Winch Tension & Power Monitoring Automation

I’m upgrading a winch so it can look after itself. The end-goal is a single PLC-driven package that (1) keeps live watch on cable tension and (2) tracks voltage and current feeding the AC-servo and every auxiliary circuit, reacting in real time when any limit is crossed.

What has to happen
• AC-servo installation: size, mount, wire and commission the drive so the winch can wind or unwind in both auto and manual modes—each must remain instantly selectable and carry equal priority in the logic.
• Continuous tension loop: fit a load cell (or comparable sensor), scale it in the PLC and build high/low thresholds that trigger alarms and safe shutdown.
• Power supervision: add transducers on the servo supply and on the other subsystems; create threshold-based trips for over/under-voltage and over-current with data logging.
• Protection layer: integrate converters, breakers or electronic trippers for automatic cut-off when any limit is breached.
• Touchscreen HMI: design screens that present live tension, volts, amps and system status, plus jog buttons and set-point entry.
• Field wiring & panels: fabricate, label and terminate every cable, then land everything in a clean, serviceable panel.
• PLC programming & hand-over: write, test and document the code, run through all fault scenarios, and stay on site (or remote into the PLC) until the system passes demonstration.

Acceptance checklist
1. Smooth pay-in/pay-out under closed-loop tension control.
2. Seamless switching between auto and manual at any time.
3. Verified trips for over-tension, under-tension, over-voltage and over-current, each captured in the HMI log.
4. Intuitive, fully functional touchscreen interface.

If your background covers PLCs, servo drives and industrial HMIs, let’s pin down the hardware platform you’d like to use and the timeline needed to fabricate, program and commission the system.

**Prefer Engineers from Hyderabad