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The Winch Spool was an integral part of our UAV team's winch-basket system used to deliver the payloads. The spool was what rotated to extend or shorten the cable. However we found a critical design flaw during testing that would affect competition use. I had the honor of solving this flaw.
Transparent Winch Spool Design
Process
Process
During testing, we discovered the screw connecting spool to collar clamp loosened when the spool was spun. The 100s of feet of cable wrapped around it also made it impossible to reach and tighten so I:
Designed a cut-out on spool for allan key to reach
Used rounded shapes and fillets to maximize space without taking any essential geometry
Fitted to hex shaft of motor
Tested to ensure success
Opaque Winch Spool Design
Manufacturing
Manufacturing
3D printed using PETG and PLA
Purchased clamps, screws, and hex shaft from McMaster-Carr to assemble
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