— How Do Winches Ensure Efficient, Safe, and Stable Operation of Cableway Systems?

In aerial tramway transportation systems, the design and selection of power units directly determine operational efficiency and safety. This article delves into how winches serve as the “power brain” for trolley traction in aerial tramways, analyzing engineering requirements and incorporating real-world test parameters.

I. Project Background

A 100-meter-span aerial tramway system, supported by two 25-meter towers, features a trolley traveling back and forth along the cable for:

✔ Aerial material transport

✔ Large-item hoisting and deployment

✔ Equipment handling and commissioning

The challenge lies in:

II. Engineering Challenges

📌 01 Large span with significant cable sag Before tensioning:

 100m span

 Sag exceeding 4.28m

Design requirement: sag ≤ 3m. Otherwise:

 Reduced traction efficiency

 Increased trolley impact during operation

 Shortened cable lifespan

📌 02 Balancing trolley speed and stability Trolley requirements:

➡ ≥2m/s operating speed

➡ Shock-free start/stop

➡ Stable, secure traction force output

📌 03 Complex cable loading requires high safety margin In cable load calculations:

 Vertical load approx. 0.255 tons

 Safety factor ≥ 3.15

 Utilizes D16-6×19S+IWR 1770MPa wire rope

Ensures reliability and safety under prolonged high tension.

III. Overall Solution Architecture

We designed a multi-winch cooperative system:

IV. Core Power Unit Details

🟡 01 Main Traction Winch (High Efficiency & Stability)

Key Parameters:

 Motor Power: 15kW

 Reduction Ratio: 14.45

 Output Speed: 101 rpm

 Cable Speed: 120 m/min

 Guaranteed Operating Speed ≥2 m/s

This unit serves as the primary propulsion force for the trolley, meeting high-speed operation demands in large-span scenarios.

🟢 02 Cable Tensioning & Sag Control!

The system integrates a servo electric cylinder + pressure sensor + real-time tension feedback to achieve:

✔ Automatic compensation for cable elongation

✔ Real-time tension control

✔ Precise sag adjustment

The tensioning unit delivers 3× rated cable force, effectively maintaining sag within controlled limits.

🔵 03 Auxiliary Return Module (Stable & Reliable)

 Power: 3kW

 Cable Speed: Approx. 14m/min

 Equipped with electromagnetic clutch

 Provides deceleration drive during trolley return, enhancing comfort and safety

V. System Performance Outcomes

🚀 Operational speed meets specifications

📏 Cable sag controlled at ≤3m

🔩 Ample safety margin

🔄 Stable multi-winch coordinated operation

The entire power system not only meets performance requirements but also achieves:

✔ Smooth starts

✔ Precise braking

✔ Automatic tension compensation

✔ Long-term stable operation

VI. Engineering Highlights Summary

🔹 Core tensioning technology employs servo electric cylinder combination tensioning, enabling real-time automatic cable adjustment and significantly enhancing operational stability.

🔹 Dual-speed operation strategy outperforms single-speed solutions by separating high-speed traction and low-speed return, balancing efficiency and safety.

🔹 Multi-unit coordination enhances system stability through main drive + auxiliary module combinations, enabling more flexible and efficient traction processes.

VII. Suitable Application Scenarios

✔ Aerial material logistics transportation

✔ Large-span cable installations

✔ Industrial testing and equipment handling

✔ Robotic arm/hoisting track systems

VIII. Conclusion

A robust aerial cableway power system relies not on individual components but on system synergy, precision control, and standardized engineering safety. This integrated winch-based power solution not only meets high-efficiency operational demands but also incorporates engineering safety redundancy, serving as an exemplary reference for the aerial cableway industry.

VII. FAQ: Frequently Asked Questions

Q1: Why can't aerial tramways use only one winch? A single winch can only provide power and cannot simultaneously perform:

 Tension control

 Return speed regulation

 Cable laying

Multi-unit coordinated structures are essential for long-span systems.

Q2: Why is limiting cable sag to under 3 meters critical?

Excessive sag leads to:

 Increased impact loads on trolleys

 Higher running resistance

 Accelerated cable fatigue damage

Controlling sag is key to ensuring longevity and stability.

Q3: How do you calculate if a winch meets traction requirements?

Key parameters include:

 Wire rope diameter

 Rope capacity

 Rope speed

 Reduction ratio

 Dynamic load factor

 Safety factor

Confirmation requires load calculations.

Q4: What are the advantages of servo tensioning systems over traditional counterweights?

Advantages include:

 Real-time adjustment

 Higher precision

 Automatic compensation

 Compact footprint

Suitable for modern industrial systems.

Q5: What are the three most critical factors for selecting aerial tramway winches?

① Whether pulling force meets design specifications

② Whether rope speed matches operational requirements

③ Whether safety factor meets standards

All three are essential.