Product Overview

Case: A supplier of winches for military vehicles and aircraft developed two new products with significantly higher load capacities. However, their existing test equipment could not generate the required loads. In addition, the legacy system no longer supported long-term product development. Because these winches require a 30-year support life, the customer needed a durable test solution that could support both development and production testing.

Solution: Tri-Power Design engineered an instrumented winch load test platform that monitors and controls both load and speed. The system meets the customer’s design specifications and allows quick changeover between the two winch models. Furthermore, the platform supports future winch designs with only tooling and software updates.

Design Challenges: The platform needed to reel in and pay out 250 feet of cable without causing damage. At the same time, it had to maintain precise tension control throughout each test. To meet these requirements, Tri-Power Design designed a 42-inch diameter drum with a helical groove that guides cable placement.

Because of the drum size, the platform needed to deliver up to 21,000 ft-lbs of torque to achieve 12,000 pounds of cable tension. To exceed this requirement, the system provides up to 24,000 ft-lbs of torque using two radial, seven-cylinder hydraulic position motors coupled directly to the drum. For safety, the team enclosed the platform in 80/20 framing with clear Lexan panels and installed multiple emergency stop buttons around the system.

Finally, a dedicated PC running a LabVIEW® graphical user interface controls the test platform. Through the interface, operators select programs, monitor tests in real time, and store or retrieve test data.

Call 973.227.8214 or email us today to learn more about the Production Winch Test Stand.