Designof7tRopeDrumHoist

foroperationofUnderSluiceGateofWajooNallah

1.0 GeneralDescription
An manually operated Rope drum hoist of 7 t capacity is provided for operation of

Under Sluice Gate for Check dam on Wajoo Nallah. The hoisting mechanism mainly comprises

of central drive unit having an manual reduction and worm reducer. Two end gear boxes,

p gear
each with one sets of spur g p
/ pinion p drum are connected to the gate
and a rope g byy rope.
p

One end of the rope is fixed to the drum and other end after passing over gate pulley is

connectedtohoistbridgestructure.

2.0 TechnicalDetails

Number of Hoists
NumberofHoists 4 Nos

HoistCapacity 7t

Totallift 9m

LiftingSpeed (Required) 0.2 m/min

(Actual) 0.12
0 12 m/min

TypeofHoist RopeDrumHoist

3.0 EfficiencyoftheSystem

Efficiency
SlNo. Components Type Pairs
St ti
Starting Running
R i
i RopeDrum Bush 1 0.93 0.95
ii Pulleys Bush 1 0.93 0.95
iii Gear/Pinion Spur 1 0.93 0.95
iv CentralReduction Spiral 3 0.95 0.97
OVERALLEFFICIENCY 0.69 0.783

StartingSystemEfficiencywithoutpulley 0.742
RunningSystemEfficiencywithoutpulley 0.883
4.0 Materials

o st Co po e ts, o st Suppo t g St uctu e,

HoistComponents,HoistSupportingStructure,
Trestlesetc. = StructuralSteel IS:2062
RopeDrum = CastSteel IS:1030
GearWheel = CastSteel IS:1030
Pinions = ForgedSteel IS:2004
Shaft = ForgedSteel IS:2004
Pins = ForgedSteel IS:2004
Bush Bearings
BushBearings = Aluminum Bronze
AluminumBronze IS : 305
IS:305

4.1 PermissibleStress AsperIS:6938

RopeDrum IS:1030Grade 340 570

2
CompressiveStress(0.2*UTS) 5814 x0.2 1163 Kg/cm
GearWheels IS:1030Grade 280 520
R
RootStress(0.2*UTS)
S (0 2*UTS) 5304 x0.2
02 1061 K / 2
Kg/cm
Pinions IS:200445C8 320 620
2
RootStress(0.2*UTS) 6324 x0.2 1265 Kg/cm

Shafts IS:2004
2
YP 3264 Kg/cm
UTS 6324 Kg/cm2
2
BendingStressWithoutKeyway(0.2*UTS) 1264 Kg/cm
2
BendingStressWithKeyway(0.75*0.2*UTS) 948 Kg/cm
2
ShearStressWithoutKeyway(0.3*YP) 979 Kg/cm
2
ShearStressWithKeyway(0.75*0.3*YP) 734 Kg/cm
2
EquivalentBendingStress(1.2*0.2*UTS) 1517 Kg/cm
Equivalent Shear Stress (1.2*0.3*YP)
EquivalentShearStress(1.2 0.3 YP) 1174 Kg/cm2
2
CombineStressforBendingandTorsion 1517 Kg/cm
(0.6*YPor0.24*UTSwhicheverisless)

BushBearing(AlBronze) IS:305GradeAB1 170 500

CompressiveStress(0.04*UTS) 5100 x0.04 204

For Hoist Bridge Calculation

ForHoistBridgeCalculation ImpactFactor
Impact Factor 1.1
1 1
YP UTS
StructuralSteel IS:2062 250 410
DirectTension,CompressionStress(0.66*YP/ImpactFactor) 1530 Kg/cm2
2
AverageShearStress(0.40*YP/ImpactFactor) 927 Kg/cm
5.0 WireRope

NoofDrums
oo u s 2

NoofFallsoneachsiden 2

W 1
MaximumRopeTension T=
1
n
2

RopeTensionT 1795 Kgs

MinimumStrengthofRopeRequired 1795x6= 10770 Kgs

Provide 16 mmDia. 6x37 constructionUTS 180 Tensiledesignation,

galvanized,Fibercorewireropehaving (conformingtoIS:2266)

Weightofwirerope 88.6 Kg/100m

Approximate length of wire rope
Approximatelengthofwirerope 56 m

NormalBreakingStrength= 13558 Kgs

FactorofsafetyunderNormalcondition 7.6
>6Hence,OK

60
6.0 Rope Drum
RopeDrum

RopeDiameterd 16 mm

MinimumDrumP.C.D.(20*d) 320 mm Provide 400 mm

MinimumPitchofGroovep 18.5 mm Provide 18.5 mm

DepthofGroove(0.35*d) 5.6 mm Provide 6 mm

RadiusofGroove(0.53*d) 8.48 mm Provide 9 mm

ThicknessofDrum@bottomofGroove(minCS16&CI20mm)t 16 mm

MaterialForRopeDrum CastSteelIS:1030Gr230450N
2
Having YP 230 Mpa 2346 Kg/cm
2
UTS 450 Mpa 4590 Kg/cm
2
PermissibleCompressiveStresses(N) 918 Kg/cm (AsperCl4.3.3.1ofIS:6938)
2
PermissibleCompressiveStresses(BDT) 1876.8 Kg/cm

Number of Layers of Rope Over the drum

NumberofLayersofRopeOverthedrum 1
6.1 CrushingStressinDrum
K T
Ct =
pt
Where
K= 1
RopeTension T= 1795 kg
PitchofScoring p= 1.85 cm
UndergrooveThickness t= 1.6 cm

2
CrushingStrengthofDrum(Normal) 606.42 Kg/cm
2
< 918 Kg/cm HenceOK

NumberofTurnsondrum
Lift FallEachSi de
NoOfTurn
DrumP.C.D.

No.ofActiveturnsonthedrum 14.3239449 Say 15 Nos.

TotalnoofGroovesonDrum 18 Nos.

GroovedLengthofDrum 333 mm

Adoptoveralllengthofdrumas 450 mm

Corediameterofdrum 352 mm

TurnDiameterofDrum 396 mm

Pitch
FleetAngle = tan 1
PCD
FleetAngleofGroovesondrum 0.843 degree
<5,HenceOK
 FleetAnglewhenthegateis@Top FleetAnglewhenthegateis@Sill

100
00 mm 233
33 mm

1500
mm 9000 mm

= 3.8 Degree = 1.5 Degree

<5,HenceOK <5,HenceOK

6.2 BendingStressinDrum
Normal
BendingMomentinDrum(rope@centre) 20193.75 kgcm

SelfweightofDrum(Approximate) 250 Kg

BendingMomentinDrum(selfweight) 1406.25 kgcm

TotalBendingMoment 21600 kgcm

3
SectionModulusofDrumZ 1633.9633 cm

2
BendingStressinDrum 13.22 Kg/cm

6.3 TortionalStressinDrum

Torqueondrum 37789.474 kgcm

2
TortionalShearStress 11.57 Kg/cm

2
CombinedEquivalentStresses 607.01 Kg/cm
2
< 918 Kg/cm HenceOK
6.4 DesignofGearWheel&DrumConnectionbolts

ate a o o ts
MaterialofBolts C ass 8 o S 36
Class4.8ofIS:1367
2
Having YP 320 Mpa 3264 Kg/cm
2
UTS 420 Mpa 4284 Kg/cm
NumberofBolts 6 Nos
ProposedDiameterofBolts 16 mm
ShankDiameterofBolts 17 mm
2
ShankAreaofBolts 2.27 cm
PCDofBolts
PCD fB l 450 mm
MaximumDeadloadonBolts =(1795+250)= 2045 Kgs
MaximumShearloadonEachBolts
=(2045x400)/(450x6)= 303 Kgs

2
ShearStressinBolts 134 Kg/cm

ShearStressinBoltsare WithinLimit.

7.0 CentralDriveUnitReduction

Adopt ThreeStageHelicalGearReductionUnit
ReductionRatio 28 :1

8.0 ManualOperation

TorquerequiredatDrum 1795x40/2= 35900 kgcm

NoofPersonrequiredforoperation = 2 Nos.

Crankradius = 400 mm

Effort/Forceappliedperman = 10 Kgs

CrankRPM = 24 rpm

Simultaneity Factor for 2 men

SimultaneityFactorfor2men = 0 97
0.97
CrankEffortbypersons = 19.4 Kgs

TorqueappliedatCrank 19.4x40= 776 kgcm

TotalTorquerequiredatdrumend 2x35900= 71800 kgcm

SystemEfficiency = 0.742

Total Reduction Required

TotalReductionRequired 71800 / ( 776 x 0.742 ) =
71800/(776x0.742)= 124.698

WormReducerRatio = 28

OpenReductionRequired = 4.45

ProvidefollowingReduction

Gear Pinion Gear Pinion HelicalReduction

Drum 1 85 19 28

ActualOpenReduction= 85/19= 4.4736842

ActualTotalReduction= 28x4.474= 125.26316

ActualLiftingSpeed =(24/125.26)x3.14x0.4/2= 0.12 m/min

9.0 TorqueTransmission

Torqueinkgcm
Sl.No. Componentset
Output
O Input
I
1 DrumGear/Pinion 1795x40/2= 35900 35900/0.95= 37790
2 1stPinionShaft 37790x19/85= 8448 8448/0.95= 8893
10.0 Gear&PinionDetails

10.1
0. Detail
eta
DrumGear
NoofTeethonGearN = 85

No.ofTeethonPinionN = 19

ModuleofGear&PinionSetm = 8 mm

FaceWidthofGearF = 80 mm

FaceWidthofPinionF = 90 mm

TypeofGear/Pinion = Spur

Pressure Angle ( in degree)

PressureAngle(indegree) 20 FulldepthInvolutestoothSystem
Full depth Involutes tooth System

10.2 MaterialforGears&Pinions
YPMpa UTSMpa
GearMaterial CaststeelIS:1030,Gr280520 280 520

PinionMaterial ForgedsteelIS:2004,Class4(45C8) 320 620

10.3 AllowableStresses

2
GearStresses = 1060.8 Kg/cm
2
PinionStresses = 1264.8 Kg/cm

10.4 RootStressesforGearsandPinions
f

Therootstressingearandpiniontoothisgivenby

Pq
root =
F m

RootStressesUnderNormalCondition

Module PCD Tooth Root

Noof FaceWidth Strength Torquekg
Parts (m) (Nxm) Loadkgs Stress
teeth(N) (F)mm Factor(q) cm
mm mm (P) Kg/cm2
DrumGear
W1 85 8 680 80 2.6 37790 1111.5 451.55
Pinion
P1 19 8 152 90 33
3.3 8448 1111 6
1111.6 573 17
573.17

2
MaximumGearStress 451.55 islessthan 1060.8 Kg/cm OK
2
MaximumPinionStress 573.17 islessthan 1264.8 Kg/cm OK
11.0 DrumShaft

11.1 DirectionofToothLoadonGearandPinion
F2 F3

DRUM

F1 F2

416

F1(H)= RopeTension= 1795 Kgs

F2(V)= ToothLoad= 1111.5 Kgs
F3(H)= F2tan200= 404.6 Kgs

80 mm

450
A 60 60
60 X Y
60
C D

450
20
A 570 B
11.2 LoadingComponentsForDrumAxle

i)) RopeTensionF1
ope e s o 1795
95 Kgs
gs Downward
o ad
ii) ToothloadofgearF2 1111.5 Kgs Downward
iii) HorizontalLoadF3 404.6 Kgs Horizontal
DeadWeights
RopeDrum 250 Kgs Downward
DrumGear 75 Kgs Downward
iv) DeadWt.onGearSide@B 200 Kgs Downward
Dead Wt. on Drum Side @ A
v) DeadWt.onDrumSide@A 125 Kgs Downward

X 1795

Drum 60 390 Gear

450
A B
Reactions@DrumSupportduetoRopeTension
Reactions @ Drum Support due to Rope Tension

Reaction@DrumSupportA 1555.67 Kgs

Reaction@GearSupportB 239.33 Kgs

BendingMoment&ReactionsforDrumShaft
Loading@A

i) ReactionduetoRopeTension 1555.67 Kgs Downward

ii) ReactionduetodeadWt. 125 Kgs Downward

TotalVerticalLoad 1680.67 Kgs Downward

Loading@B

i) ReactionduetoRopeTension 239.33 Kgs Downward

ii) ReactionduetodeadWt. 200 Kgs Downward
iii) Reactionduetotoothload 1111.5 Kgs Downward

TotalVerticalLoad 1550.83 Kgs Downward

TotalHorizontalLoad 404.6 Kgs Horizontal

Resultantload 1602.74 Kgs Downward

 1680.67 1602.74 Downward
A B
Drum Gear
60 450 60
C 570 D

ReactionofDrumShaft@C= 1672.47 Kgs Downward

ReactionofDrumShaft@D=
Reaction of Drum Shaft @ D = 1610.94 Kgs Downward

BendingMoment@A= 10034.82 kgcm

BendingMoment@B= 9665.64 kgcm

MaximumBendingMoment= 10034.82 kgcm

11.3
11 3 Stresses in Drum Axle
StressesinDrumAxle
Provide YP UTS
ShaftMaterial ForgedSteelIS:2004,Class4,45C8 320 620 Mpa

MaximumAllowableStressinBending 1264.8 Kg/cm2

2
MaximumAllowableStressinTorsionalShear 979.2 Kg/cm
2
MaximumAllowableStressCombined 1517.76 Kg/cm

DrumShaftDiameter@Support 60 mm
DrumShaftDiameter@Centre 50 mm

3
SectionModulusofDrumShaftZ(D3/32) 12.27 cm
2
AreaofDrumShaftZ(D2/4) 19.63 cm

MaximumBendingMoments 10034.82 kgcm

MaximumReactions 1672.47 Kgs
2
BendingStressinShaft(Normal) 817.83 Kg/cm
< 1264.8 HenceOK
2
ShearStressinShaft(Normal) 85.2 Kg/cm
< 979.2 HenceOK
11.4 BushBearingforRopeDrum

t Gea d(@ )
AtGearEnd(@B)

Maximumload 1602.74 Kgs

I.D.ofBush 60 mm
O.D.ofBush 80 mm
LengthofBush 80 mm
MaterialofBush Al.BronzeofIS:305,GrAB1 5100 Kg/cm2UTS

2
BearingStress 33.39 Kg/cm
2
<204 Kg/cm HenceOK

AtDrumFlangeEnd(@A)

Maximumload 1680.67 Kgs

I.D.ofBush 60 mm
O.D.ofBush 80 mm
LengthofBush 80 mm
MaterialofBush Al.BronzeofIS:305,GrAB1 5100 Kg/cm2UTS

2
BearingStress 35.01 Kg/cm
2
< 204 Kg/cm
<204 Hence OK
HenceOK

12.0 PinionShaft
1197.8336
Pinion 90

155 30
200 75
R1 275 R2

SelfWeightofPinion 15 Kgs
SecondPinionResultantToothload(F2/Cos20+selfWt.) 1197.8336 Kgs

Reaction@R1 326.68 Kgs

Reaction@R2 871.15359 Kgs

MaximumBendingMoment@Pinioncentre 6533.6 kgcm

a u o que
MaximumTorque 8 8 kgcm
8448 gc

Provide YP UTS
ShaftMaterial ForgedSteelIS:2004,Class4,45C8 320 620 Mpa

MaximumAllowableStressinBending 948.6 Kg/cm2

2
MaximumAllowableStressinTorsionalShear 734.4 Kg/cm
M i
MaximumAllowableStressCombined
All bl S C bi d 1138 32
1138.32 K / 2
Kg/cm

DrumShaftDiameter@Support 40 mm
DrumShaftDiameter@Centre 50 mm

3
SectionModulusofDrumZ(D3/32) 12.27 cm

BendingStressinShaftb 532.49 Kg/cm2

2
TorsionalShearStress(Tmax/2.Z) 344.25 Kg/cm

CombinedStress c = b2 + 3 2 799.42 Kg/cm

2

AlltheStressesare
All th St areWithinLimit
Withi Li it

12.1 CheckforCombinedBendingandTwisting

CombinedTwisting Te = M 2
+T 2

TwistingMoment 10679.73 kgcm

2
ShearStress 435.2 Kg/cm

2
AllowableStress 881.28 Kg/cm
CombinedBending M e = 0.5 ( M + M 2 +T2 )

BendingMoment 8606.67 kgcm

2
BendingStress 701.44 Kg/cm

2
AllowableStress 1138.32 Kg/cm
HenceOK

12.2
12 2 Bearing for Pinion Shaft Support
BearingforPinionShaftSupport
Provide
PlummerBlockHousing SNH509TC
AdapterSleeve H309
Bearingno 22209EK ofSKF@eitherEndsofShaft
I.D.ofBearing 40 mm
O.D.ofBearing 80 mm
SSupportwidthofBearing
id h f B i 23 mm
StaticCapacityofBearing 81500 N
DynamicCapacityofBearing 73600 N
MaximumloadunderBDTCondition 8546 N
DynamicCapacityofBearingis morethanrequiredHenceOK

13.0 FloatingShaft

Provide YP UTS
ShaftMaterial ForgedSteelIS:2004,Class3,30C8 270 490 Mpa

MaximumAllowableStressinTorsionalShear 619.65 Kg/cm2

ShaftDiameter@Flange 45 mm
ShaftDiameter@Centre 45 mm

3 3
SectionModulusofDrumZ(D /32) 8.95 cm

MaximumTorquetobeTransmitted 8448 kgcm

2
Torsional Shear Stress (Tmax/2 Z)
TorsionalShearStress(Tmax/2.Z) 96 Kg/cm
471.96
471
HenceOK