WRC-C captive winch design
After producing aluminium frame captive winches for many years the decision was made to redesign the winch range, utilising advancements in materials and an innovative design, to achieve the following goals:
- Significant weight reduction
- Simplification of design to reduce the number of components
- Reduced friction between load-carrying surfaces
By using a carbon laminate for the car and base plate we have achieved these goals. The load induced by the line turning 90º around the sheave is transferred onto the base plate without any additional support tracks or guide rails, as the carbon base plate is able to absorb this load.
Friction is also reduced by a custom composite lay-up on the wear surface of the car, and the line load is now taken between two carbon components.
Modern line materials such as Vectran and Dyneema, have reduced the line diameters required for any given load. This has allowed a smaller drum diameter to be used which effectively reduces the torque on the drum drive transmission, allowing further weight savings to be realized. The drum is also composite material with a carbon-kevlar outer layer to take the wear induced by the line friction.
All structural aspects of the new design, including manufacture of the composite components, have been achieved in co-operation with New Zealand's leading custom carbon component specialists.
The reliable mechanical features of the previous alloy winches have been retained on the carbon model.
A simple stainless chain provides the drive between the drum and the car screw drive. In the event of a control system or limit switch failure, the chain acts as a ‘fuse’, which prevents damage to the winch chassis and screw drive mechanism. This chain is inexpensive, fast to replace, and available world-wide.
The winch drive and brake are industry standard epicyclic track drives, coupled with a choice of motor combinations to achieve variable or multi speed operator interfaces to suit the application.
At present the winch is available in 3 basic versions which share similar components: