drilling winch ensures operation with a wide range of heights, long cables, and especially reliable emergency stop mechanisms. Particular attention is paid to reliability and safety; elevator systems take into account the requirements for smooth running and stopping, restrictions on stretching and sagging of the cable. Such mechanisms have several cables to redistribute loads.
The design of the cargo winch of a crane and truck crane takes into account a wide range of load weights, load distribution over several cables, reliability of locking and smooth return, speed and safety requirements, especially in the event of a sudden failure of the power system.
The design features of a car winch allow it to be used as a means of creating horizontal traction for self-pulling. Attention is paid to the possibility of operation from a motor and a manual lever drive with a ratchet mechanism and a frog winch format.
Design features
The most popular today are drum models and mechanical lever-type manual winches. Although these tools have a similar purpose, however, the principle of their operation is somewhat different.
Drum type equipment
In terms of its external qualities, this type of tool is reminiscent of automobile winches with which special vehicles are equipped. Their design includes a gearbox and a drum. The first is usually a worm or gear type. The drum in this device is designed for winding tape or steel cable around it.
Worm-worm mechanism variations have an undeniable advantage, namely that their gearboxes have a much simpler system for locking the device at the right moment. Thanks to this, the safety of using this equipment significantly increases. This tool is also distinguished by its high reliability and variety of fastening tactics. Although it also has certain disadvantages:
- The large size of the equipment makes it more comfortable to use in a room like a garage.
- Relatively light weight that this type of equipment can pull.
- Complex operating mechanism.
- The need for ongoing maintenance.
- A kind of “conflict” with dirt.
From the above it follows that this type of winches is not the best option for use on mobile devices.
As for gear devices, their design also includes a gearbox and a drum, however, unlike worm devices, they are easier to manufacture and therefore somewhat cheaper. The cable is attached to them using a ratchet, which has good reliability.
The gearbox is characterized by ease of maintenance. A rather important point is the quality of the metal used in the manufacture of gears, therefore, when choosing such equipment, it is not recommended to give preference to cheaper, untested analogues. It is better to choose a well-known manufacturer.
The main disadvantages include the following:
- A method of laying a cable, which often gets into the cavities of the gearbox gears and ceases to perform its functions.
- Small internal diameter of the drum, which causes strong bending of the steel cable. As a result, the latter deteriorates quite quickly.
- Due to the dimensions of the device, the size of the drum is limited, and this, in turn, limits the range of action of the mechanism.
From the above, we can conclude that the process of using drum-type winches in field conditions may not always be comfortable. It is better to use this mechanism in the garage.
Lever type equipment
Winches of this type are most often used in mobile devices. It is these that drivers usually purchase in order to be able, if necessary, to rescue the car from a trap.
The standard structure of the device includes a frame made of metal, inside which there is a mechanism activated by pressing a lever located on the equipment body. Due to the fact that greater force can be applied to the lever, the device is effective in cases where drum winches would not cope. The traction force of such a mechanism can reach several tons. Moreover, this figure can be further increased by strengthening the standard lever. Some manufacturers immediately include a special amplifier in the equipment package or manufacture this element using the telescopic method.
The main components of the device include a ratchet that secures the cable in a taut state. It is a kind of wheel on which persistent teeth are located. A locking pin rests against them in turn, preventing the wheel from spinning in the opposite direction. This ensures tension in the cable.
In this case, the main load is placed on the equipment frame, as a result of which the latter must be made of durable metal of the appropriate caliber. Otherwise, the device will become deformed. Experts recommend abandoning the option of a winch with a frame whose metal thickness will be less than three millimeters.
The mechanism has small dimensions, so its operation is possible even in very inconvenient places and conditions. And also the lever type of mechanism does not require mandatory fastening of the case
However, when purchasing this modification, you should pay attention to the size of the winding drum, since the smaller it is, the greater the effort required during the work process. You should not opt for a product with a diameter of this element less than 45 millimeters
Load winches of the main lift of jib cranes are designed for lifting and lowering loads, auxiliary lift winches are designed for lifting smaller loads on a jib or grab.
In Fig. Figure 1 shows a general view of the multi-speed main hoist winch of the SKG-40A crane. The kinematic diagram of this winch was discussed earlier.
In Fig. Figure 2 shows the design of the main hoist winch for the KS-5363 crane. The winch is driven by an electric motor. The output shaft of the electric motor is connected to the input shaft of the three-stage gearbox by a gear coupling. A shoe brake pulley, controlled by a short-stroke electromagnet, is mounted on splines on the primary shaft of the gearbox.
The four gearbox shafts are supported on its housing using ball bearings.
The gearbox contains three pairs of cylindrical helical gears. The gearbox is connected to the drum by a gear coupling, one half of which is fixed to the output shaft of the gearbox, the other - to the drum shaft. The gear coupling simultaneously serves as one of the supports for the drum axis.
The drum axis is supported on one side by double-row roller bearings. On the other side, the axis is connected by a gear coupling to the output shaft of the gearbox.
Rice. 2. Main hoisting hoist of the KS-5363 crane: 1 - electric motor, 2, 7 - gear couplings, 3 - brake, 4 - electromagnet, 5 - gearbox, 6 - input shaft, 8 ~ drum, 9 - drum support
On the KS-4361A jib crane with a single-engine drive, when considering the kinematic diagram of its mechanisms, the concept of a main and auxiliary lift winch is not fully applicable, since the layout of the mechanisms with a single-engine drive does not allow one to clearly distinguish one or another winch; many elements of the kinematic chain of mechanisms are transmissions for a number of executive bodies. Therefore, this crane considers only the design of mechanisms directly connected to the executive bodies - the drums.
Three drums are mounted on a common shaft: cargo, auxiliary (grab) and boom. All three drums have a ball bearing fit and rotate freely on the shaft. The drums are activated using pneumatic chamber couplings rigidly connected to the shaft, and are kept from free rotation or from rotation under the action of loads (loaded ropes) using band brakes.
Rice. 3. Multi-drum crane winch KS-4361A: 1, 7, 12, 14 — pneumatic chamber couplings, 2, 10 — supports, 3 — cargo drum, 4 — band brake pulley, 6, 13 — hoses, 6 — shaft, 8 — boom drum, 9 - sprocket, 11 - gear wheel, 15 - tire, 16 - pneumatic chamber, 17 - brake pulley, 18 - grab drum (auxiliary)
The shaft rotates in double row spherical support bearings and is driven by a sprocket or gear wheel with a ball bearing support. The wheel is driven by a pneumatic clutch. The reversal of the shaft is carried out by engaging a chain transmission using a pneumatic chamber coupling mounted on the reversing shaft, or by engaging a gear wheel.
The operating principle of a pneumatic chamber clutch is based on the friction of the tire against the surface of the drum pulley under the influence of compressed air.
The coupling consists of a pulley, a pneumatic chamber and a tire. Air is supplied to the pneumatic chambers through rotating hinge joints from the ends of the shaft (through channels in it) and from the shaft to the chambers (through flexible hoses). When compressed air is supplied through a hose into the chamber, the latter expands and presses the friction belt with the tire against the inner surface of the drum pulley.
The brake band is adjacent to the outer surface of the drum pulley. The tape consists of two parts connected by a coupling bolt. One end of the tape is hinged with a pin on the gusset, the other end is connected to the eyelet. The eye is connected to the hydraulic cylinder rod using a lever system.
The brake control is hydraulic. When you press the hydraulic cylinder pedal with your foot, the piston moves to the left and turns the lever through the rod and fork. In this case, the eye moves up and the brake is tightened (the drum is braked). If you remove your foot from the pedal, the hydraulic cylinder piston will return to its original position under the action of the spring (the drum will be released). A spring is used to ensure that the brake band moves evenly away from the drum pulley.
A brake of a similar design is installed on a clamshell (auxiliary) drum.
The boom drum is equipped with two band brakes: permanently closed and adjustable.
The eye of the permanently closed brake is mounted on a bracket; the running end of the brake band is tensioned by a spring. A ratchet wheel is installed on the drum; With the help of a pawl, the drum is kept from rotating. If it is necessary to lower the boom, the pawl is disengaged from the ratchet wheel using a rod, a lever and a pneumatic chamber: The stroke of the pneumatic chamber rod is limited by an adjustable (screw) stop.
The controlled brake band, like the brake band of a cargo winch, consists of two parts connected by a coupling bolt. The uniform withdrawal of the belt from the drum is regulated by a tension spring.
Rice. 4. Band brake of the cargo and grab drums of the KS-4361A crane: 1 - coupling bolt, 2, 8 - springs, 3 - brake band, 4, 5 - nuts, 6 - hydraulic cylinder, 7 - rod, 9 - fork, 10, 11 — levers, 12 — eye
The brake eye is mounted on the bracket using a roller, on which a lever is also mounted, connected at one end to the brake band eye, and at the other to the pneumatic chamber rod.
The tension of the brake band (braking of the boom drum) is carried out by a spring through a rod, and the band is released using a pneumatic chamber.
Rice. 5. Adjustable boom brake of the KS-4361A crane: 1, 3 - rods, 2, 12 - levers, 3, 9 - pneumatic chambers, 4, 8 - springs, 5 - permanently closed brake band, 6 - guy wire, 7 - drum, 10, 18 — brackets, 11, 17 — stops, 14 — controlled brake band, 15 — pawl, 16 — ratchet wheel, 19, 20 — brake lugs
The main and auxiliary winches of jib cranes are equipped with special devices - rope handlers. They ensure correct laying of the rope drum in the grooves and prevent it from falling off the drum.
The main winch of the KS-6471 crane is equipped with a hydraulic drive, so its design is much different from those discussed earlier. The winch is much more compact (taking into account the multiplicity of the cargo pulley), for example the winch of the KS-5362 crane, although the lifting capacity of the crane on which it is installed is more than 1.5 times higher. The winch is driven by a hydraulic motor type 210.25 with a power of 55 hp. s, mounted in the drum.
Rice. 6. Main winch of the KS-6471 crane: 1 - shaft, 2, 9 - plugs, 3 - gear shaft, 4 - disc brake, 5 - bracket, 6 - hydraulic cylinder, 7 - bolt, 8 - spring, 10 - stubble, 12 — crown, 13 — drum, 14 — bracket, 15 — hydraulic motor, 16 — wedge
Power from the hydraulic motor to the executive body - the drum - is transmitted through a shaft with an articulated joint and a planetary gearbox with gears, a pinion shaft meshed with the gear; From the gear the power is transferred to the gear sitting with it on a common shaft. The gear is in mesh with a ring pressed into the inner cavity of the drum.
A permanently closed disc brake with a hydraulic drive is mounted on the internal cavity of the gear motor; The internal brake discs are connected to a pinion shaft.
Rice. 7. Main winch of the DEK-251 crane: 1.9 - electric motors, 2.8 - brakes, 3 - clutch brake pulley, 4.7 - gearboxes, 5.6 - drums
When not working, the disks are compressed by a spring and the gear shaft is in a braked state. When the winch is turned on, oil enters the hydraulic motor and at the same time, under pressure, into the cavity of the hydraulic cylinder. Under the influence of internal pressure in the hydraulic cylinder, its rod moves to the right, the spring is compressed, the brake discs open and the drum begins to rotate. The brake is adjusted with bolts. By changing the rotation speed of the hydraulic motor by throttling, it is possible to continuously regulate the rotation speed of the drum. This distinguishes this winch from mechanically driven winches.
The gear shafts are mounted in the bores of the gear motor housing and rest on ball bearings.
The drum has a ring cut. The rope winding on the drum is four-layer. The rope is attached to the drum with a wedge.
All bearings and gears are lubricated with oil poured into the inner cavity of the drum. Fill and drain oil through the plug. The amount of oil is controlled using a plug.
A general view of the main winch (load lifting winch) of the DEK-251 crane is shown in Fig. 7. The winch uses a block diagram of two electric motors, brakes, gearboxes and drums. The design of the winch allows you to remove one drum, leaving the other in place, which is very valuable when repairing a winch.
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Tower cranes use single-, double- and multi-speed winches. Since the speed of smooth loading of the load is mandatory for winches of all types, it is not taken into account when determining the number of winch speeds.
Single-speed winches are made of a monoblock design based on a gearbox with a three-legged statically definable support. Monoblocity is achieved by the fact that the engine is mounted on a flange to the gearbox, and the winch drum is rigidly mounted on the output shaft of the gearbox. The monoblock design makes it possible to avoid the need to align the connections between the gearbox and the engine and the drum, which simplifies the installation and maintenance of the winch. Single-speed winches are used on cranes of the third and fourth size groups (KB-309HL, KB-402V, etc.). The speed of smooth landing in these winches is ensured with the help of a TM-4A brake machine, which is mounted on a flange on the second high-speed gearbox shaft. The brake pulley is located on the free shaft of the electric motor, and the brake frame is attached to the motor feet.
Operational Capabilities
Those who prefer a high-quality hydraulic winch and carry out the installation correctly can count on very rich functionality. The mechanism is directly controlled through levers – as a rule, there are two of them. The main advantage of branded models is the support of several traction modes. For example, in the basic order, the unit performs free unwinding and locking, and the remaining several modes differ in different tension transmissions. A modern hydraulic traction winch supports several speeds, which can also be controlled via a remote control.
Manual winches
Manually driven winches are used mainly as auxiliary equipment when vertical, horizontal or inclined movement of loads is carried out during installation and loading and unloading operations. They can be single drum or lever (no drum).
| Fig.1 Manual drum winch |
In the drum winch body (Fig. 1), consisting of two sidewalls connected by coupling bolts, shafts are mounted on which a smooth cargo drum, a transmission mechanism (gears) and a load-resistant automatic brake are located. Raising and lowering the load is done by manually rotating one or two handles mounted on the drive shaft. To quickly lift light loads, hand winches are made with two speeds. The lifting speed is changed by moving the gear block along the axis of the drive shaft.
An automatic load-bearing brake, consisting of a ratchet stop and a disc brake, provides braking of the drum when lowering the load and stops it instantly if the worker releases the winch drive handle. Since the load brake is located on the second shaft, gear shifting is possible with a raised load.
Winches are available in floor and wall versions.
| Fig.2 Manual lever winch |
The scope of use of manual lever winches (Fig. 2) is the movement of loads during installation and dismantling work, in warehouses, for towing cars, etc. These mechanisms are characterized by high reliability and ease of operation, the ability to work in any spatial position, small dimensions and weight, complete autonomy and versatility. They can function in any conditions and do not require any preparatory work.
The principle of operation of the winch is based on pulling the rope through the traction mechanism using special clamps that alternately clamp the rope and thus advance it in the appropriate direction.
Additional equipment and winch controls
The control of an electric winch can be significantly improved if you use an inverter power supply circuit for the electric motor. It provides a smoother start and stop of the mechanism, provides a wide range for selecting the rotation speed, and significantly extends the winch’s overhaul period by reducing wear.
Braking devices for winches must provide mechanical speed limitation when lowering loads, and locking in the event of failure of the lifting mechanism or power system. Electromagnetic rheostatic speed limiting systems can be used as an additional means of braking. The main brake mechanism is implemented as a mechanical one with a manual or electromagnetic drive.
On a note
At our company we produce winches
all types to order according to an individual project and standard units from the catalog. Our specialists will provide installation, testing and commissioning according to the regulations.
Using a hand winch
Basically, hand winches are manufactured in the following types:
- drums;
- lever;
- installation and traction.
Manual units are used on construction sites, warehouses, automobile and home workshops, and country houses. The first type is used for lifting, lowering, and moving small-sized cargo with limited weight. The source of movement is the rotation of the drum manually. The body of the product must be rigidly fixed to the selected surface.
Mounting and traction units are structurally different from drum and lever devices. They can use ropes or slings of any length. The principle of operation is to pull the rope through the mechanism in a given direction. One option for such a device is the so-called worm winch. It uses a gear drive with reversible force. The main disadvantage of such systems is the increased coefficient of friction created between the gear and the worm screw. This circumstance leads to rapid wear of the entire mechanism.
All manually driven structures are used as auxiliary (additional) lifting equipment. Especially in cases where there is limited free space.
How to choose an electric winch?
Paying attention to the load capacity, some owners forget about other characteristics of this useful device, which leads to mistakes when purchasing equipment. Let us describe the main parameters affecting operation:
- Type of installation - in the garage, a mobile electric suspended winch with a trolley drive is more useful. You can mount these mechanisms on a wall or horizontal plane. Choosing a car electric winch requires a special approach taking into account the vehicle model.
- Power - the traction force is affected by the mass of the load, the friction factor (resistance to movement), the lift factor (the car is pulled up or forward).
- Power type – 220 or 380 V or battery.
- Control type – equipped with an electric winch with a wired or remote control.
- Rope length.
- Rope diameter.
- Weight and dimensions of the model.
Rating of electric winches
A properly selected electric winch can help out the car owner in difficult situations, help at a construction site or in the garage. There is a wide variety of interesting models on the market, so viewing the ratings will not be a bad idea before purchasing a useful device for your home. We offer a small TOP of electric winches of different types:
- Electric winch COMEUP SEAL GEN2 9.5S
– runs on 12 V, pulling force 4300 kg, hermetic design, aluminum case, synthetic cable.
Winch MASTER WINCH MW X8288
– unit power 6.8 hp, cable 32 m, traction force 3760 kg, power supply 12 V.
Octopus 9000
affordable automotive electric winch - motor power 1.5 kW, traction force 4000 kg, remote control with a cable 4.5 m long.
Sturm eh72201
– power 540 W, lifting height 12 m, load capacity 400 kg, a good option for workshops.
DENZEL TF-250 52011
– electric lifting winch for construction sites with a lifting capacity of 250 kg, 540 W motor, 220 V power supply, lifting height 12 m, speed 10 m/min.
How to choose a hand winch
When choosing a manual winch, you should pay attention to the following parameters:
- generated traction force;
- length of rope or cable (rope capacity);
- body material;
- brake mechanism design;
- drive mechanism (drum or traction);
- number of hooks attached;
- own weight;
- manufacturer's reliability.
According to the first indicator, simple models with a lever drive are capable of moving a load of no more than 600 kg. More advanced ones have a value of up to 3000 kg. When choosing the necessary device (including a manual one), it is necessary to set a certain reserve of traction force.
For most manual structures, the length of the wound rope varies from 2 m to 5 m. Some models have a drum with a rope of up to 15 m. When choosing a manual winch, it is advisable to opt for a unit with a friction brake or a double-sided ratchet. The weight of manual structures reaches 15 kg. If you need to lift or move small loads, it is better to choose a lighter product, for example, from 3 kg to 7 kg. Lightweight versions are made of aluminum alloy. Some modifications of manual structures have not two, but three hooks. This allows, when using an additional block with a roller, to create a double branch of the rope, increasing the traction force.
After determining all the necessary parameters, you should carefully study the degree of reliability and reviews of the manufacturer. You should trust only well-established companies that have been operating for a long time in the market for the production and sale of lifting equipment.
How to make a hand winch with your own hands: 5 simple and proven methods
A winch is an indispensable thing in the household. It can also provide an undeniable service to car enthusiasts.
Winch functions for cars
Manufacturers install a winch on vehicles that often drive off-road. The fact is that when a car slips or cannot drive up a slope, it is this device that helps to get out of the “trap”.
By installing a winch on a passenger car, you can safely drive on any road surface, including washed-out roads and potholes.
However, it is used not only to pull a car out of a hole or tow it, but also to transport goods. Therefore, manufacturers produce a wide variety of these devices.
What types of winches are there?
Conventionally, they are classified according to:
- designs;
- connection method;
- technical features.
In addition, they are divided into removable, which are installed if necessary, and non-removable (installed on the front of the vehicle).
The winch can be of several types:
- Manual – the advantages include compact size. Most often they are of the drum type, when the cable is tensioned on a reel and rotation occurs using a handle. The disadvantages include the fact that it can work with cargo whose weight does not exceed 1 thousand kg.
- Mechanical - comes into action with the help of a motor, since there is no independent driving unit. The design is quite bulky and is not popular among car enthusiasts.
- Electric is the most convenient option. The drum moves using an electric motor. Power comes from the car battery. Loading capacity reaches up to 4 thousand kg.
- Hydraulic – has a rather complex design. It operates silently and has great power, but is unreliable because it can fail at any time.
There is no need to purchase the device. Making a manual winch with your own hands is quite simple. First of all, you need to decide on the type and parameters of the device.
The device is equipped with a so-called “anchor”, which clings to a hard surface and helps to pull out the vehicle. A do-it-yourself anchor winch can be made from almost any scrap metal
It doesn’t matter what the “anchor” looks like, the main thing is that it clings well and does not deform under high loads
While using the device, it is prohibited to stand within the radius of the cable.
Do-it-yourself winch from the starter
A homemade winch from a starter is made from materials that are always available in the garage. The basis, of course, is the starter, and the device itself runs on battery power.
It is desirable that the gearbox for the winch be planetary. You can find it on old Zhiguli models.
For manufacturing you will need: cables, cable, gears, drum, starter, gearbox, sheet of metal.
- Secure the drum seats with bolts and a welding machine.
- Assemble the drum with gearbox.
- The starter is assembled to the gearbox using adapters.
- Equip the input shaft with a gear. It is necessary to ensure that the size of the teeth matches the design. If the shaft connects freely to the gear, then the manufacturing process is proceeding correctly.
- Place the gear onto the cylinder. After the structure is securely fastened, the electrical wiring is connected.
If dirt or dust gets into the device during assembly, everything should be cleaned and only then primed and painted.
Construction of the boom winch mechanism
Otherwise, such a system is called a boom lift of a truck crane with a rope-type suspension. It consists of:
- Boom winches;
- Pull block;
- Band type brakes.
The boom winch is built on the principle of a two-stage cylindrical gearbox with a gear ratio. A drum is mounted on the side of the low-speed shaft. The high-speed shaft is equipped with a brake system pulley. A sprocket is attached to the pulley with bolts, from which transmission to the drive occurs through a chain coupling.
The jib pulley is a four-fold type mechanism. On its holder, which is stationary, the blocks rotate, relying on bearings mounted on the portal axis. The blocks of the movable boom pulley cage are attached to the boom by the head area.
of the boom rope is fixed to the winch drum using a wedge spike. Its other end is secured with a wedge-shaped bushing to the rotating frame of the truck crane (at its rear part). The rope retrieval is the same both when working with a boom and when adding a jib. In the latter case, a longer rope is used.
The boom drum can have a groove for laying the cable, or be smooth. If there is no stream, then in order to avoid incorrect winding of the steel rope, a special pressure roller is technically provided, which prevents the rope from loosening and tangling.
Types of automobile winches
Depending on the drive design, winches for SUVs are:
- Manual.
- Electrical.
- Mechanical.
- Hydraulic.
Each of these types has its own advantages and disadvantages, so the choice is ambiguous. You need to focus on the most common situations that can happen to the car. Of course, a lot also depends on its design.
You also need to take into account the total weight of the vehicle, moreover, fully equipped, in order to purchase a winch powerful enough for this load. If it turns out to be weak, it will simply be useless in an extreme situation, since it will not be able to move the car. The traction force of the winch should be 2.5 times the weight of the car, then it will easily cope with the task without the need to unload things.
Stayer Maxpull 4310-4
Since choosing a winch for an SUV is not so easy, we will consider all these types in more detail, and then we will present the best models that have proven themselves well in practice.
Manual mechanisms
These are the simplest and cheapest devices. They are activated manually, to do this you have to rotate the handle or move the lever. By design, they are lever, drum and worm.
Manual winches for off-road vehicles are not suitable for everyone, since the thrust they develop is usually small. They can be used on light cars weighing up to 1-2 tons, and jeeps are much heavier. But there are also quite powerful designs, with a thrust of 4-5 tons.
Electrical devices
Electric winches for SUVs are much better and are the most popular. Such devices are powered from the on-board electrical network - from the battery. They are very easy to use and are launched with the press of a button. Their cost is quite reasonable, and installation and connection does not cause problems.
Such car winches develop quite a lot of force and some models can pull out a car weighing up to 6 tons. But you need to have a very good and capacious battery, since it is not always possible to start a car stuck in the mud to recharge.
Mechanical devices
Unlike manual options, mechanical winches for SUVs are driven not manually, but by a motor, using a special shaft that is connected if necessary.
The choice of such a winch may be limited by the design of the machine - not all have the ability to connect an additional shaft. One of the advantages is quite a lot of power, which is enough to pull the car out of any trouble. But for this you need to start the engine, which is not always possible, and this is the main disadvantage of this design.
Hydraulic devices
In devices of this type, a drum with a cable is driven by a hydraulic system. They are usually connected to the power steering. The force developed is quite sufficient and they work silently and smoothly, but they have many disadvantages:
- The cost is higher than other options due to the complexity of the design.
- The engine must be running.
- When turning the steering wheel, they may behave unstably, as the pressure from the hydraulic booster changes.
Finding a hydraulic winch for your SUV can be difficult as you need to consider connectivity options. Meanwhile, hydraulic winches do not have any special advantages over other designs.
Hydraulic winch Runva 10000 LBS
What is a winch
A mechanical device with which you can act on objects by applying a traction force to them from a drum with a drive at a distance through any element of a flexible structure, such as a cable, chain or rope, is called a winch. It is driven by human muscular power, an electric motor (or internal combustion engine), which depends on the purpose and power of the device.
Additional items
Various types of cables are used as equipment. The steel version is durable and has high strength, but if broken, it poses a great danger to people nearby. Specialized cable arresters are used to prevent such situations; in the absence of such a device, any material can be used.
Kevlar cable has less strength, but it is not capable of causing harm to others when it breaks. Among the advantages, it is worth noting convenient operation at low temperatures, since synthetics are not subject to freezing, as well as moisture resistance and lack of stretching even with repeated use.
Types of cables
There are mainly two types of cables used - metal and synthetic. The option of twisting steel threads may seem preferable, but, oddly enough, it has significant drawbacks. Firstly, you should not place special hopes on metal in terms of strength. Over time, some of its threads break, and at some point it is necessary to replace it. Secondly, a hydraulic winch with a metal cable is unsafe. Those same broken threads can injure the skin of your hands and damage your clothing, and if you miss the moment of critical wear, then a complete rupture of the cable during the pulling process can lead to tragic consequences. Synthetic is also not perfect, but it is less dangerous, less dynamic and lasts longer with proper care. Such a cable should be protected from sunlight, and after use in contact with sand, the fibers should be thoroughly washed.
Construction of the cargo winch mechanism
From a mechanical point of view, a winch is a unit that combines a frame, a drum, a gear system, a brake mechanism, a steel rope, a system of rollers and couplings.
A cargo winch driven by a hydraulic motor consists of the following elements:
Cargo winch - components
- Gear mechanism;
- Cable winding element;
- Hydraulic drive;
- Band type brakes;
- Brackets.
The drum rests on bearings, one of which is mounted in a bracket, the other in a gear half-coupling mounted on the shaft of the gear mechanism. To transmit rotation from the gear shaft, two gear-type coupling halves are provided. One of them is rigidly attached to the drum. Any cargo winch drum has a groove (stream) for laying the cable during winding.
The brake system pulley is mounted on a rapidly rotating shaft of the gearbox mechanism. The brake itself combines two brakes of a normally closed type band design. Each of them has a brake band with a lining, a working brake spring, a hydraulic release and a bracket.
When the hydraulic motor is turned off, the brake is closed and holds the drum stationary. As soon as the working fluid begins to rotate the hydraulic drive shaft, it simultaneously enters the hydraulic brake release, and it releases the mechanism. You can also release the drum manually.
