Project Background
In the field of industrial automation and precision tooling, a stable lifting system is critical. This project involved a client’s equipment requiring dual-point synchronized lifting for precision tooling platforms and automated production lines.
When using standard winches, the client experienced:
- Asynchronous dual-side motion, causing equipment tilt
- Inaccurate stop positions and unstable low-speed operation
- Inability to perform automated cycle actions
- Frequent manual adjustments during extended operation
It was clear that conventional winches could not meet the synchronization, precise control, and long-term stability requirements of modern automated systems.
Client Core Requirements
- Dual-point synchronized lifting: Ensure both sides move in unison, reducing misalignment risk
- Precise low-speed stopping: Accurate positioning at the end of travel
- PLC linkage control: Enable automated cycles and interlinked operations
- Long-term operational stability: Reduce manual intervention and improve productivity
Primary goal: Achieve synchronized motion, smooth low-speed operation, and fully controllable automation.
KLD Solution
To address the client’s requirements, KLD designed a servo dual-drum winch system:
- Dual-drum synchronized structure: Ensures both sides reel in/out simultaneously, reducing offset and uneven load
- Servo brake motor: Stable low-speed operation with precise start/stop, integrated with PLC and encoder for automated linkage
- PLC linkage control: Automates start, stop, cycle, and synchronization, with encoder feedback for real-time motion monitoring
- Dual grooved drums & rope tension guides: Optimize wire rope alignment, reducing tangling and wear
- Mechanical height limiters & acrylic protective cover: Prevent over-travel, improve safety, and allow easy inspection
- Precision planetary gearbox: Provides stable output torque for consistent long-term operation
Project Results
- Improved dual-side synchronization: Actions are aligned, equipment tilt significantly reduced
- Smooth low-speed stopping: Accurate positioning, minimizing start/stop impact
- Enhanced automation: PLC enables cycle and interlinked operations, reducing manual intervention
- Long-term reliability: Stable system performance suitable for repetitive industrial operations
Project Specifications
| Parameter | Specification |
| Lifting Capacity | 500 kg |
| Lifting Height | 4 m |
| Rope Speed | 5 m/min |
| Motor Power | 0.75 kW |
| Gearbox Ratio | 123.85:1 |
| Output Torque | 600 N·m |
| Wire Rope Diameter | 8 mm |
| Drum Capacity | 7 m |
| Equipment Weight | 123 kg |
Note: Actual solutions can be customized based on load, travel height, rope speed, installation space, and control logic.
KLD Engineering Advantages
KLD has extensive experience providing synchronized winch control solutions for automation equipment manufacturers, system integrators, and industrial equipment producers:
- Dual-drum synchronization solutions
- PLC linkage and servo drive integration
- Automated cycle logic
- Non-standard structural designs
- Full engineering support (solution design, drawings, assembly, debugging, project delivery)
Customer provides: lifting capacity, travel height, rope speed, wire rope specifications, application scenario, control method, PLC linkage requirements, installation space dimensions
KLD engineers provide:
✅ Free solution design
✅ Engineering drawings
✅ PLC linkage recommendations
✅ Automation control advice
✅ Non-standard customization support
FAQ (High-Coverage Version)
Q1: Can standard winches achieve dual-point synchronization?
No. Standard winches lack synchronized control, leading to deviations during low-speed start/stop and inconsistent dual-side motion.
Q2: What are the benefits of servo winches at low speed?
Servo drives precisely control start, stop, and speed, ensuring smooth, consistent motion suitable for automated cycles.
Q3: How does PLC linkage control enable automation?
The PLC receives real-time encoder feedback to control the winch for start, stop, cycle, and multi-machine coordination, reducing manual intervention.
Q4: Is the system stable for long-term operation?
Yes. Dual grooved drums, rope tension guides, limiters, and precision gearboxes ensure neatly aligned wire ropes, smooth operation, and minimal wear.
Q5: Does KLD provide customized solutions?
Yes. KLD offers dual-drum synchronization, PLC linkage, servo positioning, and non-standard structural designs to meet diverse automation equipment needs.
