1280 Field Parkway, Marietta, Georgia 30066 * (770)514-3288
INVESTIGATIVE REPORT
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ATS File No. B05507 Date 03 April, 2001
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Testing

A new 2000 year model Warn XD9000i equipped with a 4.6 hp motor was shipped directly to ATS from a Warn dealer. See Figure 1 and Figure 2. The winch was unpackaged and subjected to a series of tests under a variety of load conditions. Each test was performed using the following general methods unless otherwise noted:

  • The wire ropes on the winch for these tests were new 5/16 in. diameter 7x19 galvanized wire ropes procured from Warn.
  • The wire ropes were marked with orange spray paint at 5 ft. intervals along their length so that their speed could easily be measured.
  • At the start of each test, the wire rope was spooled off of the winch drum until only half of the bottom layer remained on the drum. See Figure 3.

 

Testing Performed on Mechanical Brake

For the first set of tests, ATS mounted the winch into a mechanical brake apparatus provided by Mile Marker. The free end of the wire rope was wrapped onto the brake drum of the mechanical brake so that loading could be applied to the winch. The load on the winch was controlled by adjusting the pressure on the brake drum of the mechanical brake. See Figure 4.
For the purposes of these tests, ATS modified and instrumented the mechanical brake as follows:

  • The output signals for all instruments were connected to a data acquisition unit.
  • Electrical power for the winch was supplied by two 12-volt car batteries in parallel. These batteries were supplemented during testing with a 200 amp battery charger during actual winching. A 0-1000 amp. ammeter was used to measure the winch’s current draw.
  • The brake drum of the mechanical brake was shackled to the base of a 10,000 lb. load cell.
  • One J-type thermocouple was attached to the outside of the motor case. A second J-type thermocouple was mounted near the data acquisition unit to measure the ambient temperature.
  • The test brake was instrumented with a 0-2000 psi pressure transducer to monitor the pressure on the brake drum so that the applied load could be manually controlled.

INVESTIGATIVE REPORT
<
>
ATS File No. B05507 Date 03 April, 2001
Page 3
of
23