Software for winch systems

Software for winch systems is the specialty of Sander de Vree, software engineer at DROMEC. With a smile on his face, he says: “Our ideal scenario is to control our electric winch systems using a touchscreen with unprecedented capabilities!”

Sander explains:
“Our process starts with the customer, and I like to be present at the initial discussion to understand the requirements for controlling the winch system. Every application comes with new questions and requirements. What does the customer need? Based on this information, I write the software for the machine’s control system. We test the software together with the winch system here at DROMEC, sometimes with the customer present, so they can learn to operate the system independently.”

Types of Control Systems

At DROMEC, various types of controls and operating systems are used. In some cases, a simple control system suffices, such as a fixed hand pendant, a radio transmitter, or a belly box. However, for more complex winch systems or large spooling machines, DROMEC employs an advanced touchscreen-based control system. This allows the operator to fully monitor and operate the machine. DROMEC has developed its own platform for this purpose, enabling operators to standardly view data logging, trace error messages, and monitor real-time forces and speeds.

Customer-Specific Software

At DROMEC, every winch system is equipped with custom-written software. Sander explains: “Each project often requires customer-specific software. Our main question is: what does the customer want to see and monitor, what is needed during operation, and how can we make the interface as user-friendly as possible? Our software supports various control mechanisms such as position synchronization, torque and speed synchronization, Constant Tension, and Active Heave Compensation. For each situation, we determine the necessary configurations and adjust our base platform accordingly. For example, in pull-in systems, it’s crucial for the operator to monitor the forces acting on the cable, with the ability to limit these forces when necessary.”
Many systems are equipped with a remote monitoring device, allowing us to diagnose and provide service remotely. “This feature is truly unique and saves us an enormous amount of time.”

Integration with External Systems

Another strength of our platform is its ability to integrate with external control systems using various fieldbus connections. This enables us to help customers consolidate data into a centralized system. Since DROMEC develops the machine, the control system, and the software in-house, our team is highly flexible in collaborating with customers on their specific needs.

Renewable Energy Applications

Sander developed the software and control system for a test setup designed for endurance testing of ropes. These ropes are used in a renewable energy system where airplanes generate energy by being tethered to a massive rotating wheel. The challenge was implementing different control mechanisms within this system: position synchronization for back-and-forth movement and Constant Tension regulation for force settings. Additionally, the system is equipped with cameras and various sensors to monitor the test. It is also connected to an external system for data exchange and can be remotely monitored. This is a prime example where everything comes together, seamlessly integrating OT (Operational Technology) with IT (Information Technology).

Drive Systems

A growing trend is the increasing demand for software and control solutions for drive systems. While the control principles are similar to those used in winches, the movements and applications differ. Thanks to our extensive base platform and our experience in winch systems, we foresee significant potential in this sector.
Sander envisions the future: “With all the data we can extract from each machine, we will be able to assist with predictive maintenance by providing alerts when specific machine components require inspection—such as brakes, gearboxes, and motors—helping to prevent downtime. Additionally, analyzing this data will allow us to continuously improve our understanding of the capabilities of DROMEC winch systems.”