PROBLEM STATEMENT:

Design the following components of a hoist

( i ) Counter weight

( ii ) Wire rope

( iii ) Beams

Maximum weight of the unload cage is equal to 1000kg and weight of

the rope is 60 kg. A speed of 40kmph is to be reached while travelling at a distance
of 10m from rest. The sheave is carried on 2 similar rolled steel joists, where the
center distance is 375mm. The location of the sheave on the middle of the beam of
span 4m.
SCHEMATIC LAYOUT:

Rope drum

Beam

Rope

Counter weight
Cage

Fig. Components of hoist

COMPONENTS TO BE DESIGNED:

1. Counter weight
2. Wire rope
3. Beams

CONSIDERATIONS:
Cage weight = 1000kg
Rope weight =60 kg
Speed of cage = 40 kmph = 11.1 m/sec
Distance required to obtain the speed = 10m
Beam span = 4m
Weight to be carried = 1000kg
I.CALCULATION OF COUNTER WEIGHT:

Counter weight = 40% of the carrying load + Cage weight

= ( 0.4 × 1000) + 1000

= 1400 kg.

II.DESIGN OF ROPE

DATA:

Total weight = Load to be carried+ cage weight + Counter Weight

= 1000+1000+1400

= 3400 Kg = 34000 N

Speed = 11.1 m/sec

= 666 m/min

1. Assume FOS as 15

Design load = 34000×15=510000 N

2. Rope diameter :

Selecting 6×19 Rope

d = 25 mm with ϭu = 1250 N/mm2

Breaking strength= 230 KN

3. Drum diameter:

Dmin/d = 27×(1.08)13.32-1 for class 4

 Dmin/d = 69.68 Say 70

D = 70× 25 = 1750 mm

4. Area of useful cross section :

A = 0.4 d2 = 0.4 × 252

= 250 mm2

5. Wire diameter:

𝑑
dw =
1.5√𝑖

25
= = 1.56 mm
1.5√114

Standard wire gauge (SWG) = 16 from PSGBB 13.1

Standard dw = 1.63 mm

6. Weight of the rope:

It is given as (Wr)=60kg= 600N

7. Calculation of loads:

(i) Direct Load (Wd) = W + Wr = 34000 + 600

= 34600 N

(ii) Bending load(Wb) = ϭ × A = Er dw/D × A

Er = 80000 N/mm2 for steel rope

Wb = 80000× (1.63 /1750)× 250 = 18628.5 N

(iii) Acceleration load = (W + Wr)×a/g

 a = (V2– V1)/t = 11.1/0.9=12.3m/s(t=10/11.1=0.9sec)

Wa = 34600×12.3/9.81

=43382.3N

(iv) Effective load due to acceleration:

Wea = Wd+Wb+Wa

=34600+18628.5+43382.3

= 96610.7 N

(v) Load during starting:

Ws = 2 × Wd =69200 N

(iv) Effective load during starting:

Wes = wb + ws

= 18628.5 + 69200 =87828.5 N

Maximum stress =Wea/A = 96610.7/250 =386 N/m2

The max. stress is less than 1250 N/mm2 .So the selected rope is
safe for the application.

8. Working FOS:

Fsw = Breaking load / Effective load

= 230000 /96610.7 = 2.4

Recommended FOS = n’ = 6 from PSGDB 9.1

Number of ropes = n’/Fsw = 6/2.4 = 2.5 = 3 ropes

RESULT

Selected rope = 6×19

Rope diameter = 25 mm

Drum diameter= 1750 mm

Wire diameter = 1.63 mm

Number of ropes= 3

SELECTION OF ROPE DRUM: (PSGDB 9.9)

r
C

r = 15.5mm

S = 31mm

C = 18mm
III.DESIGN OF BEAMS:

DATA:

No. of beams =2

Position of loads = Center

Span length = 4m

Approx. weight of the rope drum =150kg

Total carrying weight =3400+150 = 3550kg

Load on each beam = 3550/2 = 1775kg = 17750N

Type of cross section = ‘I’ section

Material of beam = C40 Steel

BENDING MOMENT:

17750N
A B C

2m RC
RA
4m

Fig. Forces acting on beam

Maximum bending moment

Mmax = (WL)/4 = (17750×4)/4 = 17750N

For C40 steel σy = 330 N/mm2. Assume FOS as 4.

Thus Safe stress (σ) = 82.5N/mm2

𝑀 𝜎
Bending Equation = ( y = h/2 )
𝐼 𝑦

17750000 82.5×2
=
𝐼 ℎ

I / h = 107575.7 mm3

From PSGDB 5.130

For ISWB 175 I / h = 86251.4 mm3

For ISWB 200 I / h = 131225 mm3

So “ISWB 200” Rolled steel beams are selected.

RESULT:

Depth of section h = 200mm

Width of section b = 140mm

Thickness of flange tf = 9mm

Thickness of web tw = 6.1mm