TECHNICAL FIELD
[0001] The present disclosure relates to a field of rope or cable pulling devices, and in particular, relates to a portable winch assembly for pulling pre-pilot and pilot ropes.

BACKGROUND
[0002] In recent years, cables/conductors have been frequently laid along large distances to meet the rising demand of electrical power around the globe. Many electrical power transmission and distribution systems have been adopted for transmitting and distributing electrical power. However, the overhead electrical power transmission and distribution system provide a most efficient way of transmitting and distributing the electrical power along the large distances. In the overhead electrical power transmission and distribution system, the cables/conductors are stringed overhead across transmission towers. As these cables/conductors carry very high voltages and currents, these cables/conductors are made of thicker cross-sections and therefore, they are heavier. Due to heavy weights, manual installation of these cables/conductors across the transmission towers is impractical. Nowadays, when stringing such a cable/conductor, a pilot rope is initially laid across the transmission towers. Once the pilot rope is laid across the transmission towers, the cable/conductor is connected to the pilot rope at one end. In addition, the other end of the pilot rope is then connected to a rope pulling assembly known as a winch assembly. The winch assembly pulls in (or alternatively let out) the pilot rope, wire or cable. In its simplest form, the winch assembly consists of a drum (that winds and unwinds) attached to a crank—which can either be hand or machine driven.

[0003] Traditionally, winch assemblies are bulkier in size and are designed for a larger scale of pulling heavy metallic conductors. These traditional winch assemblies require proper portability solutions for the cable/conductor installations across the transmission towers and terrains. With the advancement in the cable/conductor stringing technology, certain modifications are done in the winch assembly design. Nowadays, typical winch assemblies consist of a power supplying source connected to a power transmission source. The power supplying source and the power transmission source works simultaneously to rotate a drum for winding and unwinding operations. However, these typical winch assemblies require an alternating current power supplying source or a combustible fuel power supplying source to operate. Moreover, most of these typical winch assemblies are unable to operate at high pulling speed. In addition, some of these typical winch assemblies are unable to pull and wind the pilot rope in a structured manner at a high pulling speed.

[0004] In light of the above stated discussion, there is a need for an assembly that overcomes the above stated disadvantages.

OBJECT OF THE DISCLOSURE
[0005] A primary object of the present disclosure is to provide a portable winch assembly for pulling pre-pilot and pilot ropes.

[0006] Another object of the present disclosure is to provide a light-weight winch assembly.

[0007] Yet another object of the present disclosure is to provide the portable winch assembly capable of pulling and winding the pre-pilot and pilot ropes at high speed.

[0008] Yet another object of the present disclosure is to provide the portable winch assembly powered by a direct current power source.

[0009] Yet another object of the present disclosure is to provide the portable winch assembly composed of relatively inexpensive components that are economical to manufacture and assemble together.

SUMMARY
[0010] In an aspect, the present disclosure provides a portable winch assembly for pulling cables. The portable winch assembly includes a portable winch for pulling, winding, unwinding and housing the cable. In addition, the portable winch assembly includes a power supply unit for storing and supplying electrical energy to a direct current electrical motor assembly associated with the portable winch. Moreover, the portable winch assembly includes a control unit for controlling the direct current electrical motor assembly. Further, the portable winch includes a support frame designed and configured to provide a rigid support to the portable winch. The support frame includes a base plate having a first section and a second section. In addition, the portable winch includes a power transmission unit mounted on the support frame. The power transmission unit includes the direct current electrical motor assembly mounted on the support frame and positioned proximate to the second section of the support frame. In addition, the power transmission unit further includes a gearbox assembly mounted on the support frame and positioned proximate to the second section of the support frame. Furthermore, the portable winch includes a winch unit mounted on the support frame and positioned proximate to the first section of the support frame. The winch unit includes a traction means mounted in a fixed rotative engagement on an output shaft of the gearbox assembly. Going further, the direct current electrical motor assembly is configured to generate a pre-defined mechanical output power of about 0.5 horsepower for winding and unwinding the cable. The direct current electrical motor assembly has a pre-defined rotational speed of up to 1550 revolutions per minute. Further, the gearbox assembly includes an input shaft and the output shaft. The input shaft is mechanically linked to a motor shaft of the direct current electrical motor assembly and the output shaft is connected to a winch unit. Moreover, the traction means rotates about a rotational longitudinal axis associated with the output shaft of the gearbox assembly to enable the winding and the unwinding of the cable. Further, the portable winch is configured to have a pre-defined rope pulling capacity of about 100 kilogram-force. The power supply unit includes one or more rechargeable batteries. The one or more rechargeable batteries are portable rechargeable batteries symmetrically positioned within a power housing. The control unit includes a casing having a control panel and a plurality of components. The control panel and the plurality of components are configured to control the operational characteristics of the direct current electrical motor assembly. The portable winch assembly has a pre-defined weight of about 60 kilograms. In addition, the portable winch assembly is configured to have a pre-defined rope pulling speed of up to 30 meters per minute.

[0011] In an embodiment of the present disclosure, the traction means includes at least one of rollers, spools and drums.

[0012] In an embodiment of the present disclosure, the portable winch assembly is configured to pull cables. The cable has a pre-defined cross-sectional diameter in a range of about 2 millimeters to 18 millimeters. The cable includes at least one of pre-pilot ropes, pilot ropes and wires.

[0013] In an embodiment of the present disclosure, each rechargeable battery is characterized by a potential difference of about 12 volts and an energy storing capacity of about 65 ampere hours.

[0014] In an embodiment of the present disclosure, the direct current electrical motor assembly operates at a pre-defined potential difference of about 220 volts and at a pre-defined current of about 2 amperes.

[0015] In an embodiment of the present disclosure, the gearbox assembly is a worm type gearbox assembly. The worm type gearbox assembly have a speed reduction ratio of about 20.

[0016] In an embodiment of the present disclosure, the control unit is operated manually to control the direct current electric motor. The control panel includes one or more programmable logic controllers, one or more frequency drives, one or more resistors, and one or more electric relays and barriers. Further, the plurality of components includes a speed controller, a display panel and one or more switches.

[0017] In an embodiment of the present disclosure, the control unit is operated remotely to control the direct current electrical motor assembly.

[0018] In an embodiment of the present disclosure, the portable winch assembly further includes one or more bearing assemblies to provide rotational support to the traction means mounted over the output shaft for winding and unwinding the cable.

STATEMENT OF THE DISCLOSURE
[0019] The present disclosure relates to a portable winch assembly for pulling cables. The portable winch assembly includes a portable winch for pulling, winding, unwinding and housing the cable. In addition, the portable winch assembly includes a power supply unit for storing and supplying electrical energy to a direct current electrical motor assembly associated with the portable winch. Moreover, the portable winch assembly includes a control unit for controlling the direct current electrical motor assembly. Further, the portable winch includes a support frame designed and configured to provide a rigid support to the portable winch. The support frame includes a base plate having a first section and a second section. In addition, the portable winch includes a power transmission unit mounted on the support frame. The power transmission unit includes the direct current electrical motor assembly mounted on the support frame and positioned proximate to the second section of the support frame. In addition, the power transmission unit further includes a gearbox assembly mounted on the support frame and positioned proximate to the second section of the support frame. Furthermore, the portable winch includes a winch unit mounted on the support frame and positioned proximate to the first section of the support frame. The winch unit includes a traction means mounted in a fixed rotative engagement on an output shaft of the gearbox assembly. Going further, the direct current electrical motor assembly is configured to generate a pre-defined mechanical output power of about 0.5 horsepower for winding and unwinding the cable. The direct current electrical motor assembly has a pre-defined rotational speed of up to 1550 revolutions per minute. Further, the gearbox assembly includes an input shaft and the output shaft. The input shaft is mechanically linked to a motor shaft of the direct current electrical motor assembly and the output shaft is connected to a winch unit. Moreover, the traction means rotates about a rotational longitudinal axis associated with the output shaft of the gearbox assembly to enable the winding and the unwinding of the cable. Further, the portable winch is configured to have a pre-defined rope pulling capacity of about 100 kilogram-force. In addition, the portable winch is configured to have a pre-defined rope pulling speed of up to 30 meters per minute. The power supply unit includes one or more rechargeable batteries. The one or more rechargeable batteries are portable rechargeable batteries symmetrically positioned within a power housing. The control unit includes a casing having a control panel and a plurality of components. The control panel and the plurality of components are configured to control the operational characteristics of the direct current electrical motor assembly.

BRIEF DESCRIPTION OF FIGURES
[0020] Having thus described the disclosure in general terms, reference will now be made to the accompanying figures, wherein:

[0021] FIG. 1 illustrates an overall perspective view of a portable winch assembly, in accordance with an embodiment of the present disclosure; and

[0022] FIG. 2 illustrates a front view of portable winch, in accordance with an embodiment of the present disclosure.

[0023] It should be noted that the accompanying figures are intended to present illustrations of exemplary embodiments of the present disclosure. These figures are not intended to limit the scope of the present disclosure. It should also be noted that accompanying figures are not necessarily drawn to scale.

DETAILED DESCRIPTION
[0024] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present technology. It will be apparent, however, to one skilled in the art that the present technology can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form only in order to avoid obscuring the present technology.

[0025] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present technology. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.

[0026] Moreover, although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present technology. Similarly, although many of the features of the present technology are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present technology is set forth without any loss of generality to, and without imposing limitations upon, the present technology.

[0027] It should be noted that the terms "first", "second", and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0028] FIG. 1 illustrates an overall perspective view of a portable winch assembly 100, in accordance with an embodiment of the present disclosure. The portable winch assembly 100 is used for pulling a cable. The cable includes but may not be limited to a pre-pilot rope, a pilot rope and a wire. In an embodiment of the present disclosure, the portable winch assembly 100 is used for pulling the pre-pilot rope and the pilot rope. In general, the pre-pilot and pilot ropes are stranded cables made of materials such as steel, nylon or polyethylene, and the like. At least one of the pre-pilot rope and the pilot rope is laid initially across transmission towers for stringing conductors. In an embodiment of the present disclosure, the cable has a pre-defined cross-sectional diameter in a range of about 2 millimeters (hereinafter as “mm”) to 18 mm. In an embodiment of the present disclosure, the portable winch assembly 100 has a pre-defined weight of about 60 kilograms. Moreover, the portable winch assembly 100 has a pre-defined rope pulling speed of up to 30 meters per minute.

[0029] Referring to FIG. 1, the portable winch assembly 100 includes a portable winch 102, a power supplying unit 104, a control unit 106 and one or more power cables 108. The portable winch 102, the power supplying unit 104, the control unit 106 and the one or more power cables 108 operate simultaneously to pull, wind and unwind the cable in a structured manner. Further, the portable winch 102 is equipped with a winch unit 102a and a power transmission unit 102b mounted over a support frame 102c. The portable winch 102 has a pre-defined rope pulling capacity of about 100 kilogram-force. The winch unit 102a and the power transmission unit 102b are arranged and positioned over the support frame 102c to enable ease of portability (discussed below in detailed description of FIG. 2).

[0030] Going further, the portable winch 102 is powered by the powered supplying unit 104. The power supplying unit 104 includes one or more rechargeable batteries (not shown) to store electrical energy. In an embodiment of the present disclosure, each rechargeable battery is characterized by a potential difference of about 12 volts (hereinafter as “V”) and an energy storing capacity of about 65 ampere-hours (hereinafter as “AH”). The one or more rechargeable batteries are symmetrically positioned within a power housing 104a. In general, the power housing includes one or more compartments or one or more chambers for holding batteries. Operation and construction of the power housing 104a, involved here, are generally known to a person skilled in the art so that a detailed discussion has been omitted for the sake of simplicity.

[0031] Continuing with FIG. 1, the rope pulling, winding and unwinding operations of the portable winch 102 is controlled and monitored by the control unit 106. The control unit 106 includes a control panel (not shown) installed within a casing 106a. The control panel is configured to generate control signals for controlling a direct current electrical motor assembly (described below in detailed description of FIG. 2) associated with the power transmission unit 102b. Moreover, the control panel includes but may not be limited to at least one of programmable logic controllers, frequency drives, power distribution systems, resistors, and electric relays and barriers. Further, the control unit 106 is equipped with a plurality of components. The plurality of components include but may not be limited to a speed controller, a display panel and one or more switches. In an embodiment of the present disclosure, the control unit 106 is manually operated to control the direct current electrical motor assembly. In another embodiment of the present disclosure, the control unit 106 is operated remotely to control the direct current electrical motor assembly.

[0032] Referring to FIG. 1, the portable winch 102, the power supplying unit 104 and the control unit 106 are interconnected by the one or more power cables 108. In an embodiment of the present disclosure, the direct current electrical motor assembly is connected to the power supplying unit 104 through the one or more power cables. The one or more power cables 108 facilitates an electrical connection between the power supplying unit 104 and the direct current electrical motor assembly. Also, the one or more power cables 108 facilitates a suitable electrical connection between the control unit 106 and the direct current electrical motor assembly.

[0033] FIG. 2 illustrates a front view of the portable winch 102, in accordance with an embodiment of the present disclosure. The portable winch 102 is supported by the support frame 102c. The support frame 102c provides a rigid support to the portable winch 102. In an embodiment of the present disclosure, the support frame 102c is an open frame structure. In addition, the support frame 102c is formed by at least one material selected from a group of metals and plastics. In an embodiment of the present disclosure, the support frame 102c is formed of by casting aluminum alloy.

[0034] Further, the support frame 102c includes a base plate 202a. The base plate 202a provides a rigid support against a plurality of vertically downward loads associated with the winch unit 102a and the power transmission unit 102b. The base plate 202a includes a first section 202b and a second section 202c. The first section 202b is used to mount the winch unit 102a associated with the portable winch 102. The second section 202c is used to mount the power transmission unit 102b associated with the portable winch 102. Furthermore, the portable winch 102 includes one or more handles connected to the support frame 102c. The one or more handles are connected to the support frame 102c through at least one joint selected from the group of bolted joints, riveted joints and welded joints. In an embodiment of the present disclosure, the one or more handles include a first handle 204a mounted on the first section 202b of the support frame 102c and a second handle 204b mounted on the second section 202c of the support frame 102c.

[0035] Referring to FIG. 2, the winch unit 102a associated with the portable winch 102 includes a traction means 206 for housing, winding and unwinding the cable. The traction means 206 include at least one of rollers, spools and drums. The traction means 206 is equipped with a first flange 208a and a second flange 208b at both axial ends associated with the traction means 206. The first flange 208a and the second flange 208b defines the width of a plurality of cable layers wound on the traction means 206. Construction of the first flange 208a and the second flange 208b, involved here, are generally known to a person skilled in the art so that a detailed discussion has been omitted for the sake of simplicity.

[0036] Further, the traction means 206 is connected to the power transmission unit 102b of the portable winch 102. The power transmission unit 102b facilitates transferring of the power from the power supplying unit 104 to the winch unit 102a. The power transmission unit 102b receives an electrical power from the one or more rechargeable batteries associated with the power supplying unit 104. The power transmission unit 102b is configured to convert an electrical power into a mechanical power. Moreover, the power transmission unit 102b is configured to transfer the mechanical power to the winch unit 102a. The power transmission unit 102b includes a direct current electrical motor assembly 210 and a gearbox assembly 212.

[0037] The direct current electrical motor assembly 210 is mounted on the second section 202c of the support frame 102c. The direct current electrical motor assembly 210 includes a housing 210a including a motor case (not shown) and a motor shaft (not shown). In addition, the direct current electrical motor assembly 210 includes an armature (not shown) rotatably supported within the motor case (not shown) by a bearing assembly (not shown). The direct current electrical motor assembly 210 is powered by a direct current received from the one or more rechargeable batteries of the power supplying unit 104. In addition, the direct current electrical motor assembly 210 is controlled by the control unit 106.

[0038] The direct current electrical motor assembly 210 is characterized by an operational current and voltage ratings. In an embodiment of the present disclosure, the direct current electrical motor assembly 210 operates at a pre-defined potential difference of about 220 volts and at a pre-defined current of about 2 amperes. The direct current electrical motor assembly 210 generates a mechanical output power in a form of a driving torque. In an embodiment of the present disclosure, the direct current electrical motor assembly 210 generates a pre-defined mechanical output power of about 0.5 horsepower. Moreover, the direct current electrical motor assembly 210 generates the driving torque to rotate the motor shaft at a pre-defined rotational speed. In an embodiment of the present disclosure, the pre-defined rotational speed of the motor shaft is up to 1550 revolutions per minute.

[0039] Continuing with FIG. 2, the direct current electrical motor assembly 210 is connected to the gearbox assembly 212 mounted over the support frame 102c. The direct current electrical motor assembly 210 is connected to transfer the driving torque to the gearbox assembly 212. The gearbox assembly 212 is mounted over the second section 202c of the support frame 102c. In addition, the gearbox assembly 212 is operatively coupled between the winch unit 102a and the direct current electrical motor 210. In an embodiment of the present disclosure, the gearbox assembly 212 is a worm type gearbox assembly having a speed reduction ratio of about 20.

[0040] The gearbox assembly 212 includes a gearbox housing 212a including an input shaft (not shown), one or more worm gears (not shown) and an output shaft 212b. The input shaft and the output shaft are rotatably supported by one or more bearing assemblies (not shown) associated with the gearbox assembly 212. The input shaft of the gearbox assembly 212 is mechanically linked to the motor shaft of the direct current electrical motor 210. The input shaft and the motor shaft are mechanically linked through any suitable coupling generally known to a person skilled in the art so that a detailed discussion has been omitted for the sake of simplicity.

[0041] The input shaft and the output shaft 212b are connected in a worm and worm gear arrangements. In an embodiment of the present disclosure, a rotational axis of the input shaft is orthogonally arranged relative to a rotational longitudinal axis 214 of the output shaft 212b. The input shaft operates as a worm shaft. Moreover, the input shaft is in contact with a worm gear (not shown) associated with the one or more gears engaged with the output shaft. The worm gear is in rotative fixed engagement with output shaft 212b. In an embodiment of the present disclosure, the input shaft transfers the driving torque to the worm gear engaged to the output shaft 212b.

[0042] Further, the output shaft 212b is connected to the traction means 206 associated with the winch unit 102a. The output shaft 212b is connected to transfer an output driving torque to the traction means 206 at a reduced rotational speed. In an embodiment of the present disclosure, the traction means 206 is mounted in a fixed rotative engagement on the output shaft 212b of the gearbox assembly 212. The traction means 206 is mounted over the output shaft 212b such that an imaginary longitudinal axis of the traction means 206 coincides with the rotational longitudinal axis 214 of the output shaft. Moreover, the traction means 206 rotates about the rotational longitudinal axis 214 to enable the winding and the unwinding of the cable.

[0043] Continuing with FIG. 2, the traction means 206 mounted over the output shaft 212b is substantially supported by a first bearing assembly 216a and a second bearing assembly 216b. In an embodiment of the present disclosure, the first bearing assembly 216a is mounted over the first section 202b of the support frame 102c and the second bearing assembly 216b is mounted over the second section 202c of the support frame 102c. Operation and construction of the first bearing assembly 216a and the second bearing assembly 216b, involved here, are generally known to a person skilled in the art so that a detailed discussion has been omitted for the sake of simplicity.

[0044] The foregoing descriptions of specific embodiments of the present technology have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present technology to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present technology and its practical application, to thereby enable others skilled in the art to best utilize the present technology and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present technology.

[0045] While several possible embodiments of the invention have been described above and illustrated in some cases, it should be interpreted and understood as to have been presented only by way of illustration and example, but not by limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.

What is claimed is:
1. A portable winch assembly, comprising:

a portable winch, wherein the portable winch is configured to have a pre-defined rope pulling capacity of about 100 kilogram-force and wherein the portable winch comprises:

a support frame including a base plate having a first section and a second section, wherein the support frame is designed and configured to provide a rigid support to the portable winch;

a power transmission unit mounted on the support frame, wherein the power transmission unit comprises:

a direct current electrical motor assembly mounted on the support frame and positioned proximate to the second section of the support frame, wherein the direct current electrical motor assembly is configured to generate a pre-defined mechanical output power of about 0.5 horsepower for winding and unwinding the cable and wherein the direct current electrical motor assembly has a pre-defined rotational speed of up to 1550 revolutions per minute; and
a gearbox assembly mounted on the support frame and positioned proximate to the second section of the support frame, the gearbox assembly having an input shaft and an output shaft, wherein the input shaft is mechanically linked to a motor shaft of the direct current electrical motor assembly and the output shaft is connected to a winch unit;

a winch unit mounted on the support frame and positioned proximate to the first section of the support frame, wherein the winch unit includes a traction means mounted in a fixed rotative engagement on the output shaft of the gearbox assembly and wherein the traction means rotates about a rotational longitudinal axis associated with the output shaft of the gearbox assembly to enable the winding and the unwinding of the cable;

a power supply unit for storing and supplying electrical energy to the direct current electrical motor assembly associated with the portable winch, wherein the power supply unit includes one or more rechargeable batteries and wherein the one or more rechargeable batteries are portable rechargeable batteries symmetrically positioned within a power housing; and

a control unit for controlling the direct current electrical motor assembly, wherein the control unit comprising a casing including a control panel and a plurality of components, the control panel and the plurality of components are configured to control the operational characteristics of the direct current electrical motor assembly, wherein the portable winch assembly has a pre-defined weight of about 60 kilograms and wherein the portable winch assembly is configured to have a pre-defined rope pulling speed of up to 30 meters per minute.

2. The portable winch assembly as recited in claim 1, wherein the traction means includes at least one of rollers, spools and drums.

3. The portable winch assembly as recited in claim 1, wherein the portable winch assembly is configured to pull a cable, the cable has a pre-defined cross-sectional diameter in a range of about 2 millimeters to 18 millimeters and wherein the cable includes at least one of pre-pilot ropes, pilot ropes and wires.

4. The portable winch assembly as recited in claim 1, wherein each rechargeable battery is characterized by a potential difference of about 12 volts and an energy storing capacity of about 65 ampere hours.

5. The portable winch assembly as recited in claim 1, wherein the direct current electrical motor assembly operates at a pre-defined potential difference of about 220 volts and at a pre-defined current of about 2 amperes.

6. The portable winch assembly as recited in claim 1, wherein the gearbox assembly is a worm type gearbox assembly, the worm type gearbox assembly having a speed reduction ratio of about 20.

7. The portable winch assembly as recited in claim 1, wherein the control unit is operated manually to control the direct current electric motor, wherein the control panel includes one or more programmable logic controllers, one or more frequency drives, one or more resistors, and one or more electric relays and barriers and wherein the plurality of components includes a speed controller, a display panel and one or more switches.

8. The portable winch assembly as recited in claim 1, wherein the control unit is operated remotely to control the direct current electrical motor assembly.

9. The portable winch assembly as recited in claim 1, further comprising one or more bearing assemblies to provide rotational support to the traction means mounted over the output shaft for winding and unwinding the cable.