Hazards of the Winch

Operating a 4x4 vehicle recovery winch can be a very dangerous business. The mechanical forces generated are large, the attach points often uncertain, and the terrain awkward. If something breaks or gives way it usually means some object will come flying towards the winch at high speed - better not to be too close to it if possible. Many serious injuries have been caused by winch tackle breaking and attachments flying about.
To do his job the winch operator often needs to move all the way around the recovery operation to see how things are progressing. This entails a lot of running to and from the winch control. With a remote winch control the winch can be operated anywhere around the recovery site, and a mobile phone is something most people have near at hand, and the battery is usually charged. Safety and convenience.
To remotely control a 4x4 winch you need to connect a mobile phone remote control for 4x4 winch unit into the existing hand-held switch panel input, and install the mobile phone winch control app on your Android mobile phone.


The Versatile Vehicle Winch

 There are many other uses for a winch other than vehicle recovery. Winches are used for a variety of purposes including raising flagpoles, roof trusses, and water-tank stands. Often while performing such duties the workplace is not fault visible from the winch's location, so that an operator, bound by the length of the switch-panel cable, cannot properly see what is happening at the hook end. Frequently there is an entire building between the winch and the business end of the cable.
At such times it is a great help to have remote control capability that can place the operator at the workplace where he can see exactly what needs to be done and does not rely on instructions yelled at him from afar. The mobile phone remote control for 4x4 winch makes that easy.


The Mobile Phone Winch Control App

 The line-of-sight range betwen the mobile phone can be up to 60 metres under ideal conditions - more than enough distance to allow free movement all around the vehicle recovery site. 
Should the  mobile phone lose touch with the control unit for any reason the winch will stop within less than half a second.
Feedback from the controller to the mobile include values for motor temperature, current draw and he battery voltage supplied to the winch, all of which are transmitted from the control unit and displayed on the screen of the mobile phone. When correctly interpreted this gives an important indication of the condition of the winch and the charge state and general condition of the battery.
Small variances can be significant so it is vital that the voltage reading should be accurate and, since component values can vary somewhat there is a simple callibration facility to eliminate the variances.
Should the battery voltage fall below the critical level of 11,7V at any time the background to the voltage display will turn RED as a warning that battery damage will soon occur.


The Remote 4x4 Winch Control

The Controller comprises a buck regulator, a micro controller, a Bluetooth module, and a pair of relays, which simulate the function of the switches in the hand-held panel. They energize either the Reel-in or Reel-out contactor that powers the winch motor. The controller can be built into the contactor box, or it can be contained within an external, pluggable housing.
There is a wide variety of 4x4 winches available and new models regularly coming onto the market, all of which have their own housings and control-switch plugs. This means that a certain amount of ingenuity might be needed to successfully implement remote control, and puts it out of reach for many winch owners.
To be pluggable the connector that accepts the control panel must be equipped with more than 3 pins. Some winch manufacturers, such as Warn, employ a custom 3-pin plug which allows no modification, and makes it unsuitable for this remote control. Others, such as T-Max use an industry-standard connector with 4 or more pins, of which only 3 are used to control the winch, leaving at least one pin to be used by the Remote Control. The Remote Control requires 4 connections: +12V, GND, OUT 1, OUT 2, whereas the manual switch panel needs only three wires connected - either +12V or GND are unused.
Adding the ground wire is simply a matter of soldering a short single core of auto-electrical wire to a pin of the connector on one side and a lug to the vehicle GND on the other. 

The Handheld Winch Control

The handheld control unit will remain as functional as before. If the controller is built into the contactor box the handheld can be used simultaneously. Great care should then be taken that conflicts are avoided. If the pluggable unit is being used it will have to be unplugged to revert to the handheld panel.