Dwg no.01
Title
Small Scale Winch System
Engineering Design & Problem Solving
3:1Speed mode: 60T motor gear to 20T spool via belt
1:3Power mode: gears reversed for torque
~10–12 N·mEstimated motor output torque (12 V, ~12 W)
10+ kgLoad the winch was able to pull
What
- Designing a small-scale winch system to lift and lower loads in a controlled manner
- Focus on mechanical transmission, motor control, and system modelling
- Developed as a virtual prototype using CAD and microcontroller simulation tools
How
- Designed the mechanical parts, structure and spool geometry in SolidWorks
- Built and tested the Arduino motor control logic as a circuit simulation in TinkerCAD
- Explored gear ratios, torque requirements, and speed control for safe lifting
Features
- Dual-mode operation. Speed mode: motor (60T gear) drives the spool (20T gear) via belt for higher speed
- Power mode: gear configuration reversed for increased torque output
- 12 V DC motor with worm gear for controlled motion and load holding
- Potentiometer speed control with a dead zone for safe stopping
- Direction control through an integrated switch system
- H-bridge for full motor control (direction and speed)
Results
- Speed mode gear ratio 60T : 20T = 3:1 (speed increase, torque reduction)
- Power mode gear ratio 20T : 60T = 1:3 (torque increase)
- Estimated motor output torque ~10–12 N·m (based on 12 V, ~12 W assumption)
- Able to pull more than 10 kg
- Consistent pulling force across variable speeds using potentiometer control
- Effective torque amplification in power mode via gear switching
Dwg no.01
Title
Winch System: Engineering Drawings
Bill of materials
5 designed parts · 13 purchased items| Item | Part | Details | Make / buy | Qty |
|---|---|---|---|---|
| Designed parts · SolidWorks | ||||
| 01 | Winch Spool | DWG 1 · Ø50 flanges, Ø35 drum | 3D printed | 1 |
| 02 | Spool Support | DWG 2 · holds the spool shaft bearings | 3D printed | 2 |
| 03 | Spool Bracket | DWG 3 · clamps over each support | 3D printed | 2 |
| 04 | Motor Mount (Rev 2) | DWG 4 · redesigned for even load spread after the first print failed | 3D printed | 1 |
| 05 | Winch Base | DWG 5 · 200 × 200 mm plate | Laser-cut acrylic | 1 |
| Purchased components | ||||
| 06 | 12 V DC worm gear motor | 10 RPM worm drive, holds the load when unpowered | Buy | 1 |
| 07 | Motor driver | L293D H-bridge | Buy | 1 |
| 08 | Arduino Uno | PWM speed and direction control | Buy | 1 |
| 09 | Breadboard | Control circuit | Buy | 1 |
| 10 | Potentiometer | 10 kΩ · proportional speed control | Buy | 1 |
| 11 | Push buttons | Direction select | Buy | 2 |
| 12 | 9 V battery | Power | Buy | 1 |
| 13 | GT2 pulley, 60 teeth | 6 mm width, 8 mm bore · motor shaft | Buy | 1 |
| 14 | GT2 pulley, 20 teeth | 8 mm bore · spool shaft | Buy | 1 |
| 15 | 2GT-6 closed-loop belt | 122 mm toothed belt | Buy | 1 |
| 16 | Ball bearings | Steel, 8 × 22 × 7 mm | Buy | 2 |
| 17 | Linear motion rods | 8 mm × 400 mm, pack of 2 | Buy | 1 pack |
| 18 | Fasteners | M6 and M8 nuts and bolts | Buy | 1 set |
