Cross-Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Application No. 63/141,443, filed on January 25, 2021, now pending, the disclosure of which is incorporated herein by reference.

Field of the Disclosure

[0002] The present disclosure relates to winches, and in particular, to gearsets for winches.

Background of the Disclosure

[0003] When using a winch, the winch motor can operate to let out the winch cable and take in the cable. Most winches also include a freespool mode, which allows an operator to pull out the winch cable manually rather than using the motor to let out the rope. This is generally quicker and saves wear on the motor and geartrain, if any. With typical winches, an operator must exit a vehicle to access manual controls located on the winch to switch between winching and freespool modes.

Brief Summary of the Disclosure

[0004] The present disclosure provides the ability to switch a winch between freespool and winch modes electronically and/or manually. Embodiments herein enable the user to engage either mode, from inside or outside of the vehicle, electronically or manually. This enables the vehicle occupant(s) to, among other things, avoid potentially hazardous or undesirable terrain upon exiting the vehicle.

Description of the Drawings

[0005] For a fuller understanding of the nature and objects of the disclosure, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:

Figure 1 depicts a winch according to an embodiment of the present disclosure; Figures 2A and 2B depict an exploded view of a spool assembly, gearbox assembly, drive lock assembly, and solenoid and rocker switch assembly of the winch of Figure 1;

Figure 3 depicts a cross-section of a spool assembly, gearbox assembly, drive lock assembly, and solenoid and rocker switch assembly of the winch of Figure 1;

Figure 4 is a exploded view of a portion of a winch having a gear-changing transmission according to another embodiment of the present disclosure;

Figure 5 is a portion of the winch of Figure 4 showing a motor shaft and a planetary gearset, among other components;

Figure 6 is a portion of the winch of Figure 4 showing an actuator plate, solenoid, and rocker switch, among other components;

Figure 7 is a portion of the winch of Figure 4 showing a spool, winch rope, and a housing, among other components;

Figure 8 is a partial cross-section view of another embodiment of a winch having a gear changer according to the present disclosure;

Figure 9 is a partial cross-sectional view of the winch of Figure 8 configured for winching mode;

Figure 10 is a partial cross-sectional view of the winch of Figures 8 and 9 configured for rope-recovery mode;

Figure 11 is a partial cross-sectional view of the winch of Figures 8-10 configured for freespool mode;

Figure 12 is a partial cross-sectional view of the winch of Figures 8-11 configured for freespool mode, wherein the spline is highlighted;

Figure 13 is an actuation plate according to an embodiment of the present disclosure;

Figure 14 is a carrier plate according to an embodiment of the present disclosure;

Figure 15 is a drive plate according to an embodiment of the present disclosure;

Figure 16 is a motor pinion according to an embodiment of the present disclosure;

Figure 17 is a motor shaft according to an embodiment of the present disclosure; and

Figure 18 is a detail view of the portion of the motor shaft of Figure 17 labeled as ‘A’.

Detailed Description of the Disclosure

[0006] The present disclosure provides a winch with the ability to switch between a freespool mode and a winch mode electronically and/or manually. Embodiments of the present disclosure enable an operator to switch between winching modes from either direct access on the winch or from a remote location, such as inside of the vehicle. For example, in muddy or wet terrain, embodiments may enable the driver, a passenger, or a bystander to avoid needing to wade through mud or water to switch between winching modes.

[0007] Winches generally have a gearset for torque generation/multiplication. For example, a planetary gearset is commonly used. To generate/multiply torque, at least one of the gears of the gearset must remain grounded (e.g., fixed relative to a housing). Embodiments of the present disclosure allow one or more gears of a gear set to be ungrounded when freespool mode is commanded. In this way, the winch spool (on which the cable is wound) is effectively decoupled (but not necessarily disconnected) from the motor shaft. In a typical planetary gear set, a ring gear (annulus gear) remains grounded for torque generation/multiplication. Some embodiments of the present disclosure provide for such a ring gear to be ungrounded for freespool mode. Ungrounding the ring gear permits the entire gearset to rotate with the winch spool and therefore not develop any torque, allowing the spool to rotate freely (i.e., independently from the motor). Grounding the ring gear involves holding the ring gear in a fixed position relative to a reference (a housing, mounting bracket, etc.) such that motor torque can be multiplied via the gear set to the spool for winching purposes.

[0008] More specifically, embodiments may enable this selection function by selectively engaging a coupler (e.g., a spline, dog tooth clutch, pin, etc.) of a non-rotating actuation plate that is configured to cooperate with a corresponding receiver of the ring gear or a receiver fixed to the ring gear (e.g., a drive plate). The actuation plate may be engaged with the freespool gear by an actuator, for example, a solenoid, a latching solenoid, a piston, etc., and/or by a manual and/or mechanical switch. In some embodiments, the actuation plate is configured to only travel axially (z.e., it is prevented from rotating). Once the coupler is engaged with the receiver, the gearset may generate torque for the spool from the motor shaft because the ring gear is fixed by its engagement with the coupler of the actuation plate. If the coupler is disengaged from the receiver, the ring gear is able to rotate and the spool is effectively decoupled from the motor shaft. It should be noted that, as used herein and unless expressly noted, decoupled does not necessarily mean disconnected. In other words, two components may be decoupled while still being in mechanical communication with each other.

[0009] The present disclosure may be embodied as a winch having a motor with a motor shaft connected to a spool by way of a gearset. The gearset is able to selectively couple the motor shaft to the spool such that drive forces are selectively transmitted from the motor to the spool. The gearset includes at least one freespool gear which has a “winch” state wherein the freespool gear is grounded and the motor shaft is coupled to the spool, and an ungrounded “freespool” state in which the motor shaft is decoupled from the spool. An actuation plate is provided and configured to engage the at least one freespool gear to selectively ground the freespool gear. The freespool gear may include a receiver configured to cooperate with a mating coupler to fix (rotationally) the actuation pate to the freespool gear.

[0010] Figure 1 depicts a winch according to an non-limiting exemplary embodiment of the present disclosure, provided to illustrate the mechanism of the winch and gearset. Figures 2A and 2B depict exploded views of the winch of Figure 1. The axes of Figures 2A and 2B refer to the same axis in the embodiment, and thus several components are discussed herein as aligned to this central axis. Figure 3 depicts a cross-section view of the winch of Figure 1.

Description of Exemplary Embodiment of Figures

[0011] In a first subassembly, two bearings 2 may be press-fitted onto the outside diameter of a ring gear 1. The ring gear 1 may provide internal gear teeth for gearbox operation. A bearing 2 may support the ring gear 1 and accommodate low friction rotation. A drive plate 10 may be attached to the face of the ring gear 1 with fasteners. The drive plate 10 may be part of a splined interface 9 comprising a female spline 12, which accepts a male spline 11 when the unit is in winching mode. The splined interface 9 may transmit torque from one component to another or inhibit the transmission of torque from one component to another. The male spline 11 may be a toothed feature that engages the female spline (when commanded) to transmit torque. The female spline 12 may be a toothed feature that accepts engagement from male spline 11, when engaged, to transmit torque. The drive spline 13 may be a single-toothed feature that transmits torque from the gearbox to the spool, and may be located on an output stage carrier plate. The drive plate 10 may also be attached to a face of ring gear 1. A linear bearing 3 may be slip-fitted into an inside diameter of the drive plate 10. The linear bearing 3 may provide support for an actuation plate 8 and provide a low friction surface for linear travel of the actuation plate 8. A return spring 7 may sit inside the actuation plate 8. The return spring may be slightly preloaded when a solenoid 6 is installed.

[0012] The actuation plate 8, attached to the male spline may travel axially when engaged either electrically (by the solenoid) or mechanically (by the rocker switch). The position of the actuation plate 8 may either inhibit or permit rotation of the drive plate 10 based on its axial position within the assembly and whether the male and female splines are meshed at their interface. To accomplish this, the actuation plate 8 may have an anti-rotation key 15 that engages a keyway or key seat in the solenoid housing 14. The anti-rotation key 15 and its respective key way may be single-toothed feature that prohibits rotation of the actuation plate 8.

[0013] A solenoid housing 14 may support, for example, a solenoid 6, a rocker switch 4, and/or other components. The solenoid housing 14 may also contain keyway, which engages the anti-rotation key 15 on the actuation plate 8.

[0014] The solenoid 6 may be a latching solenoid that, when commanded, electromagnetically moves its shaft axially. The shaft of the solenoid may be attached to the actuation plate 8, and therefore, the shaft may be configured to move the male spline 11 into and out of engagement with the female spline 12 of the drive plate 10. Further, since the solenoid 6 may be a latching solenoid, it may also magnetically hold position at the end of travel. The solenoid 6 may also automatically reset the correct position of a rocker switch 4 based on its axial position.

[0015] In a second subassembly, a rocker switch 4 may be attached to the solenoid housing 14 with a rocker switch pivot pin 5. Such a pin 5 may pass through the rocker switch 4 and into the solenoid housing 14. The rocker switch 4 may manually engage and disengage the male spline 11 on the actuation plate 8 with the female spline 12 on the drive plate 10. The pivot pin 5 may be a point/axis of rotation for rocker switch 4.

[0016] The return spring 7 may provide a preload force to the actuation plate 8 after either the rocker switch 4 is depressed to a “lock” position or the solenoid 6 has been actuated to the engaged position. This preload may provide axial force to the male spline 11 after the solenoid 6 has cycled, to aid in the meshing of the splines. This may assist functionality when the spline teeth do not mesh immediately and a few degrees rotation of the gearbox is required for spline tooth alignment.

[0017] A solenoid shaft bushing 17 may be pressed into the solenoid housing 14. The solenoid shaft bushing 17 may provide a low friction shaft support for the solenoid 6. The solenoid 6 may be attached to the solenoid housing 14 using a mounting bracket 18 and fasteners, and the shaft of the solenoid 6 may slip-fit into the solenoid shaft bushing 17. The solenoid 6 may be attached to the rocker switch 4 with a push/pull pin 16. The push/pull pin 16 may pass through the shaft of the solenoid 6 and into the solenoid housing 14. The push/pull pin 16 may attach the shaft of the solenoid 6 to the rocker switch 4. The actuation plate 8 may be attached to the shaft of the solenoid 6 with a fastener (for example, a screw threaded into the end of the shaft of solenoid 6).

[0018] The solenoid mounting bracket 18 may attach the solenoid 6 to the solenoid housing 14 using fasteners (e.g., screws, etc.) To assemble the two sub-assemblies, the actuation plate 8 may pilot into linear bearing 3, and the second subassembly may slip-fit into the first subassembly being retained with screws.

[0019] Embodiments of the presently-disclosed winch may operate manually or electrically. For manual operation of an embodiment winch, rocker switch 4 can be toggled to “lock” the winch into winching mode or “free” the winch into freespool mode.

[0020] When the “lock” side of rocker switch 4 is depressed, the force from this action pushes solenoid shaft 6 towards the gearbox. The shaft of the solenoid 6 may also be attached to actuation plate 8, which has anti-rotation key and keyway 15 to prevent rotation. Thus, actuation plate 8 is only able to travel axially. The actuation plate 8 may also have a male spline 11, which engages fa emale spline 12 when the “lock” side of the rocker switch 4 is depressed. The female spline 12 may be a fixed feature on the drive plate 10, and the drive plate 10 may be fixed to the ring gear 1. Therefore, if the “lock” mode is selected, the male spline 11 engages the female spline 12 and torque generation using the gear set can occur.

[0021] When the “free” side of the rocker switch 4 is depressed, the force from this action pulls the shaft of the solenoid 6 away from the gearbox, which disengages the male spline 11 from the female spline 12. Therefore, the ring gear 1 is no longer grounded (i.e., fixed) to any other component, and it may rotate freely on bearings 2 if subjected to a load (e.g., a tug on the winching rope/cable).

[0022] For electrical operation of an embodiment winch, the solenoid 6 may be actuated to “lock” the winch into winching mode or “freespool” the winch into freespool mode.

[0023] When the “lock” or “free” (“freespool”) modes are selected remotely or electronically (e.g., from inside of the vehicle), the solenoid 6 either engages or disengages, respectively, the male spline 11 and the female spline 12. When the male spline 11 is disengaged from the female spline 12, the ring gear 1 may rotate freely on bearings 2. When the male spline 11 is engaged with the female spline 12, the ring gear 1 may be grounded, enabling torque generation using the gear set to the winch’s spool.

[0024] Since the male spline 11 and the female spline 12 may not mesh without a small amount of rotation from the drive plate 10 (female spline), the return spring 7 applies a force to the actuation plate 8 in the event that the splines do not mesh before electrical power to solenoid is terminated. Therefore, when the spline teeth lineup, an axial force may be available to complete the mesh. Furthermore, the solenoid 6 may be a latching solenoid. In this way, when the “free” mode is selected, the latching functionality may magnetically hold the shaft in the disengaged position without the need to continually provide power to the solenoid.

[0025] Various means may be used to communicate with the winch electronically to cause the solenoid 6 to actuate. In some embodiments, a wireless key fob may be employed. In others, an interface (e.g., a touch pad) may be in a vehicle having the winch attached thereto. Various button pushes, along with controller area network (CAN) bus communication interface to communicate between the vehicle and the winch.

[0026] Advantages of embodiments herein may include decoupling the gearbox for freespool mode, permitting the entire gearbox to rotate freely when required, resetting the rocker switch automatically, and/or enabling a user to mechanically or electrically (e.g., remotely) switch between winching modes.

[0027] In another aspect, the present disclosure may be embodied as a gear-changing transmission for a winch. The gear-transmission provides an electronic or manual means of changing gears (i.e., switching reduction ratios) in a winch. This capability is beneficial when, for example, an operator wants to recover the winch rope at a higher speed than when the winch is configured to pull a load (i.e., when high torque may not be necessary). A winch so configured can recover the winch rope at a higher speed, thereby saving the operator time that would otherwise be lost through the gear reduction.

[0028] Such a winch transmission allows an operator to, for example, command a “change gear” or “rope recovery” event, through an integrated electronic controller, and without manual human intervention. This function could be utilized when the winch is commanded to recover the synthetic rope or cable (without a load), and low torque and high speed are required. This transmission switches the motor’s gearing from a low ratio to a higher ratio, and, allows the electric motor to perform in a range where it’s most efficient or capable, therefore providing a higher rope recovery rate when desirable. The transmission may also allow the user to command the “change gear” or “rope recovery” event manually (from outside of the vehicle), by accessing the rocker switch that is located on the end of the winch.

[0029] More specifically, the winch is capable of automatically and/or manually disengaging or bypassing a portion, or all of a gear reduction system to increase the spool speed (e.g., the rope recovery rate) at a given motor speed. In an exemplary embodiment, this capability can be commanded from inside of the vehicle (control panel or touch screen), wirelessly, through CAN (Controller Area Network), by operating an end-mounted rocker switch located on the winch, or other techniques or a combination of one or more of these. For example, after a winching scenario is performed, the load is uncoupled from the rope or cable and the winch automatically recovers the rope, and at a much higher rate than if it had to drive thru the entire gearbox. In addition, the user can switch gears from the insider of the vehicle or from accessing the end mounted rocker switch on the winch itself.

[0030] In an exemplary embodiment, the gear-changing transmission includes a three- stage planetary gearset and is driven by an electric motor by way of a clutch. In a “winching” mode (i.e., a mode requiring a high amount of torque), a motor shaft drives a pinion gear, which in turn drives the planet gears of a first stage. This first stage provides the largest amount of gear reduction relative to the other stages (described below).

[0031] The motor shaft can be translated along its primary (longitudinal) axis such that the motor shaft disengages the motor pinion gear of the first stage and engages a second stage sun gear/carrier plate. In this way, the overall reduction ratio is reduced by one stage. The motor shaft may be translated by, for example, a linear solenoid, a manual action of an operator, and/or otherwise. In the embodiment shown in Figures 4-10, a linear solenoid 6 and a rocker switch 4 are provided for moving the motor shaft 19 either electronically via the solenoid, or manually via the rocker switch. The action of the solenoid may be commanded by, for example, an electronic controller. An interface may be provided so that an operator can activate the solenoid (through the controller or otherwise). For example, an interface (e.g., push buttons, switches, dials, touch interfaces, etc. or combinations of these or others) may be placed in the interior of the vehicle, on a pendant, a key fob, etc.

[0032] The motor shaft can be translated back into engagement with the first stage to provide full reduction.

[0033] Figures 4-10 show an exemplary configuration where a winch has both a spool lock (for freespool operation) and a gear-changing transmission. In such an embodiment, the motor shaft may translate from a first position where the first stage is engaged (“winch” mode depicted in Figure 9) to a second position where the second stage is engaged (“rope recovery mode” depicted in Figure 10), and an actuation plate may be moved to a freespool position where a planetary ring gear is grounded such that the motor shaft is not coupled to the spool (“freespool” mode depicted in Figures 10-11). An actuator, such as a linear solenoid, rocker switch, etc., may directly or indirectly engage both the motor shaft and the actuator plate to select any of the three winch modes as commanded.

[0034] Unless otherwise stated, the terms “wire rope,” “rope,” and “cable” are used herein interchangeably to describe rope, cable, cord, of any diameter, monofilament, or multifilament, and made from metal, plastic, natural materials, or other materials including combinations of materials. Although specific components are described herein (e.g., rocker switch), it should be noted that alternative components may be used as will be apparent to one having skill in the art in view of the present application.

[0035] Although the present disclosure has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present disclosure may be made without departing from the spirit and scope of the present disclosure.