Military-Grade Servo Dual-Drum Synchronous Winch | 1,000 kg Capacity, ≤50 kg Lightweight Design | KLD Engineering Case

I. Project Background & Industry Pain Points

In a military special vehicle application, the equipment must perform dual-rope synchronous hoisting within limited space. Traditional winches are often heavy, prone to rope misalignment, and lack synchronization — making it difficult to meet the military’s strict requirements for weight, precision, and reliability.

Common issues include:

Excessive winch weight, affecting vehicle payload
Asynchronous rope movement, causing uneven loading
Rope misalignment and accelerated wear on steel cables
Insufficient servo control precision for accurate positioning
Poor environmental adaptability, failing military standards

✔ Therefore, a lightweight, high-synchronization, servo-driven dual-drum winch system is required.

II. Customer’s Core Technical Requirements

The customer, a military vehicle integrator, specified the following:

1️⃣ Rated load: 1,000 kg, single-side rope length: 10 m
2️⃣ Total unit weight: ≤50 kg — a strict weight limit
3️⃣ Synchronized dual-rope operation, no uneven loading
4️⃣ High stopping accuracy for mission-critical positioning
5️⃣ Compliance with military environmental and reliability standards

III. KLD Custom Solution

To meet the conflicting demands of light weight and synchronous operation, KLD developed an all-aluminum servo dual-drum winch:

Gearbox: all-aluminum housing
Drum and base plate: machined from aluminum alloy
Rope type: Kevlar fiber rope instead of steel cable
Servo motor with built-in high-resolution encoder
Dual drums driven by mechanical synchronization

This design solves both the lightweight requirement and the synchronization challenge.

IV. Technical Specifications

Parameter	Value
Rated load	1,000 kg
Rope length per side	10 m
Total unit weight	≤50 kg
Motor type	High-performance servo motor
Rated power	1.5 kW
Rated speed	30.1 m/min
Rated torque	2 N·m
Rope type	Kevlar fiber rope
Control method	Encoder-based closed-loop control
Surface finish	Matte black

V. Design Highlights

✔ Lightweight construction — gearbox, drum, and base plate all in aluminum alloy; total weight ≤50 kg
✔ Synchronized dual-drum drive — mechanical synchronization eliminates uneven loading and rope lag
✔ Kevlar fiber rope — high tensile strength, low weight, good abrasion resistance
✔ Servo closed-loop control — built-in encoder provides millimeter-level positioning accuracy
✔ Matte black finish — reduces visual signature and improves corrosion resistance

VI. Application Scenarios

Military special vehicle integration
Vehicle-mounted dual-rope synchronized hoisting
Compact, lightweight lifting equipment for confined spaces
High-precision positioning platforms
Military equipment testing and support

VII. Project Value

This solution delivered:

Total weight kept under 50 kg, meeting vehicle payload constraints
Synchronized dual-rope operation, improving stability
Kevlar rope reduces rope weight by more than 60% compared to steel cable
Precise positioning meets military-grade accuracy requirements
Design validated and approved for batch deployment

VIII. Customization & Inquiry

Manufacturer: Beijing Tianheng Kairui (KLD Winch)
Website: https://kldwinch.com

Manufacturer Direct — cost advantage without intermediaries.
Customized according to CAD/PDF drawings — we work directly from your technical drawings.
Key component reliability — all critical components are selected or designed for long-term field performance.

One-on-one technical consultation and project-specific quotations available.

IX. FAQ

Q1: Is the winch customizable?
Yes. KLD offers full customization — load capacity, rope length, materials, and control system.

Q2: What is the maximum rated load available?
This case is 1,000 kg. KLD supports higher loads, up to several tens of kN.

Q3: Does it support variable speed control?
Yes. The servo motor provides closed-loop speed control with significantly better precision than traditional VFDs.

Q4: What environments is this winch suitable for?
Military, vehicle-mounted, confined spaces, high-precision positioning, and similar demanding applications.

Q5: Does KLD provide technical support?
Yes — from initial design and drawing review to on-site commissioning and after-sales support.