8.2 CASE STUDY 8—A HAY-BALE LIFTER Adairy farmer in Bellows Falls, Vermont, needs a small winch-hoist to use for the lift- ing of hay bales into the barn loft. A preliminary design concept is shown in Figure 8-4. Anelectric motor is coupled to a worm-wheel gearset to reduce its speed and boost the torque appropriately. The best ratio for this gearset is to be determined. The gearbox output shaft is coupled to the winch-drum shaft, and both turn in bearings to be selected. The drum serves as a capstan around which is wound a rope that has a forged hook at itsend. The entire winch assembly will ultimately be suspended from the rafters in the hayloft above a central floor-hatch. Hay bales will be manually attached below and manually removed above. The electric motor is reversible, and the worm-wheel set must be designed to be self-locking in order to hold the load when the motor is unpowered. The above problem statement is very unstructured, as it gives no information about the size and weight of a hay bale nor what number of bales should be lifted at a time forthe best efficiency. These considerations in combination with the choice of winch- drum diameter will determine the torque requirements that the drive train will have to meet. The start-up load can be significantly higher than the steady-state lifting load due492 MACHINE DESIGN An Integrated Approach to shock loading when the slack is frst taken out ofthe Fine and the loa il. dynamic loading at start-up willbe modeled using a diferential-equation solvet area Kaen Preliminary Design of a Winch Lift Problem Determine the force-time function in the lifting cable, the neces drum éiameter, and the torque-time function acting on the sb the winch drum during any 1 cycle. Define the gear ratio and power and torque requirements forthe motor Given ‘Avhay bale's weight varies depending on its moisture content but bbe assumed to average about 60 Ib. The hay truck holds 100 andthe farmer would like to unload itn 30 min. The it hgh 2a Assumptions Nylon rope of 3/4 in dia has a minimum break strength of. 18000 Ib and a pring constant of sbout 50 000 Ibin per ft in axial tension. Solution See Figures 8-4 to 8-6 and files CASE®-A. | The nominal lood depends on the number of bales tobe ited at onetime ath ‘weight of any structure used to support the bales. To unload 100 bales from thet ‘one time in 30 min, requires that the average bale rate be 100/30 =3.3balevnig fran 18-sce average period per bale. Since some ofthis time must be used tom the empty liftto the ground, we cannot use the entre 18sec to ifthe Toad. We mut Also allow some time for manual loading and unloading of the bales at wp and ie fom. The portion ofthe ttl period during which the mechanism is workings all ite dy eyele, Lets assume that 1/3 of the period is used to load/unlod, 13 ti FIGURE 8-4 ‘Motor even Winch with Gear Tan hats Beanngs and Coupings ae worm E teaings shaft bearngs - st Sales coupin| rope wech winch ram gun oakDESIGN CASE STUDIES 483 chapt 101. Ths allows Sn er bai we it nly on i tine. The ene vhely of ei wold ernest fee M.A nso wal scan eto wears incon fe Ts te fel Sms tc ine sve rng 12a ee ae win Beveocty to Nello te ny of on 1 yd wih vo koe its 1201. The ela wb te wih of @) Sib say pnt seston vega ir h.Sc in sn 4 fre as yet to be designed, its weight is unknown. We will assume that we ean keep of this dead weight under 50 Ib. The total nominal Toad will then be 170 Th forthe lit has, and 50 Ib fr the lowering phase rope ‘Asealy state, the load on the rope should be the above numer. However, a start ‘up, the load can be significantly higher due to the need to accelerate the load to its a steady-state velocity and due also to the fac that there are both spring and mas in the ead system. combination of spring and mass in a dynamic system allows oscillations 2 to ccuras the kinetic enerpy ofthe moving mass is transferred t potential enorgy in the elastic spring and vice versa. The rope is a sping. When the slack inthe rope is saddealy taken up agains! the mass of the load, the rope wil stretch, string potential energy. When the force inthe stretched rope becomes sufficient to move the lea it will accelerate the mass upward, inereasing its velocity and transferring the spring's Dotential energy to Kinetic ener inthe mass. If the mass accelerates sufficiently, it Wil ake the rope slack again. When the mass falls to take up the slack, the eycle re pats. Thus, ast tarts up, the force inthe rope can oscillate from zero to some value : aL. ing requires writing and solving the differentil equations of motion forthe system, Figure 8.5a shows a simplified schematic ofthe portion of the dynamic system con- taining the lift mass and the rope spring. Figure $-5b shows the system modeled asa lumped mass supported by a spring and a damper. Figure 8-Sc shows a free-hody dia gram (FBD) of the mass acted upon by its weight W, the spring force F,, and the et damper force Fy, Writing Newton's second law fr this FBD gives rem w Fenway ©) Lampe mode where Ay 93) Fy= ein) o es ‘Substitute the initia conditions: whens =0 (0) HO)= 9-0 2-0 0 £0 from which £0) @ ie mia tn —m)+eGi—ia)- (0 Freebdy dagam [a(t -¥2) +b —5e)-W] Figure e-5 Dyrame Spon tone ote nd re asp Dapaafamape Hoc then ©asa MACHINE DESIGN - An Integrated Approach 5 The constants for this equation are defined as follows 0.00 an 20 I ‘ i Thea al damping c, is esily calculated from the known mass and spring values. This system is only lightly damped by the ropes internal ition. We fssume thats vaio of actual damping to ertcal damping tne this wo calculate a damping value for equation Ee pas) 28 fm 204 oa = Iy-see e=Ge, =0.10(61)=6.1 ¢_ 6 im 0aa is about 105 (LI) {6 Equation (e) was solved with the ASDEQ” simulation package, The acceleration the load over the first second of operation is shown ia Figure 8-61. Downward celeration gravity is taken as negative. Note the periods of ne 1 limiting value of -2) during which the loa i in free-fall and the rope i slack no tension. The fore in the rope over the First second of operation is shown i fre 8-66, Note that the tension force rises to over Four Himes the nominal ean fist oscillation and then drops to 270 as the ope goes slack. sine it cannot i ‘compressive force. This pater repeats for 3 cycles, a which pint the damping Tedaced the osilltions tothe point that the rope is alway in tension, fer abou yeles, it has settled down tthe value of the Nominal load er 1 Teton rgd ie trum sta wil depen on he fia” Then the der of un ees mal Rete keg source tege, Alupe dem dnser il nowse ree Weston WHat a hs and increase the package size. A 3/4-in-dia rope can wrap around 20-in-ia sh OStatic wth his Since T= Fr, the torque required on the shaft will then be 10 times the tension it & seeing ki aafedt eee sa erosion sb 150 fs + ‘ sa + 1 aco fh ppb of do 0 ghd dt 5 500. ry | in » “OT 0 20 |] OY L 00 ! L oll 0 02 04 06 U8 1010 0024S ( Aecteton ot ost 0) Onanefocein cae FIGURE 8-6 ‘ecseration and abe Force 8 Saup of Load LitChapter 8 DESIGN CASE STUDIES ‘The average power required can be easily found from the change in potential energy ‘over the time desired. ‘To raise a 170-Ih load 24 f1 in 12 see requires _ 170 1b (248) 12 see P. ay Since there will be losses in the gear train and winch, we will need an input power larger than this, say 1 hp fora first trial. tis desirable to keep it ator below this level since larger horsepower motors will require higher voltage than 110 V. This average power is based on the nominal load. The peak load at start-up requires ‘more power, Rather than size the motor to accommodate the transient start-up load, another approach isto provide sufficient flywheel effect in the system to supply the transient pulse of energy to get it past the star-up phase. It is possible that the rota- tional inertia ofthe drum and worm gear will supply enough flywheel effec, assuming thatthe winch is up to speed before the slack is first taken out of the rope. ‘The average drum angular velocity is determined from the required average linear velocity of the rope, which is 2 flsec. Ata 10-in drum radius this gives » _ 2inksee o=" 4 radlsec = 23 rpm a 7 10in = 2 Electric motors for 60-Hz AC operation are made in only a few standard rotational speeds, the most common of which are 1 725 rpm and 3 450 mpm. These speeds come about from the line-frequency-synchronous speeds of 1 800 rpm and 3.600 rpm mi- ‘nus some slippage in these nonsynchronous motors. To minimize the gear ratio in the \wormset, we should choose the slower ofthe two standard speeds, or 1 725 rpm. This {ives a desired gear ratio of 23:1 725 or 1:75. This ratio is obtainable in one stage of a worm-wheel combination, and so is feasible. ‘To summarize the parameters determined from this preliminary design study. we are looking to design a system that has a I-hp, 1 725 rpm, 110-V AC electric motor, driving 41:75 reduction worm-whee! set that in turn, drives a 20-in-dia winch drum at 23 rpm. ‘A3/4-in rope is eapstan-wound around the drum and its forged hook attached toa plat form that weighs no more than 50 Ib and stably supports two hay bales of up to 60 Tb each. These constitute a set of task specifications for our design. This formerly unstructured problem now has some structure that can be used as a ‘arting point for more detailed design of the various components. Some of the com- ponents of this case study will be addressed in the ensuing chapters as the relevant topics sich as shafts, gears, bearings, etc., are presented. Note that though the load is rela tively steady with time in this device, the oscillations at start-up and the repeated cycles ‘ofuse make this a fatigue-design problem, as virtually any machine will be. The parts ae subjected to fatigue loading and must be designed accordingly, using the theories colined in Chapters 6 and 7, 485