Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Design of Hoisting Mechanism
of EOT Crane
The following data refers to an EOT crane:
Application class: II
Load to be lifted: 50 kN
Hoisting speed : 8 m/min
Maximum lift : 10 m
Design hoisting mechanism
Solution:
Step 1: Calculation of Design
Load and Load per Fall
Given: Load to be lifted = 𝑊𝐿 = 50 𝑘𝑁
𝑊𝐿 = 5 𝑡𝑜𝑛𝑛𝑒𝑠
Dead weight of tackle (a mechanism consisting of
ropes, pulley blocks, hooks, or other things for lifting
heavy objects):
𝑊0 = 0.1𝑊𝐿
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝑊0 = 0.1𝑊𝐿 = 0.5 𝑡𝑜𝑛𝑛𝑒𝑠
Total weight to be lifted, 𝑊𝑇 = 𝑊𝐿 + 𝑊0
𝑊𝑇 = 5 + 0.5 = 5.5 𝑡𝑜𝑛𝑛𝑒𝑠
On the basis of magnitude of load to be lifted, select a
multiple pulley system with appropriate number of
parts (falls).
Since load is less than 25 tonnes, select 4 falls multiple
pulley system.
Using efficiency (𝜂) of the selected multiple pulley
system, calculate design load in kg as,
𝜂 = 0.94
𝑊𝑇 5500
Design load, 𝑊 = = = 5850 𝑘𝑔
𝜂 0.94
Calculate load or tension per part (fall) in kg as,
𝑊
𝐹= =5850/4 =1462.5 kg
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑙𝑙𝑠
Step 2: Selection of Steel Rope
• For selected multiple pulley system with
appropriate number of parts (fall); design bends in
rope = (No. of total bends/2)
Design bends in rope = (6/2)=3
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Select ratio (𝐷𝑚𝑖𝑛 /𝑑 ) corresponding to design
bends (PSG 9.1)
𝐷𝑚𝑖𝑛
= 23 [𝑃𝑆𝐺 9.1]
𝑑
• Find breaking strength of the rope (P) for 6x19 and
6x37 groups (PSG 9.1)
• {{{If sure @ group determine rope diameter (d)
using equation for A (PSG 9.1) and find P}}}
• Assume material HTS and assume 𝜎𝑢
𝜎𝑢 = 180 kg/mm2
𝜎𝑢 = 18000 kg/cm2
n = Design factor 𝑛 = 𝑛′ . 𝐷𝑢𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟
n= 4.5 for Class II [PSG 9.1]
Duty factor = 1.2 for Class II [PSG 9.2]
For 6x19: Breaking strength
𝐹𝜎𝑢
𝑃= 𝜎𝑢 𝑑 = 22705.31 kg= 22.71 tonnes
− 50000
𝑛 𝐷𝑚𝑖𝑛
For 6x37: Breaking strength
𝐹𝜎𝑢
𝑃= 𝜎𝑢 𝑑 = 14888.73 kg = 14.89 tonnes
− 36000
𝑛 𝐷𝑚𝑖𝑛
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Select rope diameter (d) corresponding to
breaking strength for 6x19 and 6x37 groups (PSG
9.4 and PSG 9.5)
For 6x19: d = 20 mm [PSG 9.5]
For 6x37: d = 18 mm [PSG 9.4]
• Find 𝐷𝑚𝑖𝑛 for both groups and select group with
smaller dimensions (d and 𝐷𝑚𝑖𝑛 ).
Selecting 6x37: d = 18 mm and 𝑫𝒎𝒊𝒏 = 𝟒𝟏𝟒 𝒎𝒎
• Design for life of Hoist ropes (PSG 9.7)
0.4𝑍
𝑁= [PSG 9.7]
𝑎𝛽𝑍2
𝑎 = 3400 [Table 2- PSG 9.8]
𝑍2 = 3 [Table 2- PSG 9.8]
𝛽 = 0.4 [Table 2- PSG 9.8]
10𝐹
𝜎= = 14.368 𝑘𝑔/𝑚𝑚2 [PSG 9.7]
𝜋𝑑 2
𝐶1 = 1 [Table 3- PSG 9.8]
𝐶2 = 0.89 [PSG 9.7]
𝐶 = 1.04 [Table 4- PSG 9.8]
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝐷
= 𝑚𝜎𝐶1 𝐶2 𝐶 + 8 [PSG 9.7]
𝑑
𝑚 = 1.13
To find value of Z from Table 1 PSG 9.8, multiply m by
100. Find Z by interpolation and multiply Z by 1000.
𝑍 = 160.9 [Table 1- PSG 9.8]
𝑍 = 160 900
0.4𝑍
𝑁= = 𝟏𝟓. 𝟕 𝒎𝒐𝒏𝒕𝒉𝒔
𝑎𝛽𝑍2
Since Rope life (N) is greater than 12 months, design
safe and satisfactory.
d = 1.5 dw √i
Where, d = diameter of rope, dw = diameter of
wire, i = total number of wires in the rope.
𝑑𝑤 = 0.805 𝑚𝑚 ≅ 1 𝑚𝑚
Rope Specifications:
6x37 ordinary cross lay rope with
𝑑 = 18 𝑚𝑚
𝑑𝑤 = 1 𝑚𝑚
Minimum rope length = lift x No. of falls
= 40 m
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Step 3A: Design of Movable
Pulley
a. Selection of Pulley/Sheave Grooves
• Total Number of pulleys = No. of falls – 1 = 3
• Number of movable pulleys = No. of falls/2 = 2
• Number of compensating pulleys = 1
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
b. Find overall Pulley Dimensions
PCD of pulley, D = 𝐷𝑚𝑖𝑛 = 414 mm
Inner diameter of pulley,
𝐷𝑖 = 𝐷 − 𝑑 = 414-18 = 396 mm
Outer diameter of pulley,
𝐷o = 𝐷𝑖 + 2ℎ = 396+(30x2) = 456 mm
Hub length,
𝐴 = 1.25 𝑡𝑜 1.5 = 1.4a = 1.4x55 = 77 mm
Bearing groove in hub,
𝐵 = (𝐴/2) – 10 = 28.5 ≅ 30 𝑚𝑚
Step 3A: Design of Movable Pulley
c. Design of Pulley Axle
• Select Material : C-45 and its yield strength (PSG
1.9 )
𝑘𝑔𝑓 𝑁
𝜎𝑦 = 36 = 360
𝑚𝑚2 𝑚𝑚2
• Assume FOS = 4
• Determine allowable tensile and shear stresses
𝑁
𝜎𝑡 = 90
𝑚𝑚2
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝑁
𝜏 = 45
𝑚𝑚2
• Find max. BM and determine diameter (𝑑1 ) of axle
using bending equation
2F 2F
𝐿2 𝐿1 𝐿2
2F 2F
Fig. Forces on Pulley Axle
Fig. BMD-Pulley Axle
Max. BM,
𝑀𝑏𝑚𝑎𝑥 = 2𝐹. 𝐿2 = 1.755 × 106 𝑁 − 𝑚𝑚
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝑑1
𝑀𝑏𝑚𝑎𝑥 𝑦 𝑀 𝑏𝑚𝑎𝑥 2
𝜎𝑡 = = 𝜋
𝐼 𝑑14
64
𝑑1 = 58.35 𝑚𝑚 ≅ 60 𝑚𝑚
• Length, 𝐿1 = A + spacing between pulleys (8 to 12
mm)
𝐿1 = 𝐴 + 10 = 87 𝑚𝑚
𝐴 𝑡𝑠ℎ
• Length, 𝐿2 = + 𝑡𝑠 + = 58.5 𝑚𝑚 ≅ 60 𝑚𝑚
2 2
• Shackle plate thickness,
(𝑡𝑠ℎ = 10 to 20 mm)
𝑡𝑠 = 10 mm (Clearance)
• Take 𝑑2 and 𝑑3 with 5 to 10 mm step
• Considering step of 10 mm,
𝑑2 = 50 𝑚𝑚
𝑑3 = 40 𝑚𝑚
• Check trunnion (𝑑2 ) for bearing and shear failure
Allowable Bearing Stress,
𝑁
[𝜎𝑏𝑟 ] = 0.8𝜎𝑡 = 72
𝑚𝑚2
𝑊
2 𝑁
𝜎𝑏𝑟 = = 29.25 < 72
𝑑2 𝑡𝑠ℎ 𝑚𝑚2
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Hence, trunnion is safe in bearing failure.
2𝐹 𝑁
𝜏=𝜋 = 14.89 2
< 45
𝑑 2 𝑚𝑚
4 2
Hence, trunnion is safe in shear failure.
Step 3A: Design of Movable Pulley
d. Selection of Bearing
• Type of bearing : DGBB
• No of bearing per pulley = 2
• Peq = (X.V.Fr + YFa) x S; Fa = 0 and Fr = F
• Assuming , Radial load factor X = 1,
Race rotation factor V = 1.2 and
Service factor S = 1.2
𝑃𝑒𝑞 = 1 × 1.2 × 𝟏𝟒𝟔𝟐. 𝟓 × 𝟏. 𝟐 =2106 kgf
• Bearing life in hr, 𝐿ℎ = 9000 ℎ𝑟𝑠 (PSG 9.2)
𝑚
• 𝑣𝑝𝑢𝑙𝑙𝑒𝑦 = 2𝑣𝐻𝑜𝑖𝑠𝑡 = 16
𝑚𝑖𝑛
𝜋𝐷𝑁
• and 𝑣𝑝𝑢𝑙𝑙𝑒𝑦 = , Find N in rpm
60
16
𝑁= = 12.3 𝑟𝑝𝑚
𝜋 × 0.414
• Life in millions of rev., 𝐿𝑚𝑟 = 𝐿ℎ x N x 60
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝐿𝑚𝑟 = 9000 × 12.3 × 60 = 6.64 × 106
• Life of bearing for 90% survival at 1 mr,
𝐿10 = 1 𝑚𝑟
• Dynamic capacity , C (PSG 4.2)
1
𝐿 3 1
𝐶= . 𝑃𝑒𝑞 = 6.643 × 2106 = 3958.35 𝑘𝑔𝑓
𝐿10
• Select a proper series ball bearing (PSG 4.12 to
PSG 4.15 )
Selecting SKF Bearing No. 6212,
since C = 4050 kgf > 3958.5 kgf.
Step 3B: Design of Load Handling Attachments
a. Selection of Standard Trapezoidal Section
Hook
Fig. Crane Hook (PSG 9.11)
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Select Material : HTS
• Allowable stresses:
For Shank and Saddle
[𝜎𝑡 ] = 200 N/mm2
[𝜏] = 0.5𝜎𝑡 = 100 N/mm2
For threaded portion
[𝜎𝑡 ] = 100 N/mm2
[𝜏] = 0.5𝜎𝑡 = 50 N/mm2
• On the basis of design load (W = 5.5 tonnes),
Select dimension C (PSG 9.11)
Selecting for 8 tonnes,
𝐶 =93 mm
• Find other dimensions such as
H, M, Z, G, Gi , Select thrust bearing series (PSG
9.11)
𝐻 = 0.93𝐶 = 86.49 𝑚𝑚
𝑀 = 0.6𝐶 = 55.8 𝑚𝑚
𝑍 = 0.12𝐶 = 11.16 𝑚𝑚
𝐺 = 50 𝑚𝑚
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝐺𝑖 = 𝑀48 𝑥 5 𝑚𝑚
Thrust bearing series: 513
• Find trapezoidal cross-section dimensions
(PSG 6.3)
PSG 6.3
𝐻 = ℎ = 86.49 𝑚𝑚
𝐶
𝑟𝑖 = = 46.5 𝑚𝑚
2
𝑟𝑜 = 𝑟𝑖 + ℎ = 132.99 𝑚𝑚
𝑀 = 𝑏𝑖 = 55.8 𝑚𝑚
𝑏𝑜 = 2𝑍 = 22.32 𝑚𝑚
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
1
× (55.8 + 22.32) × 86.49
𝑟𝑛 = 2
(55.8 × 132.99) − (22.32 × 46.5) 132.99
[( 86.49 ) × ln ( )] − (55.8 − 22.32)
46.5
𝑟𝑛 = 76.76 𝑚𝑚
86.49(55.8 + (2 × 22.32))
𝑅 = 46.5 +
3(55.8 + 22.32)
𝑅 = 83.56 mm
𝑒 = 𝑅 − 𝑟𝑛 = 6.8 𝑚𝑚
Cross-sectional area,
1
𝑎 = (𝑏𝑜 + 𝑏𝑖 )ℎ = 3378.3 𝑚𝑚2
2
Slide 39
• Check threaded portion of hook for direct tensile
failure (A-A),
𝑊
𝜎𝑡 = 𝜋
𝑑2
4 𝑐
Nominal diameter of threaded portion,
𝑑𝑜 = 48 𝑚𝑚
Core diameter of threaded portion,
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝑑𝑐 = 0.84𝑑𝑜 = 40.32 𝑚𝑚
𝑊 5850×9.81
∴ 𝜎𝑡 = 𝜋 = 𝜋 = 44.94 𝑁/𝑚𝑚2 < 100
𝑑2 40.322
4 𝑐 4
Hence design is safe.
• Check Shank of hook for direct tensile failure (B-B),
𝑊 5850×9.81 𝑁
𝜎𝑡 = 𝜋 = 𝜋 = 29.22 < 200
𝐺2 502 𝑚𝑚2
4 4
Hence design is safe.
• Check horizontal section through saddle of hook
for direct tensile and bending stress failure (C-C :
most critical),
𝑊 𝑁
𝜎𝑜 = = 16.98
𝑎 𝑚𝑚2
where, a = c/s area of trapezoidal section
Find bending moment,
M = W.R = 4.7 x 106 N-mm
Find bending stress at outer and inner fibre
(PSG 6.2)
Bending stress at outer fibre (compressive)
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
ℎ𝑖 = 𝑟𝑛 − 𝑟𝑖 = 30.26 𝑚𝑚
ℎ𝑜 = ℎ − ℎ𝑖 = 56.23 𝑚𝑚
4.7×106 ×56.23
𝜎𝑏𝑜 = = 86.5 𝑁/𝑚𝑚2
3378.3×6.8×132.99
Bending stress at inner fibre (tensile)
4.7×106 ×30.26
𝜎𝑏𝑖 = = 133.14 𝑁/𝑚𝑚2
3378.3×6.8×46.5
Find total tensile stress at outer and inner
fibre by addition of direct tensile (𝜎𝑜 ) and bending
stresses (𝜎𝑏 ). 𝜎𝑏 is positive if fibre is between
centroidal axis and centre of curvature;
otherwise negative
The maximum tensile stress is at inner fibre.
The total tensile stress at inner fibre,
𝑁
𝜎𝑡 = 𝜎𝑜 + 𝜎𝑏𝑖 = 150.12 < 200
𝑚𝑚2
Hence design is safe.
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Slide 40
• Check section through saddle of hook at 450 for
Max principal stress failure (D-D),
𝑊1 = 𝑊𝑠𝑖𝑛45 = 40.57 × 103 𝑁
and 𝑊2 = 𝑊𝑐𝑜𝑠45 = 40.57 × 103 𝑁
𝑊1 𝑁
𝜎𝑜 = = 12
𝑎 𝑚𝑚2
where, a = c/s area of trapezoidal section
Find bending moment,
𝑀1 = 𝑊1 . R = 3.39 × 106 𝑁 − 𝑚𝑚
Find bending stress at outer and inner fibre
(PSG 6.2)
Find total tensile stress at outer and inner
fibre by addition of direct tensile (𝜎𝑜 ) and bending
stresses (𝜎𝑏 ). 𝜎𝑏 is positive if fibre is between
neutral axis and centre of curvature;
otherwise negative
3.39×106 ×30.26
𝜎𝑏𝑖 = = 96.03 𝑁/𝑚𝑚2
3378.3×6.8×46.5
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
The maximum tensile stress is at inner fibre.
The total tensile stress at inner fibre,
𝑁
𝜎𝑡 = 𝜎𝑜 + 𝜎𝑏𝑖 = 108.03
𝑚𝑚2
Find direct shear stress,
𝑊2 𝑁
𝜏= = 12
𝑎 𝑚𝑚2
Find max. principal stress,
𝜎𝑡 𝜎 𝑁
𝜎1 = + √ 𝑡 + 𝜏 2 = 68.08 < 200
2 2 𝑚𝑚2
Hence design is safe.
• Check vertical section through saddle of hook for
shear stress failure (E-E),
𝑊 𝑁
𝜏= = 16.98 < 100
𝑎 𝑚𝑚2
Hence design is safe.
Step 3B: Design of Load Handling
Attachments
b. Design of Nut for Hook
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Select Material : C-20 and its yield strength (PSG
1.9 )
𝑁
𝜎𝑦 = 260
𝑚𝑚2
• Assume FOS = 4
• Determine allowable tensile and shear stresses
𝑁
[𝜎𝑡 ] = 65
𝑚𝑚2
𝑁
[𝜏] = 0.5[𝜎𝑡 ] = 32.5
𝑚𝑚2
𝑁
[𝜎𝑐 ] = 1.3[𝜎𝑡 ] = 84.5
𝑚𝑚2
• Check nut threads for shear failure,
𝑊 𝑁
𝜏= = 7.92 < 32.5 ,
𝜋𝑑𝑜 𝐻 𝑚𝑚2
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
where 𝑑𝑜 = 𝐻
Hence design is safe.
• Check nut for crushing failure,
𝑊 𝑁
𝜎𝑐𝑟 = 𝜋 = 10.77 < 84.5 ,
(𝑑𝑜2 −𝑑𝑐2 )𝑛 𝑚𝑚2
4
𝐻
• where 𝑛 = = 9.6 ≅ 10 For p (PSG 5.83)
𝑝
Hence design is safe.
c. Design of Thrust Bearing for Hook
• On basis of 𝑑 = 𝐺 = 50 𝑚𝑚 (PSG 9.11),
• select thrust bearing : (PSG 4.27- 4.28)
Selecting thrust bearing series 513
Thrust bearing: 51310
• Find Static capacity: 𝐶𝑜 = 16300 𝑘𝑔𝑓
• Peq = (X.V.Fr + YFa) x S; Fa = W and Fr = 0
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Assuming , Axial load factor Y = 1, and Service
factor S = 1.2
𝑃𝑒𝑞 = 1 × 5850 × 1.2 = 7020 𝑘𝑔𝑓
• Selection is safe, if Peq < 𝐶𝑜
Since Peq < 𝐶𝑜 , Selected thrust bearing is safe.
Step 3B: Design of Load Handling
Attachments
c. Design of Crosspiece for Hook
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Select Material : C-40 and its
yield strength (PSG 1.9 )
𝑁
𝜎𝑦 = 360
𝑚𝑚2
• Assume FOS = 4
• Determine allowable tensile
and shear stresses
𝑁
[𝜎𝑡 ] = 90
𝑚𝑚2
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝑁
[𝜏] = 0.5[𝜎𝑡 ] = 45
𝑚𝑚2
𝑁
[𝜎𝑏𝑟 ] = 0.8[𝜎𝑡 ] = 72
𝑚𝑚2
• Length, 𝐿1 = 2𝐴 + 3𝑡𝑠
= (2 × 77) + (3 × 10) = 184 𝑚𝑚
𝑡𝑠ℎ
• Length, 𝐿2 = = 10 𝑚𝑚
2
• Length, 𝐿3 = Axle length
𝐿3 = (𝐿1 + 2𝐿2 ) = 207 𝑚𝑚
• Height of crosspiece, ℎ = 1.8𝑑𝑖 (1.5𝑑𝑖 to
2𝑑𝑖 ) and 𝑑𝑖 = G
ℎ = 1.8 × 50 = 90 𝑚𝑚
• 𝑑𝑜 = 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑑𝑖𝑎
𝑑𝑜 = 95 𝑚𝑚
• ℎ1 = 5 𝑚𝑚 (Assume)
ℎ2 = ℎ − ℎ1 = 85 𝑚𝑚
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Find Max bending moment (M)
W W
2 2
𝑑𝑜
𝐿3
W W
2 2
𝑊 𝐿3 𝑊 𝑑𝑜
𝑀 =( × )−( × )
2 2 2 4
∴ 𝑀 = 2.33 × 106 𝑁 − 𝑚𝑚
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
2
𝑏𝑒𝑓𝑓 ℎ𝑒𝑓𝑓
• Section modulus 𝑍 =
6
• 𝑏𝑒𝑓𝑓 = 𝑏 − 𝑑𝑜 and ℎ𝑒𝑓𝑓 = ℎ2
𝑀
• Find b using, 𝜎𝑏 =
𝑍
𝑀 6
𝑏=( ) + 𝑑𝑜 = 116.5 𝑚𝑚 ≅ 120 𝑚𝑚
𝜎𝑏 ℎ22
• Check trunnion (𝑑2 ) for crushing and shear failure
Find 𝑑2 using shear failure:
Hence, trunnion is safe in bearing failure.
2𝐹
𝜏=𝜋
𝑑22
4
∴ 𝑑2 = 28.77 𝑚𝑚 ≅ 30 𝑚𝑚
𝑊
2 𝑁
𝜎𝑏𝑟 = = 48.75 < 72
𝑑2 𝑡𝑠ℎ 𝑚𝑚2
Hence trunnion design is safe.
25
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Step 3C: Design of Shackle Plate
• Select Material : C-20 and its
yield strength (PSG 1.9 )
𝑁
𝜎𝑦 = 260
𝑚𝑚2
• Assume FOS = 4
• Determine allowable tensile and shear stresses
𝑁
[𝜎𝑡 ] = 65
𝑚𝑚2
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Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝑁
[𝜏] = 0.5[𝜎𝑡 ] = 32.5
𝑚𝑚2
𝑁
[𝜎𝑐 ] = 1.3[𝜎𝑡 ] = 84.5
𝑚𝑚2
𝐷𝑜 ℎ
• Height, 𝐻1 = + +
2 2
𝐶𝑜𝑣𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 + 𝑚𝑎𝑟𝑔𝑖𝑛
• Cover height = 𝑁𝑢𝑡 ℎ𝑒𝑖𝑔ℎ𝑡 +
𝑇ℎ𝑟𝑢𝑠𝑡 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 + 𝑚𝑎𝑟𝑔𝑖𝑛 = 48
+31+15= 94 mm
456 90
𝐻1 = + + 94 + 30 = 397 𝑚𝑚
2 2
ℎ 90
• Height, 𝐻2 = + 𝑚𝑎𝑟𝑔𝑖𝑛 = + 15 = 60𝑚𝑚
2 2
• Width of shackle plate, 𝑏 = 1.5 𝑑2 (Bigger of
Axle/Crosspiece trunnion dia)
𝑏 = 1.5 × 50 = 75 𝑚𝑚
• Check shackle plate for tensile and shear failure
𝑊/2 58500/2 𝑁
𝜏= = = 12.18 < 32.5
2𝐻2 .𝑡𝑠ℎ 2×60×20 𝑚𝑚2
Hence, shackle plate design is safe in shear.
𝑊/2 58500/2 𝑁
𝜎𝑡 = =( = 58.5 < 65
(𝑏− 𝑑2 )𝑡𝑠ℎ 75−50)20 𝑚𝑚2
Hence, shackle plate design is safe in tension.
27
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Step 4: Design Rope Drum Assembly
a. Design of Rope Drum
(PSG 9.2 )
• Select Material : GCI-40
• 𝜎𝑢 = 400 N/mm2
• Assume FOS = 4
• Determine allowable tensile,
shear and crushing stresses
𝑁
[𝜎𝑡 ] = 100
𝑚𝑚2
𝑁
[𝜏] = 0.5[𝜎𝑡 ] = 50
𝑚𝑚2
𝑁
[𝜎𝑐 ] = 1.3[𝜎𝑡 ] = 130
𝑚𝑚2
28
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• PCD: 𝐷 ′ = 𝐷𝑚𝑖𝑛 = 414 𝑚𝑚
• Drum diameter,
𝐷 = 𝐷 ′ − 𝑑 = 414 − 18 = 396𝑚𝑚
• Wall thickness, 𝑤 (PSG 9.3 )
𝑤 = 0.02𝐷 + 1 = 1.792𝑐𝑚
= 17.92𝑚𝑚 ≅ 20𝑚𝑚
• Flange dia, 𝐷𝑓 (PSG 9.3 )
𝐷𝑓 = 𝐷 + 6𝑑 = 396 + (6 × 18)
= 504 𝑚𝑚 ≅ 510𝑚𝑚
• 𝐷𝑖 = 𝐷 − 2𝑤
= 396 − (2 × 20) = 356𝑚𝑚
• Find drum groove dimensions: (PSG 9.9 )
(PSG 9.9 )
𝑟1 = 11.5 𝑚𝑚
𝑆1 = 22 𝑚𝑚
𝐶1 = 5 𝑚𝑚
29
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Step 4: Design Rope Drum Assembly
a. Design of Rope Drum
• Number of turns of rope on drum on one side, Z
(PSG 9.2 )
𝑛𝑓
𝑖= =2
2
𝐻𝑖
𝑍= + 2 = 18. 07 ≅ 18
𝜋𝐷
• Find length of drum, L (PSG 9.2 ) Assume 𝑙1 =
100 mm
2 × 10 × 100 × 2
𝐿=( + 12) × 2.2 + 10.0
𝜋39.6
= 107.135 𝑐𝑚 = 1071.35 𝑚𝑚 ≅ 1075 𝑚𝑚
30
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Find max bending stress induced in drum
(PSG 9.3 )
8 × 2 × 1462.5 × 9.81 × 1075 × 396
𝜎𝑏 = ( )
𝜋(3964 − 3564 )
= 3.71 𝑁/𝑚𝑚2
• Find torque on drum (PSG 9.3 )
𝑀𝑡 = 2 × 1462.5 × 9.81(414/2)
= 5.94 × 106 𝑁 − 𝑚𝑚
• Find max shear stress induced in drum (PSG
9.3 )
𝜏 = 1.17 𝑁/𝑚𝑚2
• Find crushing stress induced in drum (PSG
9.3 )
31
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
𝜎𝑐 = 65.21 𝑁/𝑚𝑚2
• Find total normal stress induced in drum
(PSG 9.3 )
𝜎𝑛 = 65.31 𝑁/𝑚𝑚2
• Check for combined equivalent stress induced in
drum (PSG 9.3 )
𝜎𝑒 = 65.38 𝑁/𝑚𝑚2 ≤ 100
Design of rope drum is safe.
a. Design of Rope Drum Shaft
Select Material : C-45/Alloy steel and its yield
strength
32
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• 𝜎𝑦 = 540 N/mm2
• Assume FOS = 4
• Determine allowable tensile,
shear stresses
𝑁
[𝜎𝑡 ] = 135
𝑚𝑚2
𝑁
[𝜏] = 0.5[𝜎𝑡 ] = 67.5
𝑚𝑚2
F F
𝑙1
𝐿s
F F
33
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
Find length of drum shaft, 𝐿𝑠=𝐿+120mm
(100 to 120mm)
𝐿𝑠 = 𝐿 + 120 = 1195 𝑚𝑚
•Find max bending moment in drum shaft
(𝑀𝑏)
𝐿𝑠 − 𝑙1
𝑀𝑏 = 𝐹 × = 7.855 × 106 𝑁 − 𝑚𝑚
2
•Torque on drum shaft = torque on drum
(𝑀𝑡)(PSG 9.3 )
𝑀𝑡 = 2 × 1462.5 × 9.81(414/2)
= 5.94 × 106 𝑁 − 𝑚𝑚
•Equivalent torque on drum shaft,
𝑀𝑒 = √(𝑀𝑏 )2 + (𝑀𝑡 )2
𝑀𝑒 = 9.848 × 106 𝑁 − 𝑚𝑚
•Find diameter of drum shaft using torsion
equation
𝜋 3
𝑀𝑒 = 𝑑𝑠 [ 𝜏 ]
16
𝑑𝑠 = 90.57 𝑚𝑚 ≅ 95𝑚𝑚
34
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
b.Selection of bearing for Drum Shaft
•Select DGBB or Cylindrical roller bearing
•Repeat Step 3A-d
• Type of bearing : DGBB
• No of bearing for rope drum and shaft = 2
• Peq = (X.V.Fr + YFa) x S; Fa = 0 and Fr = F
• Assuming , Radial load factor X = 1,
Race rotation factor V = 1.2 and
Service factor S = 1.2
𝑃𝑒𝑞 = 1 × 1.2 × 𝟏𝟒𝟔𝟐. 𝟓 × 𝟏. 𝟐 =2106 kgf
• Bearing life in hr, 𝐿ℎ = 9000 ℎ𝑟𝑠 (PSG 9.2)
𝑚
• 𝑣𝑅𝑜𝑝𝑒𝐷𝑟𝑢𝑚 = 2𝑣𝐻𝑜𝑖𝑠𝑡 = 16
𝑚𝑖𝑛
𝜋𝐷𝑁
• and 𝑣𝑅𝑜𝑝𝑒𝐷𝑟𝑢𝑚 = , Find N in rpm
60
16
𝑁= = 12.3 𝑟𝑝𝑚
𝜋 × 0.414
• Life in millions of rev., 𝐿𝑚𝑟 = 𝐿ℎ x N x 60
𝐿𝑚𝑟 = 9000 × 12.3 × 60 = 6.64 × 106
35
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
• Life of bearing for 90% survival at 1 mr,
𝐿10 = 1 𝑚𝑟
• Dynamic capacity , C (PSG 4.2)
1
𝐿 3 1
𝐶= . 𝑃 = 6.643 × 2106 = 3958.35 𝑘𝑔𝑓
𝐿10 𝑒𝑞
• Select a proper series ball bearing (PSG 4.12 to
PSG 4.15 )
Selecting SKF Bearing No. 6212,
since C = 4050 kgf > 3958.5 kgf.
Step 5: Selection of Hoisting Motor and
Transmission
120𝑓
• Motor speed, 𝑁𝑚 = = 1000 rpm
𝑃𝑜𝑙𝑒𝑠
(Assume poles as 6 and f = 50 Hz)
𝑊𝑣ℎ𝑜𝑖𝑠𝑡
• Motor power, 𝑃𝑚 = (Assume 𝜂𝑜 =
𝜂𝑜
0.84 to 0.88)
36
Dr. Pradeepkumar Suryawanshi
Design of Hoisting Mechanism (BE Mech:DMS Sem-VIII)
58.5 × 8
𝑃𝑚 = = 9.069 𝑘𝑊
0.86 × 60
• Select motor (PSG 5.125 )
Selecting 6 pole, 1000 rpm, F300B, 3-phase induction
motor (PSG 5.126)
• Overall reduction ratio for transmission,
𝑁𝑚 1000
𝑖= = = 81.3
𝑁𝑝 12.3
• Reduction ratio per stage,
𝑛
• 𝑖𝑠𝑡𝑎𝑔𝑒 = √𝑖 = 4.33 < 6
Selecting a 3-stage Gear box.
37
Dr. Pradeepkumar Suryawanshi
