Note: Descriptions are shown in the official language in which they were submitted.
=
WINCH INCLUDING INTEGRATED CONTACTOR AND MOTOR
[0001]
FIELD
1000211 The present application relates generally to a winch including a
motor and a
contactor assembly positioned within a same housing.
SUMMARY AND BACKGROUND
[0003] Winches may include a motor for driving a rotatable drum of the
winch to pull in or
pull out a cable wound around the drum. In one example, winches may be
controlled via a
control unit located at a location away from the motor. Further, a remote
control may wirelessly
(or via a wired connection) control winch operation through electronic
communication with the
control unit.
[0004] The winch motor may be electrically coupled with a power source in
order to drive
the motor. In some examples, a contactor assembly is electrically coupled
between the motor
and the power source in order to control a flow of electrical current from the
power source to the
motor. The contactor assembly is often mounted to an exterior surface of a
housing of the winch
or motor, thereby resulting in a plurality of wires electrically coupling the
motor to the contactor
assembly and the contactor assembly to the power source. In examples in which
a control unit is
coupled to the winch, the control unit may also be electrically coupled to the
contactor assembly
via another plurality of wires. As a result of the numerous wired electrical
connections between
the motor, contactor assembly, power source, and control unit, an installation
and/or setup time
of the winch may be increased. Additionally, in some environments the
plurality of wires may
be exposed to harsh weather conditions, may be become tangled and/or frayed,
etc., thereby
resulting in degradation of the electrical connections between components of
the winch and/or
the power source.
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CA 2986290 2017-11-17
Date Recue/Date Received 2023-08-31
[0005] Thus in one example, the above issues may be at least partially
addressed by a motor
assembly for a winch, comprising: a motor including a motor armature; a
contactor assembly
coupled to the motor, the contactor assembly including two or more coils
spaced apart from one
another within a contactor housing of the contactor assembly and a brush
assembly including a
plurality of brushes surrounding a rotational axis of the motor and arranged
axially to the motor
armature; and a motor housing surrounding and enclosing the motor and
contactor assembly
within an interior of the motor housing.. In this way, an amount of wired
electrical connections
between the motor, contactor assembly, and a power source of the winch may be
reduced. By
reducing the amount of wired electrical connections, the installation and/or
setup time of the
winch may be reduced and winch maintenance may be perfoimed more easily.
[0006] It should be understood that the summary above is provided to
introduce in
simplified form a selection of concepts that are further described in the
detailed description. It is
not meant to identify key or essential features of the claimed subject matter,
the scope of which
is defined uniquely by the claims that follow the detailed description.
Furthermore, the claimed
subject matter is not limited to implementations that solve any disadvantages
noted above or in
any part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows a perspective view of a winch including a motor
housing.
[0008] FIG. 2 shows an exploded view of a motor assembly including a motor
and a
contactor assembly coupled within the motor housing.
[0009] FIG. 3A shows a cross-sectional view of the motor and the contactor
assembly
included within the motor housing.
[0010] FIG. 3B shows an assembled view of the motor assembly of FIGS. 2 and
3A.
[0011] FIG. 4 shows an exploded view of an alternate embodiment of a motor
assembly
including a motor and a contactor assembly coupled within the motor housing.
[0012] FIG. 5 shows a cross-sectional view of the alternate embodiment of
the motor and
the contactor assembly included within the motor housing.
[0013] FIG. 6 schematically shows a motor assembly of a winch, the motor
assembly
including a motor and a contactor assembly positioned within an interior of a
motor housing.
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v
[0014] FIG. 7 shows an exploded view of a motor assembly including a
contactor assembly
mounted around a motor of the motor assembly from a first end.
[0015] FIG. 8 shows an assembled view of the motor assembly of FIG. 7.
[0016] FIG. 9 shows an exploded view of the motor assembly of FIG. 7 from a
second end.
[0017] FIGS. 10A-10E each show different views of a motor housing for a
motor of a
winch.
[0018] FIGS. 11A-11B each show different views of components disposed
within the motor
housing of FIGS. 10A-10E, with the components removed from the motor housing.
[0019] FIG. 12 shows a first exploded view of the motor and components of
the motor
housing of FIGS. 10A-10E.
[0020] FIG. 13 shows a second exploded view of the motor and components of
the motor
housing of FIGS. 10A-10E.
[0021] FIGS. 1-5 and 7-13 are shown to scale, although other relative
dimensions may be
used.
DETAILED DESCRIPTION
[0022] The following detailed description relates to systems and methods
for a winch
including a motor and a contactor assembly positioned within a same housing
and/or arranged
together within a space defined by a drum support of the winch. A winch, such
as the winch
shown by FIG. 1, includes a rotatable drum drivable by a motor and coupled
with a gear set. The
motor is positioned within an interior of a motor housing and is directly
coupled with a contactor
assembly within the motor housing. The contactor assembly includes a plurality
of electrical
terminals, a controller, a brush assembly, and a plurality of conductive
brushes mounted to the
brush assembly. In one example, each of the brushes is biased in a radial
direction toward an
outer circumferential surface of an armature of the motor and in a direction
perpendicular to a
rotational axis of the motor, as shown by FIGS. 2-3. In another example, each
of the brushes is
biased in an axial direction toward an end surface of the armature and in a
direction parallel to
the rotational axis of the motor, as shown by FIGS. 4-5. The brushes press
against the
corresponding surface of the armature and may be energized via the contactor
in order to flow
electrical energy to the motor. The brush assembly may be a separate unit
removably coupled to
a contactor housing of the contactor assembly (as shown by FIGS. 2-3), or the
brush assembly
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and contactor housing may be formed (e.g., integrated) together as a single
unit (as shown by
FIGS. 4-5). By directly coupling the contactor assembly with the motor within
the motor
housing, an amount of external electrical connections (e.g., wires) coupling a
power source to the
contactor assembly and motor may be reduced, as shown at FIG. 6. In this way,
an ease of
installation of the contactor assembly may be increased and a maintenance of
the motor may be
simplified. In an alternate embodiment, the contactor assembly may be mounted
around a motor
of the winch. For example, as shown in FIGS. 7-9, a contactor may be mounted
against and
around a portion of a motor of a winch. In another example, as shown by FIGS.
10A-13, the
motor includes a field coil array directly, electrically coupled to the
contactor assembly.
[0023] A winch including a motor and a contactor assembly positioned within
a motor
housing is described below with reference to FIGS. 1-5. FIG. 1 shows an
example of a winch
which may include a motor assembly including a motor and a contactor assembly
positioned
within a motor housing, such as the motor and contact assembly shown in a
first embodiment by
FIGS. 2-3 and a second embodiment by FIGS. 4-5. Reference axes 195 are
included by each of
FIGS. 1-5 for comparison of each view.
[0024] FIG. 1 shows a perspective view of a winch 100 including a housing
160 and a motor
assembly 199. Housing 160 includes a first drum support 110 and a second drum
support 112.
The housing 160 further includes a motor housing 105 formed by the first drum
support 110
coupled to a motor end cap 106 and a gear housing 126 formed by the second
drum support 112
coupled to a gear end cap 108. In some examples, the motor end cap 106 may be
mounted (e.g.,
fastened) directly to the first drum support 110. In other examples, the motor
end cap 106 may
be indirectly mounted to the first drum support 110 via a coupling to one or
more components
(e.g., additional housing elements) between the motor end cap and the first
drum support 110. A
motor is disposed within the motor housing 105 and a gear reduction unit
including a plurality of
gears (e.g., such as a planetary gear set) and a clutch is disposed within the
gear housing 126. A
tie structure 120 is positioned at a top side 122 of the winch. A controller
(shown by FIGS. 2-3
in a first embodiment and FIGS. 4-5 in a second embodiment) positioned within
the motor
housing 105 may be an electronic controller (such as a microcontroller) and
may control a speed
of the motor within the motor housing 105 and/or a gear selection of a gear
set (e.g., gear
reduction unit) positioned within the gear housing 126. In some examples, the
controller may
control operation of one or more accessories of the winch (e.g., winch lights,
lights of a vehicle
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coupled to the winch, etc.), as described further below with reference to FIG.
6. In one example,
an operator of the winch may provide input (e.g., instructions) to the
controller via wireless
communication (e.g., via a remote control). For example, the operator may
interface with a
remote control in order to select a mode of operation of the winch 100 as
described below.
[0025] The motor and gear set are each coupled to a drum 118 of the winch
100 in order to
rotate the drum 118 around a central axis 190. The motor housing 105 is
positioned at a first end
102 of the winch 100 and the gear housing 126 is positioned at a second end
104 of the winch
100, with the first end 102 being opposite to the second end 104 in a
direction of the central axis
190. The drum 118 is coupled to the motor through the gear reduction unit
which is coupled to
the motor through an interior of a cylindrical portion 164 of the drum 118.
The controller may
also control a position of the clutch disposed within the gear housing 126.
The clutch may
engage and disengage the gear reduction unit (e.g., transmission of the winch)
with a drum 118
of the winch 100, thereby allowing the drum 118 to be driven by the motor or
freespool (e.g.,
freely rotate without input from the motor and gear reduction unit).
[0026] In one example operation of the winch 100, the motor may drive the
drum 118 to
rotate around the central axis 190 in a first direction 165 or a second
direction opposite to the
first direction. For example, the motor may be driven in the first direction
165 in order to rotate
the drum 118 around the central axis 190, and the motor may be driven in the
second direction
opposite to the first direction in order to rotate the drum 118 around the
central axis in the second
direction. In this example, a selected gear of the gear set may adjust a
rotational speed of the
drum relative to a rotational speed of the motor. In one example, a rope
(e.g., cable) 192 may be
wound around an outer surface 119 of the drum 118 in order to perform pulling
operations via
the winch 100. In some examples, the rope 192 may be coupled with a hook 150
in order to
increase an ease of attachment of the rope 192 to an object (e.g., a vehicle)
to perform pulling
operations.
[0027] The drum 118 includes a first flange (indicated by arrow 116 and
referred to herein
as first flange 116) positioned at a first end of the cylindrical portion 164
of the drum 118 and a
second flange 114 positioned at a second end of the cylindrical portion 164 of
the drum 118.
The first flange 116 and second flange 114 each are cylindrical in shape and
have a diameter that
is greater than a diameter of the cylindrical portion 164 of the drum 118
(e.g., the portion
extending between the first flange 116 and second flange 114). The first
flange 116 is supported
CA 2986290 2017-11-17
by first drum support 110 while the second flange 114 is supported by second
drum support 112.
The first flange 116 and second flange 114 are coupled with their respective
supports (e.g., first
drum support 110 and second drum support 112, respectively) such that each
flange is rotatable
within the corresponding drum support when the motor is actuated to drive the
drum 118 (or
when the drum is in a freespool mode). In other words, as the motor within
motor housing 105 is
energized by a power source 175 (e.g., a vehicle battery, indicated
schematically by FIG. 1), the
motor may drive the drum 118 to rotate around the central axis 190. In one
example, the motor
may be energized in response to a selection of an operation mode by an
operator of the winch
(e.g., via a remote control) as described above. As the drum 118 is driven,
the first flange 116
rotates within the first drum support 110 and the second flange 114 rotates
within the second
drum support 112.
[0028] The winch 100 includes electrical terminals 180 extending outward
from a contactor
assembly positioned within an interior of the motor housing 105 and shown by
FIGS. 2-5.
Electrical terminals 180 include a first terminal 182 and a second terminal
184. In one example,
first terminal 182 may be an electrical power source input and second terminal
184 may be an
electrical ground input. In another example, first terminal 182 may be an
electrical ground input
and second terminal 184 may be an electrical power source input. In some
examples, electrical
current may flow from the power source 175 to the electrical terminals 180 via
a power cable
171 coupled to a plug 170. Plug 170 is shaped to couple with the electrical
terminals 180 in
order to flow electrical current to the contactor assembly. As described below
in a first
embodiment with reference to FIGS. 2-3 and a second embodiment with reference
to FIGS. 4-5,
electrical current may flow from the power source 175 and through the
contactor assembly to the
motor in order to energize the motor.
[0029] By positioning the contactor assembly within the motor housing 105
and directly
coupling the contactor assembly to the motor according to the configurations
described below, an
amount of wired electrical connections coupling the motor to the power source
175 may be
reduced. For example, the power cable 171 is the only wired electrical
connection coupling the
contactor assembly to the power source 175, and because the contactor assembly
is directly
coupled with the motor, electrical current may flow directly from the power
source 175 to the
motor via the contactor assembly without an additional power cable (similar to
power cable 171)
coupled between the contactor assembly and the motor.
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[0030] FIG. 2 shows an exploded view of the motor assembly 199 shown by
FIG. 1, with
the motor assembly 199 including a first embodiment of a contactor assembly
200. In some
embodiments, the motor assembly 199 may be referred to as a combined, or
integrated, motor
assembly that includes contactor assembly 200 and motor 201. In the first
embodiment shown
by FIGS. 2-3, the contactor assembly 200 includes a plurality of brushes 218
arranged in a radial
configuration relative to the central axis 190. Each of the brushes is mounted
to a brush
assembly 202, and the brush assembly 202 is removably coupled with a contactor
housing 224.
In other words, the brush assembly 202 and contactor housing 224 are not
formed together as a
single piece (e.g., not integrated together). In another embodiment, the brush
assembly 202 may be
additionally or alternatively mounted to the motor end cap 106, drum support
110, or flux ring 206.
Alternate embodiments may include an axial configuration of the brushes 218
such as the
configuration shown by FIGS. 4-5 and described below. In another embodiment,
the radial
configuration of the brushes 218 may be included in an assembly where the
brush assembly and
contactor housing are formed together as a single piece (e.g., integrated
together, similar to the
example shown by FIGS. 4-5).
[0031] As described above with reference to FIG. 1, motor housing 105
includes the first
drum support 110 and the motor end cap 106. The first drum support 110 and
motor end cap 106
may be coupled (e.g., directly coupled) together via a plurality of fasteners
(e.g., bolts, not
shown). Motor 201 and contactor assembly 200 are coupled together within an
interior of the
motor housing 105, as indicated in part by an interior 230 of the first drum
support 110 shown by
FIGS. 2-3A. The motor end cap 106 includes one or more apertures 265 (e.g.,
openings) shaped
to receive the electrical terminals 180 of the contactor assembly 200 when the
motor 201 and
contactor assembly 200 are coupled together within the motor housing 105. In
other words, the
electrical terminals 180 and aperture 265 are arranged at a same end of the
contactor assembly
200 when the motor 201 and contactor assembly 200 are coupled together within
the motor
housing 105. In this configuration, the electrical terminals 180 extend
outward from the interior
of the motor housing 105, as shown by FIG. 1 and described above. The motor
end cap 106
further includes a terminal isolator 267 coupled to an outside of the motor
end cap 106 and
adapted to electrically isolate the electrical terminals 180 from one another
and the external
environment. A plurality of o-rings 269 may also surround each of the
electrical terminals 180.
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[0032] The motor 201 includes an armature 204 shaped to fit within a flux
ring 206. Flux ring
206 is shaped to fit within the interior 230 of the first drum support 110 and
is rotationally fixed
(e.g., non-rotatable) relative to the first drum support 110. Flux ring 206 is
configured to produce a
magnetic field within the interior 230 of the first drum support 110 (e.g.,
within an inner diameter
331 of the flux ring 206, as shown by FIG. 3A). In one example, the magnetic
field produced by
the flux ring 206 may be due to a plurality of permanent magnets included
within the flux ring 206.
In other examples, the magnetic field may be due to an energization of
electrically conductive coils
of the flux ring 206 by the power source 175 (shown schematically by FIG. 1).
In examples in
which the flux ring 206 includes electrically conductive coils, the coils may
be energized via direct
contact with one or more electrically conductive surfaces of the contactor
assembly 200.
[0033] The armature 204 includes a first portion 221, a second portion 223,
and a third portion
225. The third portion 225 may have an outer diameter 327 (shown by FIG. 3A)
slightly less than
the inner diameter 331 of the flux ring 206, and the second portion 223 may
have an outer diameter
329 (shown by FIG. 3A) less than the outer diameter 327 of the third portion
225. The aimature
204 is rotatably mounted within the motor housing 105 by one or more
fasteners, springs, and
bearings (e.g., spring 209, coupler 208, and bearing 214). In other words, the
armature 204 is
coupled to the motor housing 105 such that the armature 204 may rotate
relative to the motor
housing 105 in a direction around the central axis 190, such that the central
axis 190 is a rotational
axis of armature 204 (e.g., a rotational axis of motor 201). An interior of
the third portion 225 of
the armature 204 includes a plurality of energizable coils electrically
coupled with the second
portion 223. The coils of the armature 204 may be energized via direct contact
of the second
portion 223 with the plurality of brushes 218 of the contactor assembly 200
(as described further
below). Electrical current flowing through the coils interacts with the
magnetic field produced by
the flux ring 206 and results in a rotational motion of the armature 204
around the central axis 190.
As described above with reference to FIG. 1, the armature 204 is coupled to a
gear reduction unit
through an interior of a cylindrical portion 164 of the drum 118 (shown by
FIG. 1) such that
rotation of the armature 204 drives the gear reduction unit, and driving the
gear reduction unit may
rotate the drum 118.
[0034] Each of the brushes 218 are coupled (e.g., mounted) to the brush
assembly 202 and
in one example may be arranged such that each brush 218 presses against the
second portion 223
along an outer circumference 220 of the second portion 223, as shown by FIGS.
2-3A. In the
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example shown by FIGS. 2-3A, the brushes 218 are positioned radially around
the central axis
190. Each brush 218 may be urged toward the central axis 190 (e.g., in a
radial direction 222
relative to the central axis 190) by one or more biasing members (e.g.,
springs, not shown). The
brushes 218 and biasing members may each be formed of electrically conductive
materials. In
one example, the brushes 218 may be made of carbon and the biasing members may
be made of
a conductive metal such as copper or steel.
[0035] In the example shown by FIGS. 2-3A, the brush assembly 202 may be
coupled (e.g.,
mechanically coupled) to a first side 228 of a contactor housing 224 of the
contactor assembly
200 via one or more fasteners (e.g., push nuts 227), fastening apertures 229
on the brush
assembly 202, and mounting extensions 231 on the first side 228 of the
contactor housing 224,
with the first side 228 being opposite to a second side 226 of the contactor
housing 224 in the
direction of the central axis 190. The first side 228 of the contactor housing
224 is further from
the motor end cap 106 than the second side 226 in the direction of the central
axis 190. In other
examples, the brush assembly 202 and contactor housing 224 may instead be
formed together as
a single piece (e.g., molded together), with the brush assembly 202 positioned
at the first side
228.
[0036] The contactor housing 224 includes a first coil 205 and a second
coil 207 (shown by
FIG. 3A and indicated by arrows in FIG. 2) positioned within an interior of
the contactor housing
224. However, in alternate embodiments, the contactor housing 224 may include
two or more
coils (such as first coil 205, second coil 207, and an additional, third
coil). In the example shown
by FIGS. 2-3, the first coil 205 and second coil 207 are positioned opposite
to each other in a
direction perpendicular to the central axis 190 (and across the central axis
190) such that an outer
surface of the first coil 205 and an outer surface of the second coil 207 are
separated by a
distance 300 (shown by FIG. 3A). In some examples, the brush assembly 202 is
positioned
between the first coil 205 and second coil 207 such that the brush assembly
202 fits within the
distance 300 and surrounds the first portion 221 of the armature 204. In
alternate examples, the
brushes 218 of the brush assembly 202 may be positioned proximate to but
outside of the gap
that separates the first coil 205 and second coil 207. The first coil 205
and/or second coil 207
may be energized in order to flow electrical current through the contactor
assembly 200 and the
brushes 218, thereby energizing the armature 204 as described above. In one
example,
energization of the first coil 205 and/or second coil 207 may apply a magnetic
force to
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=
components internal to the contactor housing 224 in order to close an
electrical circuit between
the brushes 218 and the power source 175 (shown by FIG. 1), thereby flowing
electrical current
from the power source 175 to the brushes 218 via the contactor assembly 200.
[0037] In one example, energization of the first coil 205 and/or second
coil 207 may be
controlled by a controller 210 positioned within the motor housing 105. In
some examples,
controller 210 is directly coupled with the contactor assembly 200. The
controller 210 may
include instructions stored in non-transitory memory to energize the first
coil 205 and/or the
second coil 207 in response to input by an operator of the winch (e.g., winch
100 shown by FIG.
1). For example, the operator of the winch may interface with a remote control
(or another
remote controller device such as a wired remote, wireless remote, a vehicle
system controller, or
the like) in order to send a wireless signal (e.g., radio wave signal) to the
controller 210
indicating that a rotation of the drum 118 (shown by FIG. 1) in a first
direction is desired by the
operator. The controller 210 may then energize the first coil 205 and/or the
second coil 207 in
order to flow electrical current through the brushes 218 and into the armature
204, thereby
rotating the armature 204 around the central axis 109 and driving the gear
reduction unit to rotate
the drum 118 in the first direction. In another example, the operator of the
winch may interface
with the remote control in order to send a wireless signal to the controller
210 indicating that a
rotation of the drum 118 in a second direction opposite to the first direction
is desired by the
operator. The controller 210 may then energize the first coil 205 and/or the
second coil 207 in
order to flow electrical current through the brushes 218 and into the armature
204, thereby
rotating the armature 204 around the central axis 109 and driving the gear
reduction unit to rotate
the drum 118 in the second direction.
[0038] In some examples, the controller 210 may include a motor speed
sensor, motor
current sensor, voltage sensor, motor direction sensor, motor position sensor,
drum rotation
sensor, and/or motor temperature sensor, and the controller 210 may be
configured to receive
and/or transmit wired and/or wireless signals from/to a controller area
network (CAN) and/or
winch accessories (e.g., an electric free spooling clutch actuator). In
another example, as shown
in FIG. 2, the controller 210 may include a plurality of electrical wires 233
for electrically
coupling the controller 210 to an external system (such as a vehicle system)
and/or external
controller (such as a vehicle controller), which are encased within an
electrical (e.g., power)
cable 235 that extends from an exterior of the motor assembly, as shown in
FIG. 3B. In the
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embodiment shown by FIGS. 2-3A, a motor shaft sensor 216 (which may be
referred to herein as
a motor speed sensor) is coupled to the first portion 221 of the armature 204
(e.g., inserted into
the first portion 221 in an axial direction relative to the central axis 190
and extending away from
the armature 204 in the axial direction). Motor shaft sensor 216 may sense a
speed and/or
position of the armature 204 relative to the contactor housing 224 and send
electrical signals to
the controller 210 to indicate the speed and/or position of the armature 204.
For example, the
motor shaft sensor 216 may be adapted to measure one or more of a rotational
speed of the
motor, a direction of rotation of the motor, and a position of the motor.
[0039] The controller 210 may include instructions stored thereon for
adjusting operation of
the motor 201 in response to an output of the motor shaft sensor, temperature
sensor, current
sensor, voltage sensor, and/or signals from the remote control (as described
above). As shown in
FIG. 2, one or more sensors 237 (including the temperature sensor, current
sensor, voltage
sensor, or the like) may be directly coupled to the controller 210. The
temperature sensor may be
configured to measure a temperature of the motor 201. In one example, the
controller 210 may
monitor (e.g., measure) an output of the temperature sensor and compare the
measured temperature
to a threshold temperature. If the measured temperature exceeds the threshold
temperature, the
controller may de-energize (e.g., turn off) the motor 201 in order to reduce
the temperature of the
motor 201. By coupling the temperature sensor directly to the controller, the
temperature sensor may
measure the temperature of the motor 201, and the controller 210 may directly
interpret the measured
temperature from the temperature sensor without additional electrical
connections. For example, in
winches that do not include a temperature sensor directly coupled with a
controller (e.g., winches in
which the controller is positioned outside of the motor housing), the
temperature sensor may be
electrically wired with the controller, thereby increasing an amount of wired
electrical connections to
the motor housing, or the temperature sensor may be in remote communication
with the controller
(e.g., via a wireless signal), thereby increasing a complexity and/or cost of
the temperature sensor
and/or controller. By coupling the temperature sensor directly to the
controller, the amount of wired
connections and/or wireless connections between the temperature sensor and
controller is decreased.
[0040] In another example, the voltage sensor may be configured to measure
an operating
voltage of the motor 201. The controller 210 may monitor (e.g., measure) an
output of the
voltage sensor and compare the measured voltage to an upper threshold voltage.
If the measured
voltage exceeds the upper threshold voltage, the controller 210 may de-
energize the first coil 205
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and/or second coil 207 in order to reduce a likelihood of the motor 201 being
exposed to a
voltage higher than a normal operating voltage. In another example, if the
measured voltage is
lower than a lower threshold voltage, the controller 210 may de-energize the
first coil 205 and/or
second coil 207 in order to reduce a likelihood of the motor 201 being exposed
to a voltage lower
than a normal operating voltage. In this way, the motor may have a threshold
operating range
between the lower and upper threshold voltages and when a measured voltage is
outside this
range, the controller may stop operating the motor to reduce degradation to
the motor, winch,
and/or vehicle to which the winch is coupled.
[0041] In yet another example, the motor current sensor may be configured
to measure an
operating current of the motor 201. The controller may monitor an output of
the current sensor
and compared the measured current to a threshold current. If the measured
current exceeds the
threshold current, the controller 210 may de-energize the first coil 205
and/or second coil 207 in
order to reduce a likelihood of the motor 201 being exposed to an electrical
current higher than a
normal operating current.
[0042] Additionally, the controller 210 may include instructions stored
thereon for recording
and storing specific winch events in non-volatile memory of the controller
210. For example, the
controller 210 may record and store winch usage data which may include one or
more of motor
current, temperature, and/or voltage levels throughout winch operation, a
direction of rotation of
the winch motor, events where motor operation of the winch had to be
determined due to the
motor temperature, current, and/or voltage exceeding or decreasing below
threshold levels (as
described above), winch clutch operation, etc. This usage data may be stored
in the controller
210 and then referenced during servicing of the winch or via a wireless
connection with an
external device. In this way, the usage data may be obtained to aid in winch
system
development, customer service, and/or winch servicing or repair.
[0043] In some embodiments, new set points may be loaded into the
controller 210, by a
user (via a wireless or direct wired connection to the controller via the
terminals) to change how
the controller adjusts motor operation based on measured voltage, temperature,
speed, and/or
current. For example, new or updated threshold current, voltage, temperature,
and/or speed
levels for motor operation may be loaded onto the memory of the controller. As
a result, after
updating these stored thresholds, the controller 210 may adjust motor
operation according to the
newly updated thresholds (and not based on the old or previously stored
thresholds). In another
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example, a bootloader may be present to change the application code stored in
the controller
memory, in the field (e.g., during winch operation and/or when the winch is
installed on a
vehicle), in order to fix a bug or to provide new functionality for a specific
winching application.
100441 FIG. 3A shows a cross-sectional view of the motor 201 and contactor
assembly 200
assembled together within the motor housing 105 while FIG. 3B shows an
assembled view of the
motor assembly 199. As described above with reference to FIG. 2, the armature
204 may rotate
around the central axis 190 and is positioned within an interior of the flux
ring 206. As shown in
FIG. 3A, a first side 360 of the motor 201 is positioned away from the motor
end cap 106 and
toward the drum 118 (shown by FIG. 1), while a second side 362 is positioned
toward the motor
end cap 106 and the contactor assembly 200. By positioning and integrating the
motor 201 and
contactor assembly 200 together within the motor housing 105 as shown by FIGS.
2-3, the
contactor assembly 200 may flow electrical current from the power source 175
(shown by FIG.
1) to the armature 204 in order to drive a rotation of the drum 118 as
described above. The
armature 204 and contactor assembly 200 may be electrically coupled via the
brushes 218
(shown by FIG. 2) such that only the single power cable 171 (shown by FIG. 1)
electrically
couples the power source 175 to the winch 100 (shown by FIG. 1). In this way,
an amount of
wired electrical connections between the motor 201, contactor assembly 200,
and power source
175 may be reduced, thereby increasing an ease of installation and maintenance
of components
of the winch 100. In some examples, a length of the wired electrical
connections may also be
reduced by integrating the motor 201 and contactor assembly 200 together
relative to a winch in
which the contactor assembly is located outside of (e.g., remote from) the
motor, thereby
reducing a likelihood of wire degradation. FIG. 3B shows an assembled,
external view of the
motor assembly 199 where the motor housing 105 is formed by the first drum
support 110
coupled to the motor end cap 106. The electrical cable 235 coupled to the
controller 210 is
shown extending outward from the motor housing 105. Further, the electrical
terminals 180 also
extend outward from the motor housing 105 on the motor end cap 106.
100451 FIGS. 4-5 each show a second embodiment of a motor assembly 490
including a
motor 401, a contactor assembly 400, and the motor housing 105. FIG. 4 shows
an exploded
view of the motor assembly 490, while FIG. 5 shows the motor 401 and contactor
assembly 400
assembled together within the motor housing 105. Similar parts shown by FIGS.
1-3 may be
labeled similarly and may not be re-introduced below.
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[0046] The motor 401 includes the flux ring 206 and an armature 402. The
armature 402
includes a first portion 432, a second portion 434, and a third portion 436.
Similar to the
armature 204 shown by FIGS. 2-3, the armature 402 is configured to fit within
an inner
circumference of the flux ring 206 and to rotate around the central axis 190
in response to
energization of coils internal to the armature 402 (e.g., via an interaction
of electrical current
flowing through the coils with the magnetic field produced by the flux ring
206, described above
with reference to FIG. 2). In other words, the central axis 190 is a
rotational axis of the motor
401. The third portion 436 has an outer diameter 504 (shown by FIG. 5) less
than the inner
diameter 331 of the flux ring 206 and may be greater than an outer diameter
502 (shown by FIG.
5) of the second portion 434. The outer diameter 502 of the second portion 434
may be greater
than an outer diameter 550 of the first portion 432.
[0047] The contactor assembly 400 shown by FIGS. 4-5 includes a brush
assembly 409
formed together as a single piece with a contactor housing 424. In other
words, the brush
assembly 409 and contactor housing 424 are not coupled via one or more
fasteners (as in the
example of the brush assembly 202 and contactor housing 224 shown by FIGS. 2-
3) but instead
are molded and/or fused together as a single unit. Further, the brush assembly
409 may be
included as part of the contactor housing 224. In alternate embodiments, the
brush assembly 409
and contactor housing 224 may be two separate pieces coupled together via a
plurality of
fasteners (e.g., bolts). A plurality of brushes 406 are coupled with the brush
assembly 202 and
positioned radially around the central axis 190. Each of the brushes 406 is
urged away from the
brush assembly 409 in a direction 422 parallel to the central axis 190 via one
or more biasing
elements (e.g., springs, not shown). In this configuration, when the motor 401
and contactor
assembly 400 are assembled together within the motor housing 105, the brushes
406 are pressed
against an end surface 431 of the second portion 434 of the armature 402 and
are not pressed
against the second portion 434 along an outer circumference 430 of the second
portion 434. In
other words, the brushes 406 are urged in an axial direction relative to the
central axis 190
against the armature 402. The brushes 406 and biasing members may each be
formed of
electrically conductive materials. In one example, the brushes 406 may be made
of carbon and
the biasing members may be made of a conductive metal such as copper or steel.
[0048] The contactor assembly 400 includes a first coil 405 and a second
coil 407 (similar to
first coil 205 and second coil 207, respectively, shown by FIGS. 2-3)
positioned within an
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CA 2986290 2017-11-17
interior of the contactor housing 424. However, in alternate embodiments, the
contactor
assembly 400 may include two or more coils (such as first coil 405, second
coil 407, and an
additional, third coil). The first coil 405 is positioned opposite to the
second coil 407 in a
direction perpendicular to the central axis 190 such that an outer surface of
the first coil 405 is a
distance 500 (shown by FIG. 5) from an outer surface of the second coil 407.
The brush
assembly 409 is positioned between the first coil 405 and second coil 407 such
that the brush
assembly 409 fits within the distance 500 and surrounds the first portion 432
of the armature
402. As described above with reference to the first coil 205 and the second
coil 207 shown by
FIGS. 2-3, the first coil 405 and/or second coil 407 may be energized in order
to flow electrical
current through the brushes 406 of the contactor assembly 400 and into the
armature 402. In one
example, energization of the first coil 405 and/or second coil 407 may apply a
magnetic force to
components internal to the contactor housing 424 in order to close an
electrical circuit between the
brushes 406, the power source 175 (shown by FIG. 1) and the armature, thereby
flowing electrical
current from the power source 175 to the brushes 406 and to the motor (and
therefore, the armature
402) via the contactor assembly 400.
[0049] As described above with reference to FIGS. 2-3, the controller 210
may include
instructions stored in non-transitory memory to energize or de-energize the
first coil 405 and/or
the second coil 407 in response to input from the operator of the winch 100
(shown by FIG. 1).
In the example shown by FIGS. 4-5, the controller 210 is coupled to the
contactor housing 424 at
a first side 426 of the contactor housing 424. The first side 426 is opposite
to a second side 428
in the direction of the central axis 190 such that the first side 426 is
closer to the motor end cap
106 than the second side 428. The controller 210 may include a plurality of
sensors as described
above with reference to FIGS. 2-3 and may be configured to adjust winch
operation in response
to input from the operator of the winch according to the examples described
above.
[0050] FIG. 5 shows a cross-sectional view of the motor housing 105 with
the motor 401
and contactor assembly 400 positioned within the motor housing 105. The
armature 402 of the
motor 401 is mounted within the motor housing 105 such that the armature 402
may rotate
relative to the flux ring 206 and motor housing 105. However, the contactor
assembly 400 is
mounted within the motor housing 105 such that the contactor assembly is not
rotatable relative
to the motor housing 105. In the example shown by FIGS. 4-5, a first end 560
of the motor 401
is positioned away from the motor end cap 106 and toward the drum 118 (shown
by FIG. 1),
CA 2986290 2017-11-17
while a second end 562 of the motor 401 is positioned opposite to the first
end 560 in the
direction of the central axis 190 and toward the motor end cap 106 and
contactor assembly 400.
[0051] A schematic diagram of a motor assembly 600 of a winch (e.g., winch
100 shown by
FIG. 1) is shown by FIG. 6. In one example, motor assembly 600 may be a
schematic
representation of the first embodiment of a motor assembly described above
with reference to
FIGS. 1-3 or the second embodiment of a motor assembly described above with
reference to
FIGS. 4-5 (e.g., motor assembly 199 and motor assembly 490, respectively).
Motor assembly
600 includes a motor 601 (e.g., similar to motor 201 and motor 401 described
above) and a
contactor assembly 608 (e.g., similar to contactor assembly 200 and contactor
assembly 400
described above) positioned within an interior 603 of a motor housing 622
(e.g., similar to motor
housing 105 described above). Motor assembly 600 is shown by FIG. 6 in order
to illustrate a
relative number and positioning of electrical connections between components
of the motor
assembly 600 positioned within the interior of the motor housing 622 and
components of a winch
system positioned outside of the motor housing 622.
[0052] Brush assembly 616 (e.g., similar to brush assembly 202 and brush
assembly 409
described above), armature 618 (e.g., similar to armature 204 and aimature 402
described
above), and controller 609 (e.g., similar to controller 210 described above)
are each positioned
within the interior 603 of the motor housing 622 along with the contactor
assembly 608. In some
examples, the controller 609 and contactor assembly 608 are coupled together
as a single unit.
The controller 609 may communicate wirelessly (e.g., receive and/or transmit
electromagnetic
signals) via wireless signals 624 (e.g., radio waves) with a remote control
626 in order to control
an operation of the motor 601 and other components of the winch (as described
above with
reference to the examples shown by FIGS. 1-5). The controller 609 may also
communicate
wirelessly via wireless signals 629 (e.g., radio waves) with one or more
accessories 627 of the
winch. In one example, accessories 627 may include winch lights, lights of a
vehicle coupled to
the winch, and other types of accessories. Thus, in some examples, the
controller 609 may control
operation of the motor and/or the accessories 627. The brush assembly 616 is
electrically coupled
with the contactor assembly 608 by a first electrical connection 612 and a
second electrical
connection 614. In one example, first electrical connection 612 and second
electrical connection 614
are wired electrical connections extending from the contactor assembly 608 to
the brush assembly
616. In another example, the first electrical connection 612 and second
electrical connection 614
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may not be wired electrical connections but may instead be direct electrical
connections between
conductive contacts of the contactor assembly 608 and conductive contacts of
the brush assembly
616. In yet other examples, the contactor assembly may additionally be
electrically coupled with a
flux ring (e.g., flux ring 206) within the interior 603 of the motor housing
622 via one or more wired
electrical connections or direct electrical connections as described above.
The armature 618 of the
motor 601 may be coupled to a gear set of the winch via a drum 620 (as
described above with
reference to motor 201 and drum 118 shown by FIG. 1).
[0053] The motor may be powered by a power source 602 external to the motor
housing
622. In one example, the power source 602 may be a battery of a vehicle (e.g.,
a vehicle coupled
with the winch). The power source 602 transmits electrical energy (e.g.,
electrical current) to the
contactor assembly 608 via a first wired electrical connection 604 and a
second wired electrical
connection 606. In some examples, first wired electrical connection 604 and
second wired
electrical connection 606 may be bundled together as a single wire harness.
The first wired
electrical connection 604 and second wired electrical connection 606 are
coupled to terminals
610 (e.g., similar to electrical terminals 180 described above) of the
contactor assembly 608. In
one example, the terminals 610 are positioned external to the interior 603 of
the motor housing
622. As a result, the first wired electrical connection 604 and second wired
electrical connection
606 are the only external wired electrical connections (e.g., external to the
interior 603) coupled
to the contactor assembly 608. No other electrical connections external to the
interior 603 are
coupled to the contactor assembly 608, brush assembly 616, armature 618, or
controller 609.
[0054] In an alternate embodiment, the contactor assemblies described above
may be
mounted around a motor of the winch. For example, as shown in FIGS. 7-9, a
contactor 702 may
be mounted against and around a portion of a motor 704 of a winch.
Specifically, FIGS. 7-9
show a motor assembly 700 for a winch, such as the winch 100 shown in FIG. 1.
In this way, the
motor assembly 700 may be the motor assembly 199 shown in FIG. 1, in one
embodiment. The
motor assembly 700 includes the motor 704 coupled to a drum support 706 of the
winch (which
may be similar to first drum support 110 shown in FIG. 1), the contactor 702
mounted around a
portion of an outer surface 708 of the motor 704, and an electrical terminal
cover 710 coupled to
an end of the contactor 702 and around a portion of the outer surface 708 of
the motor 704. The
electrical terminal cover 710 includes a contoured surface 711 and the outer
cylindrical surface
of the motor 704 fits (e.g., sits) within and against the contoured surface
711.
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CA 2986290 2017-11-17
[0055] In one example, the motor 704 may include an armature and flux ring
housed within
the outer housing (formed by outer surface 708) of the motor 704. Thus, in
some embodiments
motor 704 may include similar components to the motors described above with
reference to
FIGS. 1-6. In other embodiments, the motor 704 may be an alternate type of
motor adapted to
operate with the contactor 702. The contactor 702 may include a contactor
assembly housed
within an outer casing (e.g., housing) 712 of the contactor 702. The contactor
assembly may
include two or more coils (such as coils 205 and 207 shown in FIG. 2) spaced
apart from one
another within an interior of the contactor 702. The contactor assembly may be
one of, or
include similar components as, the contactor assemblies described herein, such
as contactor
assembly 200 shown in FIGS. 2-3 or contactor assembly 400 shown in FIGS. 4-5.
[0056] By spacing the two or more coils apart from one another within the
contactor 702,
the contactor may be shaped to mount around a portion of the motor 704. For
example, as shown
in FIG. 7, the contactor 702 has a saddle shape with a contoured, concave
inner surface 714 that
is shaped to fit against the complementary contoured, convex outer surface 708
of the motor 704.
In this way, the concave inner surface 714 may have face-sharing contact with
the outer surface
708 when the motor 704 and contactor 702 and coupled to (or fit against) one
another. The
convex outer surface 708 has sidewalls that curve around a portion of an outer
circumference of
outer surface 708. Specifically, as shown in FIG. 7, the contactor 702 couples
around a bottom
surface of the outer surface 708 (with respect to a vertical direction and a
surface on which the
winch sits). However, in alternate embodiments, the contactor 702 may couple
around a side or
top portion of the outer surface 708 (e.g., such that the contactor 702 is
oriented above or to the
left or right side of the motor 704 instead of below the motor 704, as shown
in FIGS. 7-9).
[0057] Contactor 702 includes a plurality of electrical connections (e.g.,
terminals)
extending outward from an outer end wall 716 of the housing of the contactor
702, where the
outer end wall 716 is arranged normal to a central axis of the motor 704 and
faces an outer end of
the motor assembly 700 (e.g., an end of the motor assembly that is positioned
furthest away from
a drum of the winch and arranged opposite the drum support 706). Specifically,
as shown in
FIG. 7, the contactor 702 includes electrical motor connections 720 and
battery connections 722
which are separated from one another (e.g., divided) along the outer end wall
716 and covered
(e.g., capped or enclosed) by the terminal cover 710. As such, these separate
electrical
connections may be protected from outside contact and from contact with one
another. The
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CA 2986290 2017-11-17
battery connections 722 may be adapted to couple to one or more wires or
electrical coupling
elements coupled to a power source, such as a vehicle battery or control unit
of the winch. The
electrical motor connections 720 may couple to wires or bus bars coupled to
and extending from
the motor 704. For example, as shown in FIG. 7, the motor assembly 700
includes bus bars (or
may alternatively be wired connections) 724 which directly and electrically
couple electrical
contactor connections 726 of the motor 704 to the electrical motor connections
720 of the
contactor 702. The electrical connections between the motor 704 and contactor
702 are greatly
reduced in length due to the contactor 702 be coupled directly to and
positioned around a portion
of the motor 702, within a space (e.g., envelope, as described further below)
defined by the drum
support 706 (as compared to systems where the contactor is separated from and
not in contact
with the motor). As shown in FIG. 7, the electrical motor connections 720
extend a short
distance away from the end wall 722, in a direction of central axis 718, and
the bus bars 724
extend vertically, a short direction toward the electrical motor connections
720, in a direction
perpendicular to the central axis 718. Further, the single and same electrical
terminal cover 710
covers and encases the electrical motor connections 720, battery connections
722, and electrical
contactor connections 726 within the same space.
[0058] As shown in FIGS. 7 and 9, the outer casing 712 of the contactor 702
and an inner
surface 728 of the drum support 706 include complementary mating features 730
that lock
together, thereby, coupling the contactor 702 to the drum support 706.
Specifically, as shown in
FIG. 7, the drum support 706 includes a first mating feature 732 that
depresses into the inner
surface 728 (there may be two of the first mating features 732 arranged on the
inner surface 728,
one on each side of the inner surface 728 relative to central axis 718) and is
adapted to receive a
complementary, second mating feature 731 (as shown in FIG. 9) that protrudes
outward from an
inner end wall 734 of the contactor 702.
100591 As shown in FIG. 8, the contactor 702 mounts to the motor 704 while
staying within
an envelope defined by outer walls 736 of the drum support 706. Specifically,
the outer walls
736 of the drum support 706 define an overall width 738 and height 740 of the
motor assembly
700. The motor 704, contactor 702, and electrical terminal cover 710, all fit
within the bounds
defined by the width 738 and height 740. Said another way, an entirety of the
contactor 702 and
the motor 702 fit within and do not extend outside of the envelope defined by
the outer walls 736
of the drum support 706. For example, no part of the contactor 702 and no part
of the motor 704
19
CA 2986290 2017-11-17
extend beyond the bounds of the drum support 706, as defined by the outer
walls 736. As such,
the space occupied by the overall motor assembly 700 is reduced and the
overall form factor of
the winch is maintained at a desired size. In some embodiments, the motor 704,
contactor 702,
and electrical terminal cover 710 may all be positioned (e.g., enclosed)
within a motor housing of
the motor assembly 700. For example, as shown in FIG. 1, a motor end cap (such
as motor end
cap 106) may be positioned around the motor 704 and contactor 702 and couples
to drum support
706. In this way, the motor 704 and contactor 702 may be positioned within a
same housing. In
other examples, the electrical terminal cover 710 may be shaped to be
positioned around the
motor 704 and contactor 702 and couple to the drum support 706, and may be
referred to as a
motor end cap.
[0060] FIGS. 10A-10E each show different views of a motor housing 1000 for
a winch
(e.g., a winch similar to the winch 100 shown by FIG. 1 and described above).
The motor
housing 1000 includes a drum support 1002 and a motor end cap 1004 (e.g.,
similar to the
examples of the drum support 110 and motor end cap 106 described above). The
motor end cap
1004 may be referred to herein as an electrical teiminal cover. The drum
support 1002 and the
motor end cap 1004 are coupleable to each other. In the example shown by FIGS.
10A-10E, the
motor end cap 1004 and the drum support 1002 are coupled (e.g., mounted)
together via a plurality of
fasteners 1003 (e.g., bolts, rivets, etc.). In other examples, the motor end
cap 1004 and drum support
1002 may be coupled together in a different way (e.g., via one or more clamps,
adhesives, fused
together, etc.). Reference axes 1099 are included by FIGS. 10A-13 for
comparison of the views
shown.
[0061] The motor housing 1000 includes a motor 1280 disposed therein, the
components of
which are described further below with reference to FIGS. 11A-13. However, in
the views shown by
FIGS.10A-10C, a spindle 1006 of the motor is shown projecting from the drum
support 1002.
During conditions in which the motor within the motor housing 1000 is adjusted
to an operational
mode (e.g., a mode in which the motor is on and is energized by a power
source, such as a battery),
the spindle 1006 may be driven by the motor in order to rotate a drum of the
winch. In some
examples, the drum of the winch may be supported by the drum support 1002. The
drum support
may maintain a position of the drum relative to other components of the winch,
such as the motor
housing 1000, and may be coupled to the drum such that the drum may rotate
relative to the motor
CA 2986290 2017-11-17
housing 1000 during conditions in which the motor drives the spindle 1006
(e.g., rotates the spindle
1006).
[0062] FIG. 10B and FIGS. 10D-10E additionally show a ground connection
1008 (e.g.,
electrical ground input) of the motor housing 1000. The ground connection 1008
is positioned at
the motor end cap 1004 and, in some examples, may protrude from the motor end
cap 1004. The
ground connection 1008 may be a terminal (e.g. a post) adapted to couple to a
wire, such as a
wire from a battery of a vehicle (e.g., a vehicle coupled to the winch
including the motor housing
1000). The ground connection 1008 is an electrically grounded component of the
motor housing
1000, with an electrical voltage at the ground connection 1008 being
approximately 0 V. In
some examples, the ground connection 1008 may be formed by a contactor 1106
positioned
within the motor housing 1000, described below.
[0063] FIG. 11A shows a first view of the motor end cap 1004 with the drum
support 1002
removed. In the view shown by FIG. 11A, several components of the motor 1280
disposed
within the motor housing 1000 are shown separated from the motor housing 1000.
For example,
FIG. 11A shows a control module 1100 (which may be referred to herein as a
controller), a brush
plate assembly 1102 (which may be referred to herein as a brush assembly), a
field coil array 1104,
and the contactor 1106. The control module 1100, the brush plate assembly
1102, the field coil
array 1104, and the contactor 1106 are each shaped to fit within the motor
housing 1000 during
conditions in which the motor end cap 1004 is coupled to the drum support 1002
(shown by FIGS.
10A-10E and described above). For example, the brush plate assembly 1102
includes a first
opening 1103, a second opening 1105, a third opening 1107, and a fourth
opening 1109. The first
opening 1103, the second opening 1105, the third opening 1107, and the fourth
opening 1109 may
each be a through-hole (e.g., aperture) foinied by a brush plate 1111 of the
brush plate assembly
1102. The brush plate 1111 may couple to an interior of the motor end cap 1004
by aligning each
of the first opening 1103, the second opening 1105, the third opening 1107,
and the fourth opening
1109 with respective plate mounts of the motor end cap 1004. Specifically,
during conditions in
which the brush plate 1111 is positioned within the interior of the motor end
cap 1004, the first
opening 1103 may be aligned with a first brush mount 1118 of the motor end cap
1004, the second
opening 1105 may be aligned with a second brush mount 1114, the third opening
1107 may be
aligned with a third brush mount 1116, and the fourth opening 1109 may be
aligned with a fourth
brush mount 1120. The first brush mount 1118, the second brush mount 1114, the
third brush
21
CA 2986290 2017-11-17
mount 1116, and the fourth brush mount 1120 may each be an opening (e.g., a
blind hole, aperture,
etc.) formed by the motor end cap 1004. In some examples, a diameter of each
of the brush
mounts (e.g., an amount of opening of each brush mount) may be a same amount
as a diameter of
each opening of the brush plate 1111 (e.g., first opening 1103, second opening
1105, third opening
1107, and fourth opening 1109). In other examples, one or more of the openings
of the brush plate
1111 may have a different diameter relative to each other opening of the brush
plate 1111, and the
respective brush mounts of the motor end cap 1004 to which the openings of the
brush plate 1111
are configured to align may have similar relative diameters. For example, the
second opening
1105 may be larger than the other openings of the brush plate 1111, and the
second brush mount
1114 may be correspondingly larger than the other brush mounts of the motor
end cap 1004. Other
example configurations are possible. In order to couple the brush plate 1111
to the motor end cap
1004, a fastener (e.g., bolt) may be inserted through each opening of the
brush plate 1111 and each
corresponding brush mount of the motor end cap 1004. For example, a first
fastener may be
inserted through both of the first opening 1103 and the first brush mount
1118, a second fastener
may be inserted through both of the second opening 1105 and the second brush
mount 1114, etc. In
some examples, the fasteners may be threaded fasteners, and in other examples,
the fasteners may
not be threaded.
[0064]
The brush plate assembly 1102 includes a plurality of conductive brushes
coupled to the
brush plate 1111. In the examples described herein with reference to FIGS. 11A-
13, the brush plate
assembly 1102 includes four electrically-conductive brushes (e.g., first brush
1113, second brush
1115, third brush 1117, and fourth brush 1119), with each being positioned in
a radial arrangement
around the brush plate 1111 and being biased (e.g., urged) in a radial
direction of a central opening
1121 of the brush plate 1111 (e.g., a radial direction relative to central
axis 1005) by a biasing
member (e.g., a spring). In this configuration, a portion of an armature 1200
of the motor (shown by
FIGS. 12-13 and described further below) is positioned within the central
opening 1121, and the
conductive brushes are biased into face-sharing contact with the armature
around the central opening
1121. In other examples, the brush plate assembly 1102 may include a different
number of
electrically-conductive brushes (e.g., two, three, five, eight, etc.) and/or
may include a different
relative arrangement of the conductive brushes. For example, each of the
conductive brushes may be
biased (e.g., urged) in an axial direction of the armature toward an end
surface of the armature and
parallel to a rotational axis of the armature (and parallel to central axis
1005) by a biasing member
22
CA 2986290 2017-11-17
(e.g., a spring), similar to the example shown by FIGS. 4-5 and described
above. In the axial
configuration (e.g., the configuration described above in which the conductive
brushes are biased in
the axial direction toward the end surface of the armature), the conductive
brushes are configured to
be positioned in face-sharing contact with the end surface of the armature.
[0065] The brush plate assembly 1102 additionally includes a connector 1122
(e.g., a wire,
wire harness, electrically conductive cable, etc., configured to electrically
couple the conductive
brushes of the brush plate assembly 1102 to the contactor 1106. The connector
1122 is coupled
in direct, face-sharing contact with a corresponding connector 1132 of the
contactor 1106 (which
may be referred to herein as an electrical connection). In one example, the
connector 1132 of the
contactor 1106 may be a terminal (e.g., an electrically conductive post), and
the connector 1122
of the brush plate assembly 1102 may be wrapped around the connector 1132,
fused (e.g.,
welded, soldered, etc.) with the connector 1132, etc. In other examples, the
connector 1122 of
the brush plate assembly 1102 and the connector 1132 of the contactor 1106 may
be formed
together as a single piece (e.g., a solid bar of electrically conductive
material, such as copper).
[0066] The contactor 1106 may include a contactor assembly housed within an
outer casing
(e.g., housing) 1189 of the contactor 1106. The contactor assembly may include
two or more
coils (such as coils 205 and 207 shown in FIG. 2) spaced apart from one
another within an
interior of the contactor 1106 and arranged opposite one another across
central axis 1005 of the
contactor 1106. The coils disposed within the interior of the contactor 1106
(e.g., within the
outer casing 1189) may be referred to herein as contactor coils.
[0067] The contactor 1106 is additionally electrically coupled to the field
coil array 1104 by
a first field terminal 1128 and a second field terminal 1130 (which may be
referred to herein as
electrical connections). The first field terminal 1128 is directly coupled in
face-sharing contact
with a first connector 1124 of the field coil array 1104, and the second field
terminal 1130 is
directly coupled in face-sharing contact with a second connector 1126 of the
field coil array
1104. In some examples, similar to the example described above with reference
to the connector
1122 of the brush plate assembly 1102 and the connector 1132, the first field
terminal 1128 and
the first connector 1124 may be formed together as a single piece, and/or the
second field
terminal 1130 and the second connector 1126 may be formed together as a single
piece.
[0068] The field coil array 1104 includes a plurality of field coils
configured to produce a
magnetic field between each of the field coils. The field coil array 1104 is
enclosed by flux ring
23
CA 2986290 2017-11-17
1204. The flux ring 1204 may be a cylindrical structure shaped to house the
field coil array
1104. In some examples, the flux ring 1204 may be formed of a ferrous,
metallic material (e.g.,
iron), and the flux ring 1204 may increase an intensity (e.g., an amplitude)
of the magnetic field
produced by the field coils of the field coil array 1104. The motor may be
supported partially by
the contactor 1106, with a bottom end 1273 of the flux ring 1204 being seated
against (and
partially surrounded by) a top end 1271 of the contactor 1106. Said another
way, the motor 1280
is supported by the outer casing 1189 and is partially surrounded by the outer
casing 1189, with
the flux ring 1204 being positioned in face-sharing contact with an outer
surface of the outer
casing 1189 at the top end 1271.
[0069] In the example shown by FIGS. 11A-13, the field coil array 1104
includes four field
coils. Specifically, the field coil array 1104 includes a first field coil
1123, a second field coil
1125, a third field coil 1127, and a fourth field coil 1129. In other
examples, the field coil array
1104 may include a different number of field coils (e.g., two, six, eight,
etc.). The field coil
array 1104 includes a central opening 1131 shaped to receive and surround the
armature 1200
(shown by FIGS. 12-13). The field coils of the field coil array 1104 may be
selectively
energized via the contactor 1106 in order to produce the magnetic field in a
region of the
armature 1200. For example, as shown by FIG. 11B and FIGS. 12-13, the
contactor 1106
includes a power terminal 1134 (e.g., electrical power input) positioned at an
end of the contactor
1106 opposite to the connector 1132. The power terminal 1134 is configured to
be electrically
coupled to a power source (e.g., a battery of a vehicle). In one example, the
power source may
be connected to the power terminal 1134 via a single wire, wire harness,
cable, etc.
[0070] Although the power terminal 1134 is configured to be maintained in
electrical
communication with the power source (e.g., a voltage at the power terminal
1134 may be
maintained at a non-zero voltage value by the power source), the contactor
1106 is configured to
electrically isolate the power source from the field coils of the field coil
array 1104 and the
conductive brushes of the brush plate assembly 1102 during conditions in which
the motor is in
an non-operational mode (e.g., during a condition in which the contactor coils
are not energized).
[0071] For example, similar to the example of the control module 1100
described above,
energization of the brushes of the brush plate assembly 1102 and/or the field
coils of the field
coil array 1104 may be controlled by the control module 1100, with the control
module 1100
being positioned within the motor housing 1000. Specifically, the control
module 1100 may
24
CA 2986290 2017-11-17
include one or more openings (e.g., apertures) positioned to align with one or
more
corresponding controller mounts of the motor end cap 1004. As shown by FIG.
11A, the control
module 1100 includes a first opening 1141 and a second opening 1143, with the
first opening
1141 positioned to align with a first controller mount 1110 of the motor end
cap 1004, and with
the second opening 1143 positioned to align with a second controller mount
1112. Similar to the
examples described above with reference to the openings of the brush plate
1111 and the brush
mounts of the motor end cap 1004, fasteners may be inserted through the
openings of the control
module 1100 and the corresponding controller mounts of the motor end cap 1004
in order to
couple the control module 1100 to the motor end cap 1004. Specifically, a
first fastener may be
inserted through the first opening 1141 and the first controller mount 1110,
and a second fastener
may be inserted through the second opening 1143 and the second controller
mount 1112. The
fasteners may be threaded fasteners, or in other examples the fasteners may
not be threaded. In
some examples, the outer casing 1189 of the contactor 1106 may be coupled to
the motor end
cap 1004 in a similar way (e.g., via one or more fasteners). In other
examples, the outer casing
1189 may be coupled to the motor end cap 1004 via one or more features of the
outer casing
1189 shaped to mate (e.g., engage) with one or more counterpart features of
the motor end cap
1004.
[0072]
The control module 1100 may include instructions stored in non-transitory
memory
to energize the field coils of the field coil array 1104 and/or the brushes of
the brush plate
assembly 1102 in response to input by an operator of the winch (e.g., the
winch including the
motor housing 1000, similar to winch 100 shown by FIG. 1). In one example,
energizing the
field coils of the field coil array 1104 and/or brushes of the brush plate
assembly 1102 may
include energizing the contactor coils positioned within the outer casing 1189
of the contactor
1106 in order to move one or more components (e.g., switches) within the outer
casing 1189 and
complete an electrical circuit within the contactor 1106 between the field
coils, brushes, and the
power source (e.g., connect the power source to the field coils and brushes
via the contactor 1106
and adjust the motor to an operational mode). In another example, de-
energizing the field coils
of the field coil array 1104 and/or brushes of the brush plate assembly 1102
may include de-
energizing the contactor coils in order to move the one or more components
within the outer
casing 1189 and disconnect the power source from the field coils and/or
brushes (e.g., adjust the
motor to the non-operational mode).
CA 2986290 2017-11-17
[0073] In some examples, the control module 1100 may be in wireless
communication with
one or more devices external to the winch and the motor housing 1000. In some
examples, the
control module 1100 may control operation of one or more accessories of the
winch (e.g., winch
lights, lights of a vehicle coupled to the winch, etc.), as described above
with reference to
controller 210 and controller 609. In another example, the operator of the
winch may interface
with a remote control (or another remote controller device such as a wired
remote, wireless
remote, a vehicle system controller, or the like) in order to send a wireless
signal (e.g., radio
wave signal) to the control module 1100 indicating that a rotation of a drum
of the winch (e.g.,
similar to drum 118 shown by FIG. 1) in a first direction is desired by the
operator. The control
module 1100 may then energize the field coils of the field coil array 1104 to
produce the
magnetic field at the armature 1200, and may energize the brushes of the brush
plate assembly
1102 in order to flow electrical current through the brushes and into the
armature 1200. The
magnetic field produced by the field coils may interact with the energized
armature in order to
rotate the armature within the motor housing 1000 (e.g., rotate the armature
1200 around central
axis 1005 of the armature 1200, with the armature 1200 coupled to the drum
support 1002 via
bearing 1108 positioned around spindle 1006), with the rotating armature
driving a gear
reduction unit of the winch (e.g., gear reduction unit positioned within a
gear housing of the
winch, similar to gear housing 126) to rotate the drum in the first direction.
The central axis
1005 of the armature 1200 may be referred to herein as the central axis of the
contactor assembly
and the motor. In another example, the operator of the winch may interface
with the remote
control in order to send a wireless signal to the control module 1100
indicating that a rotation of
the drum in a second direction opposite to the first direction is desired by
the operator. The
control module 1100 may then energize the field coils of the field coil array
1104 to produce the
magnetic field at the armature 1200, and may energize the brushes of the brush
plate assembly
1102 in order to flow electrical current through the brushes and into the
armature 1200. The
magnetic field produced by the field coils may interact with the energized
armature in order to
rotate the armature within the motor housing 1000, with the rotating armature
driving a gear
reduction unit of the winch to rotate the drum in the second direction.
[0074] In some examples, the control module 1100 may include a motor speed
sensor,
motor current sensor, voltage sensor, motor direction sensor, motor position
sensor, drum
rotation sensor, and/or motor temperature sensor, and the control module 1100
may be
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CA 2986290 2017-11-17
configured to receive and/or transmit wired and/or wireless signals from/to a
controller area
network (CAN) and/or winch accessories (e.g., an electric free spooling clutch
actuator). In the
example shown by FIGS. 11A-13, the control module 1100 is configured to be
directly
electrically connected to the contactor 1106 via a controller connector 1138
of the contactor
1106. The control module 1100 may receive electrical power from the power
source via the
controller connector 1138 of the contactor 1106 protruding from the outer
casing 1189. In one
example, the control module 1100 may be plugged directly onto the controller
connector 1138 of
the contactor 1106 (e.g., the control module 1100 may include a port adapted
to seat the control
module 1100 on the contactor 1106 and receive electrical power from the
controller connector
1138).
100751 The control module 1100 may additionally be electrically coupled to
a motor sensor
1206 (shown by FIGS. 12-13). The motor sensor 1206 (which may be referred to
herein as a
motor speed and position sensor) may be coupled to a first end 1223 of the
armature 1200 (e.g.,
inserted onto the first end 1223 along the central axis 1005 of the armature
1200) and may be
housed within an annular portion 1225 of the control module 1100. The annular
portion 1225 of
the control module 1100 may include one or more electrically conductive
contacts (e.g.,
surfaces) configured to transmit electrical signals from the motor sensor 1206
to the control
module 1100. The motor sensor 1206 may sense a speed and/or position of the
armature 1200
relative to the contactor housing 1000 and send electrical signals to the
control module 1100 to
indicate the speed and/or position of the armature 1200. For example, the
motor sensor 1206
may be adapted to measure one or more of a rotational speed of the motor, a
direction of rotation
of the motor, and a position of the motor.
[0076] The control module 1100 may include instructions stored thereon for
adjusting
operation of the motor in response to an output of the motor sensor and/or one
or more other
sensors of the motor, such as a temperature sensor, current sensor, voltage
sensor, and/or signals
from the remote control (similar to the example described above with reference
to the motor
201). In one example, the temperature sensor, current sensor, and/or voltage
sensor may be
directly integrated into the control module 1100.
[0077] The temperature sensor may be configured to measure a temperature of
the motor.
In one example, the control module 1100 may monitor (e.g., measure) an output
of the
temperature sensor and compare the measured temperature to a threshold
temperature. If the
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CA 2986290 2017-11-17
measured temperature exceeds the threshold temperature, the controller may de-
energize (e.g.,
turn off) the motor in order to reduce the temperature of the motor. By
integrating the
temperature sensor into the control module 1100, the temperature sensor may
measure the
temperature of the motor, and the control module 1100 may directly interpret
the measured
temperature from the temperature sensor without additional electrical
connections. Similarly, by
housing the motor sensor 1206 within the annular portion 1225 of the control
module 1100, the
control module 1100 may directly interpret the speed and/or position of the
motor from the
motor sensor 1206 without additional electrical connections.
10078]
In another example, the voltage sensor may be configured to measure an
operating
voltage (e.g., 12 volts, 24 volts, 36 volts, or 48 volts, in some examples) of
the motor. The
control module 1100 may monitor (e.g., measure) an output of the voltage
sensor and compare
the measured voltage to an upper threshold voltage. If the measured voltage
exceeds the upper
threshold voltage, the control module 1100 may de-energize the field coils of
the field coil array
1104 and/or the conductive brushes of the 1102 via the contactor 1106 in order
to reduce a
likelihood of the motor being exposed to a voltage higher than a normal
operating voltage. In
another example, if the measured voltage is lower than a lower threshold
voltage, the control
module 1100 may de-energize the field coils of the field coil array 1104
and/or the conductive
brushes of the 1102 via the contactor 1106 in order to reduce a likelihood of
the motor being
exposed to a voltage lower than a normal operating voltage. In one example,
the normal
operating voltage may be 12 volts, and the corresponding lower threshold
voltage and upper
threshold voltage may be 9 volts and 16 volts, respectively. In another
example, the normal
operating voltage may be 24 volts, and the corresponding lower threshold
voltage and upper
threshold voltage may be 18 volts and 32 volts, respectively. In yet another
example, the normal
operating voltage may be 36 volts, and the corresponding lower threshold
voltage and upper
threshold voltage may be 27 volts and 48 volts, respectively. In yet another
example, the normal
operating voltage may be 48 volts, and the corresponding lower threshold
voltage and upper
threshold voltage may be 36 volts and 64 volts, respectively. In this way, the
motor may have a
threshold operating range between the lower and upper threshold voltages and
when a measured
voltage is outside this range, the control module may stop operating the motor
to reduce
degradation to the motor, winch, and/or vehicle to which the winch is coupled.
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CA 2986290 2017-11-17
[0079] In yet another example, the motor current sensor may be configured
to measure an
operating current of the motor. The control module 1100 may monitor an output
of the current
sensor and compare the measured current to a threshold current. If the
measured current exceeds
the threshold current, the control module 1100 may de-energize the field coils
of the field coil array
1104 and/or the conductive brushes of the 1102 via the contactor 1106 in order
to reduce a
likelihood of the motor being exposed to an electrical current higher than a
normal operating
current.
[0080] Additionally, the control module 1100 may include instructions
stored thereon for
recording and storing specific winch events in non-volatile memory of the
control module 1100.
For example, the control module 1100 may record and store winch usage data
which may include
one or more of motor current, temperature, and/or voltage levels throughout
winch operation, a
direction of rotation of the winch motor, events where motor operation of the
winch had to be
determined due to the motor temperature, current, and/or voltage exceeding or
decreasing below
threshold levels (as described above), winch clutch operation, etc. This usage
data may be stored
in the control module 1100 and then referenced during servicing of the winch
or via a wireless
connection with an external device. In this way, the usage data may be
obtained to aid in winch
system development, customer service, and/or winch servicing or repair.
[0081] In some embodiments, new set points may be loaded into the control
module 1100,
by a user (via a wireless or direct wired connection to the controller via the
terminals) to change
how the controller adjusts motor operation based on measured voltage,
temperature, speed,
and/or current. For example, new or updated threshold current, voltage,
temperature, and/or
speed levels for motor operation may be loaded onto the memory of the
controller. As a result,
after updating these stored thresholds, the control module 1100 may adjust
motor operation
according to the newly updated thresholds (and not based on the old or
previously stored
thresholds). In another example, a bootloader may be present to change the
application code
stored in the controller memory, in the field (e.g., during winch operation
and/or when the winch
is installed on a vehicle), in order to fix a bug or to provide new
functionality for a specific
winching application.
[0082] In the example shown by FIGS. 11A-13, the contactor 1106 includes a
wired remote
connection 1136. The wired remote connection 1136 may be electrically coupled
to a control
panel and/or remote control of the winch, such as the remote control described
above. For
29
CA 2986290 2017-11-17
example, the remote control may be utilized by the operator of the winch in
order to adjust the
speed of the winch, the direction of the rotation of the drum of the winch,
etc. In one example, the
first end of a wire, wire harness, cable, etc. may be coupled to the wired
remote connection 1136,
and a second end may be coupled to the remote control and/or control panel.
Within an interior of
the contactor 1106, the wired remote connection 1136 may be electrically
coupled to the controller
connector 1138. In this configuration, the control module 1100 may be seated
directly on the
controller connector 1138, and electrical signals may be transmitted between
the control module
1100 and the remote control and/or control panel. For example, the control
module 1100 may
transmit electrical signals to the remote control and/or control panel by
transmitting the electrical
signals through the contactor 1106 from the controller connector 1138 to the
wired remote
connection 1136. In another example, the remote control and/or control panel
may transmit
electrical signals to the control module 1100 through the contactor 1106 from
the wired remote
connection 1136 to the controller connector 1138. In yet other examples, the
contactor 1106 may
not include the wired remote connection 1136.
[00831 In the configurations described above with reference to FIGS. 10A-
13, there are no
additional electrical connections between the contactor 1106 and the motor
1280 outside of the
interior of the motor housing. In one example, the only electrical connection
of the contactor
1106 and motor 1280 to the power source (e.g., the vehicle battery) that
extends outside of the
interior of the motor housing 1000 is the electrical connection (e.g., wire,
wire harness, cable,
etc.) coupling the power terminal 1134 of the contactor 1106 to the power
source. The motor
1280 is adapted to receive electrical power via only the contactor 1106, and
the power terminal
1134 is the only component electrically coupling the contactor 1106 to the
power source.
[0084] FIGS. 12-13 show different exploded views of motor assembly 1289
disposed within
the motor housing 1000. During conditions in which the motor assembly 1289 is
assembled, the
contactor 1106 (e.g., contactor assembly) is positioned in face sharing
contact with a portion of
an outer surface 1290 of the motor 1280 (e.g., the flux ring 1204).
Specifically, the outer casing
1189 of the contactor 1106 includes a plurality of inner surfaces positioned
in face sharing
contact with the outer surface 1290 of the motor 1280, with the outer surface
289 being a
cylindrical outer surface of the motor 1280. For example, the outer casing
1189 includes a first
angled surface 1291 and a second angled surface 1292 positioned opposite to
each other across
the central axis 1005. The first angled surface 1291 and the second angled
surface 1292 are
CA 2986290 2017-11-17
angled opposite to each other (e.g., angled in opposite directions relative to
each other and
relative to the central axis 1005). The first angled surface 1291 and the
second angled surface
1292 may be referred to herein as inner surfaces. The first angled surface
1291 and the second
angled surface 1292 are each planar surfaces (e.g., flat surfaces, without
curvature). In other
examples, the first angled surface 1291 and/or second angled surface 1292 may
be curved (e.g.,
curving upwards or downwards in a vertical direction relative to a surface on
which the winch
including the motor assembly 1289 sits).
[0085] As described above, the bottom end 1273 of the flux ring 1204 is
positioned in face-
sharing contact with the first angled surface 1291 and the second angled
surface 1292. The
bottom end 1273 may be referred to herein as a bottom portion of the motor
1280. The bottom
end 1273 is the bottom end of the motor 1280 relative to a vertical direction
and surface on
which the winch that it includes the motor assembly 1289 sits. The contactor
1106 (e.g.,
contactor assembly) is positioned vertically below the motor 1280 in the
vertical direction (e.g.,
the direction of the z-axis of reference axes 1099).
[0086] The contactor 1106 additionally includes outer top walls positioned
at the top end
1271. Specifically, the outer casing 1189 of the contactor 1106 includes a
first outer top wall
1293 and a second outer top wall 1294. The first outer top wall 1293 is
positioned opposite to
the second outer top wall 1294 across the central axis 1005. The first outer
top wall 1293 and the
second outer top wall 1294 are each planar, outer surfaces of the outer casing
1189 of the
contactor 1106 (e.g., contactor assembly). The first outer top wall 1293 and
the second outer top
wall 1294 may be parallel and positioned at a same vertical height (e.g., a
same vertical position
along the z-axis of reference axes 1099) relative to each other in some
examples, such as that
shown by FIGS. 12-13 and described herein. In other examples, the first outer
top wall 1293 and
the second outer top wall 1294 may be positioned at different vertical heights
relative to each
other and/or may be positioned at an angle relative to each other. The second
field terminal 1130
extends upward and outward from the second outer top wall 1294, and the first
field terminal
1128 extends upward and outward from the first outer top wall 1293.
Specifically, the first field
terminal 1128 extends in the vertical direction away from the first outer top
wall 1293, and the
second field teiminal 1130 extends in the vertical direction away from the
second outer top wall
1294, with the vertical direction being relative to the surface on which the
winch that includes
the motor assembly 1289 sits (e.g., the first field terminal 1128 and the
second field terminal
31
CA 2986290 2017-11-17
1130 extend in a direction away from the outer casing 1189). The first field
terminal 1128 and
the second field terminal 1130 may be referred to herein a; electrical
connections. The first field
terminal 1128 and the second field terminal 1130 are electrically isolated
from one another at the
exterior of the outer casing 1189. Said another way, the first field terminal
1128 and the second
field terminal 1130 are not directly coupled to each other (e.g., via wires,
etc.) outside of the
outer casing 1189.
[0087] As described above, the contactor 1106 includes the connector 1132.
The connector
1132 extends in the axial direction of the central axis 1005 (e.g., extends
axially relative to the
central axis 1005, with the central axis 1005 being the rotational axis of the
motor 1280) away
from a first end wall 1237 of the outer casing 1189, with the first end wall
1237 being positioned
opposite to a second end wall 1239 of the contactor 1106 along the central
axis 1005. The first
end wall 1237 may be referred to herein as an outer end wall of the outer
casing 1189, and the
second end wall 1239 may be referred to herein as an inner end wall of the
outer casing 1189
(e.g., of the contactor 1106). The first and second end walls of the contactor
1106 may be planar
surfaces of the contactor 1106 (e.g., flat surfaces, and without curvature).
The connector 1122 of
the brush plate assembly 1102 may be coupled to the connector 1132 of the
contactor 1106 by
one or more wires extending at least partially in the axial direction of the
central axis 1005 (e.g.,
parallel to the central axis 1005). Similarly, the first field terminal 1128
and the second field
terminal 1130 may be coupled to the first connector 1124 and the second
connector 1126,
respectively, via one or more wires extending at least partially in the axial
direction of the central
axis 1005. The motor end cap 1004 encloses each of the electrical connections
described above
(e.g., connector 1132, first field terminal 1128, second field terminal 1130,
first connector 1124,
second connector 1126, etc.).
[0088] The drum support 1002 is coupled to an inner end 1255 of the motor
and an inner
end 1257 of the contactor 1106. Specifically, the motor 1280 and the contactor
1106 are
partially housed within the drum support 1002 and are supported by the drum
support 1002 (e.g.,
at inner end 1255 and inner end 1257). The motor 1280 and the contactor 1106
(e.g., contactor
assembly) are contained (e.g., housed) within bounds defined by outer walls
1269 of the drum
support 1002. The drum support 1002 has a width 1265 (e.g., in a direction of
the y-axis of
reference axes 1099) and a height 1267 (e.g., in a direction of the z-axis of
reference axes 1099),
with the width 1265 and the height 1267 being distances between opposing outer
walls 1269 of
32
CA 2986290 2017-11-17
the drum support 1002. An outer end of the motor 1280, opposite to the inner
end 1255, is
positioned away from the drum support 1002 and is enclosed entirely by the
motor end cap 1004.
[0089] In the examples described herein (and shown by FIGS. 12-13), the
first angled
surface 1291 and the second angled surface 1292 of the contactor 1106 (e.g.,
of the outer casing
1189) are angled relative to the first end wall 1237 and second end wall 1239.
In one example, a
line normal (e.g., orthogonal) to the first angled surface 1291 may be
perpendicular to both of the
first end wall and the second end wall (e.g., perpendicular to a line normal
to the first end wall
1237 and the second end wall 1239). Similarly, a line normal to the second
angled surface 1292
may be perpendicular to both of the first end wall and the second end wall
(e.g., perpendicular to
the line normal to the first end wall 1237 and the second end wall 1239).
[0090] The technical effect of coupling the motor and contactor assembly
together within
the motor housing and/or together within a space defined by a drum support of
the motor
assembly, according to the examples shown by FIGS. 1-13 and described above,
is to reduce an
amount of wired electrical connections (e.g., external wired electrical
connections that are
external to the motor housing) between the power source, the contactor
assembly, and the motor.
The winch may be powered via a single power cable coupled to the terminals of
the contactor
assembly, with the brushes of the contactor assembly flowing electrical
current from the power
source to the armature of the motor. In this way, the winch may be more easily
maintained, and
an ease of winch component installation may be increased.
[0091] FIGS. 1-5 and FIGS. 7-13 show example configurations with relative
positioning of
the various components. If shown directly contacting each other, or directly
coupled, then such
elements may be referred to as directly contacting or directly coupled,
respectively, at least in
one example. Similarly, elements shown contiguous or adjacent to one another
may be
contiguous or adjacent to each other, respectively, at least in one example.
As an example,
components laying in face-sharing contact with each other may be referred to
as in face-sharing
contact. As another example, elements positioned apart from each other with
only a space there-
between and no other components may be referred to as such, in at least one
example. As yet
another example, elements shown above/below one another, at opposite sides to
one another, or
to the left/right of one another may be referred to as such, relative to one
another. Further, as
shown in the figures, a topmost element or point of element may be referred to
as a "top" of the
component and a bottommost element or point of the element may be referred to
as a "bottom"
33
CA 2986290 2017-11-17
of the component, in at least one example. As used herein, top/bottom,
upper/lower,
above/below, may be relative to a vertical axis of the figures and used to
describe positioning of
elements of the figures relative to one another. As such, elements shown above
other elements
are positioned vertically above the other elements, in one example. As yet
another example,
shapes of the elements depicted within the figures may be referred to as
having those shapes
(e.g., such as being circular, straight, planar, curved, rounded, chamfered,
angled, or the like).
Further, elements shown intersecting one another may be referred to as
intersecting elements or
intersecting one another, in at least one example. Further still, an element
shown within another
element or shown outside of another element may be referred as such, in one
example.
[0092]
As one embodiment, a motor assembly for a winch comprises: a motor including a
motor armature; a contactor assembly coupled to the motor, the contactor
assembly including
two or more coils spaced apart from one another within a contactor housing of
the contactor
assembly and a brush assembly including a plurality of brushes surrounding a
rotational axis of
the motor and arranged axially to the motor armature; and a motor housing
surrounding and
enclosing the motor and contactor assembly within an interior of the motor
housing. In a first
example of the motor assembly, each brush of the plurality of brushes is
positioned radially
around the rotational axis of the motor, and wherein each brush of the
plurality of brushes is
urged away from the brush assembly in a direction parallel with the rotational
axis of the motor
by a biasing member. A second example of the motor assembly optionally
includes the first
example and further includes wherein each brush of the plurality of brushes is
positioned radially
around the rotational axis of the motor, and wherein each brush of the
plurality of brushes is
urged toward the rotational axis of the motor in a radial direction relative
to the rotational axis of
the motor by a biasing member. A third example of the motor assembly
optionally includes one
or more of the first and second examples, and further includes wherein the
brush assembly and
contactor housing are formed together as a single piece. A fourth example of
the motor
assembly optionally includes one or more of the first through third examples,
and further
includes wherein the brush assembly is mounted to an exterior of one side of
the contactor
housing. A fifth example of the motor assembly optionally includes one or more
of the first
through fourth examples, and further includes a controller enclosed within the
motor housing. A
sixth example of the motor assembly optionally includes one or more of the
first through fifth
examples, and further includes wherein the controller includes one or more of
a temperature
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sensor, motor speed sensor, motor current sensor, and a voltage sensor and
wherein the controller
includes memory including instructions stored thereon for adjusting operation
of the motor based
on an output of one or more of the temperature sensor, the voltage sensor, the
motor speed
sensor, and the motor current sensor, and based on signals received from a
remote in electronic
communication with the controller. A seventh example of the motor assembly
optionally
includes one or more of the first through sixth examples, and further includes
wherein the
contactor assembly further includes one or more electrical connections located
on the contactor
assembly, where the one or more electrical connections include an electrical
power source input
and an electrical ground input, the electrical power input separate from the
electrical ground
input. An eighth example of the motor assembly optionally includes one or more
of the first
through seventh examples, and further includes wherein the motor housing
includes a motor end
cap and a drum support, the motor end cap mounted directly or indirectly to
the drum support. A
ninth example of the motor assembly optionally includes one or more of the
first through eighth
examples, and further includes wherein the motor includes a flux ring and
further comprising a
motor shaft sensor coupled to the motor armature and extending in a direction
parallel with the
rotational axis of the motor, the motor shaft sensor adapted to measure one or
more of a
rotational speed of the motor, a direction of rotation of the motor, and a
position of the motor. A
tenth example of the motor assembly optionally includes one or more of the
first through ninth
examples, and further includes wherein there are no additional electrical
connections between the
contactor assembly and the motor outside of the interior of the motor housing.
[0093]
As another embodiment, a system for a winch comprises: a motor housing
including
a drum support directly or indirectly coupled to a motor end cap; and a motor
assembly housed
within the motor housing, the motor assembly comprising: a motor; and a
contactor assembly
integrated with and positioned around an end of the motor, the contactor
assembly including two
or more coils spaced apart from one another within a contactor housing of the
contactor
assembly and a brush assembly surrounding an armature of the motor. In a first
example of the
system, the contactor housing of the contactor assembly and the brush assembly
are integrated
together as a single unit and are not removably coupled with each other. A
second example of
the system optionally includes the first example and further includes wherein
the contactor
housing of the contactor assembly and the brush assembly are removably coupled
to each other
via at least one fastener coupled to both of the brush assembly and the
contactor housing. A
CA 2986290 2017-11-17
third example of the system optionally includes one or more of the first and
second examples and
further includes wherein the motor assembly further includes an electronic
controller coupled
with the contactor housing and wherein the electronic controller includes one
or more of a
temperature sensor, motor speed sensor, motor current sensor, and a voltage
sensor and wherein
the electronic controller includes memory including instructions stored
thereon for adjusting
operation of the motor based on an output of one or more of the temperature
sensor, the voltage
sensor, the motor speed sensor, and the motor current sensor. A fourth example
of the system
optionally includes one or more of the first through third examples and
further includes wherein
the brush assembly includes a plurality of brushes biased by a plurality of
biasing members and
wherein the plurality of brushes are biased toward an end surface of the
armature of the motor by
the plurality of biasing members. A fifth example of the system optionally
includes one or more
of the first through fourth examples and further includes wherein the brush
assembly includes a
plurality of brushes biased by a plurality of biasing members and wherein the
plurality of brushes
are biased toward an outer circumference of the armature of the motor by the
plurality of biasing
members.
[0094]
As yet another embodiment, a winch comprises: a rotatable drum mounted between
a
first drum support and second drum support; a motor end cap housing mounted
directly or
indirectly to the first drum support; and a motor assembly housed entirely
within the motor end
cap housing and first drum support, the motor assembly comprising: a motor
including a flux
ring surrounding an armature; and a contactor assembly integrated with the
motor, the contactor
assembly including a plurality of brushes and two or more coils spaced apart
and arranged
opposite one another across a rotational axis of the motor. In a first example
of the winch, the
winch further comprises an electronic controller coupled within a contactor
housing of the
contactor assembly and further comprising a plurality of sensors coupled to
the electronic
controller, wherein the plurality of sensors includes one or more of a
temperature sensor, current
sensor, and a voltage sensor, the temperature sensor configured to measure a
temperature of the
motor, the current sensor configured to measure an operating current of the
motor, and the
voltage sensor configured to measure an operating voltage of the motor. A
second example of
the winch optionally includes the first example and further includes a motor
shaft sensor coupled
to the armature, the motor shaft sensor in electronic communication with the
electronic controller
and configured to measure a rotational speed of the armature.
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[0095] The control methods and routines disclosed herein may be stored as
executable
instructions in non-transitory memory and may be carried out by the control
system including the
controller in combination with the various sensors, actuators, and other
engine hardware. The
specific routines described herein may represent one or more of any number of
processing
strategies such as event-driven, interrupt-driven, multi-tasking, multi-
threading, and the like. As
such, various actions, operations, and/or functions illustrated may be
performed in the sequence
illustrated, in parallel, or in some cases omitted. Likewise, the order of
processing is not
necessarily required to achieve the features and advantages of the example
embodiments
described herein, but is provided for ease of illustration and description.
One or more of the
illustrated actions, operations and/or functions may be repeatedly performed
depending on the
particular strategy being used. Further, the described actions, operations
and/or functions may
graphically represent code to be programmed into non-transitory memory of the
computer
readable storage medium in the engine control system, where the described
actions are carried
out by executing the instructions in a system including the various engine
hardware components
in combination with the electronic controller.
[0096] It will be appreciated that the configurations and routines
disclosed herein are
exemplary in nature, and that these specific embodiments are not to be
considered in a limiting
sense, because numerous variations are possible. The subject matter of the
present disclosure
includes all novel and non-obvious combinations and sub-combinations of the
various systems
and configurations, and other features, functions, and/or properties disclosed
herein.
[0097] The following claims particularly point out certain combinations and
sub-
combinations regarded as novel and non-obvious. These claims may refer to "an"
element or "a
first" element or the equivalent thereof. Such claims should be understood to
include
incorporation of one or more such elements, neither requiring nor excluding
two or more such
elements. Other combinations and sub-combinations of the disclosed features,
functions,
elements, and/or properties may be claimed through amendment of the present
claims or through
presentation of new claims in this or a related application. Such claims,
whether broader,
narrower, equal, or different in scope to the original claims, also are
regarded as included within
the subject matter of the present disclosure.
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