I have a pay-out winch. It is a spool of rope that has a disk brake attached to it, so I can control the torque required to rotate the spool. When the torque is very large, however, the rope begins to bury itself into the rope that is still on the spool, and this causes a lot of abrasion and wear on the rope. I tried a different winding pattern, but the rope still cuts into it.
I'm using 1 mile of 400 lb test kevlar. The spool diameter is 4 inches.
Does anyone have a suggestion? I was wondering if I can thread the rope through a mechanism as it leaves the spool to add friction (pink box in the picture). Are there any off-the-shelf solutions? For example the rope could go back and forth between two rows of pulleys, each of which has a little friction. The point is to avoid wearing out the rope with a lot of heat or abrasion.
Can you suggest a way to prevent the rope from burying itself? I guess I could make the spool larger and wider (decrease the depth of the rope still on the spool).