Winch Workz

Just to keep everyone informed on progress and work done.

First. my objectives on this project are a versatile winch system
able to be used by experts And beginners alike
on as wide a range of models as possible.

Before we even bought the winch, I sent the add details (including photo's) to Bill H.
we then had a phone chat. for his opinions.

He immediately realized the winch had a "micro switch line tension regulator"
which he had developed over 20yrs ago, and had been copied !

For the small outlay, we decided it was worth a risk.. and went about funding it
https://kirkleathamflyers.forumotion.co.uk/t308-glider-winch

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Most of the initial problems have been with the "micro switch line tension regulator" mechanics.
I have this sorted now and initial tests on Sunday, running on a purposely set low line tension
were good with Very smooth winch operation.

I am designing and working, on a more sophisticated electronic control system at present.

This will have "Modes of operation"

eg Modes

1. Full Power, no limiting (full Pilot Control )
2. Electronic Control ( Set by a "variable pot" on the winch)
3. Electronic Control with Max Tension micro switch cut out

Releasing the Footswitch will always turn the winch motor Off

Some before and after winch pics.

original wiring



New wiring
note all High Current connections have also been cleaned
to ensure a good connection (pulse current over 300A )
All Low Current connections have been remade and heatshrink added.
Low Current = around 20A ! for the Starter Solenoid




Pulley Mod. and mech. limit, added to stop the Microswitch actuating lever getting bent.
This happened on a launch at Kirkleatham, causing a wing failure and "Lawn Dart" on my Sonata




I'll keep you informed

Paul

Winch Control unit
designed , built and tested

Next I have to wire it to the Winch, and test Solenoid operation.

Fingers crossed !


cct



More Pics. later

nice one Paul.your electronics understanding, and building is very much appreciated on the winch.look forward to see it up and running.

Cheers Jeff

You have been busy - winching this weekend ?

Hope to complete the winch today Justin

Sonata is also fixed
I'm looking forward to more flight tests
lets hope the weather co operates


.

nice work paul,the weather forcast is bad but i am looking forward to getting my gliders on the winch , john

The winch is ready to test !

5% - 90% variable output power on the control system.
I also added a bypass switch for Full power

And we still have the option of using
the old micro switch line tensioner

Well loads of thermals here in turkey bakeing in 40pluss lol no winching though hopefully can bring ye,s some weather back.?

nice one Phil.hope your having a great time.be there in September for 2 weeks myself.

Hi. Phil
Have a good Hol.

Had a look at the winch footswitch this am

I wasn't happy with it's operation, wasn't very positive

On opening the case I found out why ..
Someone had fitted a block of epp as a damper

I have removed it and the switch is fine now.

After the torrential rain Justin, Matt and me went to Kirkleatham

Had a few good winch launches and fun flights

I identified a few issues
Justin's old Jag. battery drops voltage very quickly under load (probably a bad cell )
Anyone got a high capacity Car Batt. or Leisure Batt. laying around we can use?

My switching cct. is operating at too low a frequency
I can change this easily, but could do with a Starter Solenoid
to test the Max. pulsing freq. I can feed the Solenoid
Anyone got an old Car Starter Solenoid I can have for testing ?

We had a good evening flying
surprised nobody else turned up

Light nights it's Summer

I'll have a word with my cousin re the starter motor solenoid as he has a garage in redcar, I'm sure he will have one lying around you could use.

Thanks Keith

I found a New solenoid on ebay for £10
I have ordered it, as we will need a spare anyway.

Been working on my Pulse cct. it's now operating at x10 speed
and will result in a noticeably smoother Line Tension.
I can go far higher electronically but the Solenoid will set the usable limit.

Main problem at the moment is a good battery for the winch
We are working on this, and may have a solution soon.

Worst (Best ?) case is buying a new Battery.
We have found a Powerstart 75AH Leisure Battery
for £44.99 at Stockton (£5 each will cover it)
http://www.gooutdoors.co.uk/powerstart-75ah-battery-p157736

Paul

Updated cct diagram

The solenoid came today
I immediately tested it ........ it's faulty , open circuit coil.

rang the dealer and posted it back for replacement

sigh.

Justin brought the winch today (and a "new to us" battery)
So I was able to test the Control circuit.

It works extremely well , very smooth indeed
No need for the "mechanical limiter" now

After proving the system, I had to try it on 100% power

Phil has some pictures ....
Oh hum, another set of wings to rebuild

Should have tried 99%

No. I test to destruction

My aircraft only. so nobody else's get damaged
The Winch is tamed, yet still has 100% power available
for the few models able to use it.

Ade get that Carbon "Bird" done !

Keith's tips of the day

1) When moving planes from one place to another make sure you prop open the door with something stronger than the door closer can pull.
2) Make extra sure you dont have a plane in the doorway at this time...see rule one.




Lucky i was taking it to the garbage anyway

I will rip the motor out of my dads glider as he is building another one, and join "the syndicate"