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81

Hoist Design

Step 1: Design Aim

Hoisting Speed Traverse Speed Lifting Height Design Work Load Hoist Selft weigth 4.25 20 7.5 5000 300 0.6 m/min 5 m/min m kg kg

**Step 2: Mechanism Work Group Classification
**

2.1 Select Total working Hours

2.2 Determine Load Spectum

2.3 Determine Group Class

Step 3 Determination of Loading Catagories

Dead Load R1+R2 Dynamic factor for mass

Pw=WΦ1 Φ1

Live load R3+R4 Hoist Load Dynamic Factor

Phd=PhΦ2 Φ2

R5,R6 V1,V2, reffer to AS 1418.2-2002 Crane of other mechanism R5 Loads rising form friction force R6 Wind Action V1, V2 Load due to collision or buffer B1

Coefficient of friction Radius of drive wheel Gear ration Total Wheel force

µ

rL

Ia ∑Rmax

67yield/(3^1/3) σC=0.Load due to emergency state B2 Step 4: Determine effective stress on material Material UltimateTensile Strength Yield Strength of Material Effection strength Permissible Shear Permissible Compssion Permissible Tension σB σE σEF σS σC σT σs=0.67yield σT=0.67yield .

Sample Calculation Step by Step Step 1: As design Aim setup Step 2: Classification of Design Work hours Norminal Load Spetum Group Class T4 0.25 M5 .

016667 57643.3 N 49050 2.23298 N neglect .109208 54406.97 N 43.4 0.070833 1.1 3237.Step 3 Load Calcuation R1+R2 Hoist Self Load Dynamic factor of mass Dead Load R3+R4 Design Load Structure nature frequency Hoist ting acceleration Dynamic factor of live load Hoisting Load R5 2943 N 1.05 m 0.25 0.67 N Hz m/s^2 N R6 Loads arising from friction force V1 V2 B1 Coefficient of friction between wheel & rail Radius of Track Wheel Gear ration Motor to wheel Total wheel force Load due to collision of buffer B2 Emergency force 200 N neglect neglect 0.

Total Load in all direction

57887.2

Material (MPa) Steel Grade 250 Steel Grade 350 Steel Grade 500

Yield 250 350 500

Tensile 320 450 600

Effective shear max 237 332.5 460 110.0988 154.4636 213.6939

.

.

5 460 .compression Tension 237 332.5 460 237 332.

05% (iii) Sulfur 0. Low carbon steel quenched and tempered Steel with two or more alloying elements quenched and tempered.6WLL 77 Thread on the Shank Must Comply with AS 1721-1985 Step 6 : Rolling Element The rolling element bearing incorporated in swivel shall lhave a trust static load rating of not less than 1.25x9. AS1443.81 1.Hook Block Design AS 3777-2008.Surface finish Step 4: Dimension The actual geometric of the hook can be determin from figure below according to AS3777-2008 Step 5: Shank Design AS2318-2000 For material having a tensile stress less thank 430MPA Work load limit WLL <=50 50< <=75 >75 Average Tensile Stress 62 32+0.5xWLLx9.33 of the WLL of the swivel Step 7 Proof Force The miminum proff force should not less than 1. Fully killed and fine grained and not eceed the following maxmum allowable cast analysis of elements (i) Carbon 0.81xWLL If bearing could be subject to damage the minimum proof forces WLL(tons) <20 >=20<40 >=40 Proof force 2xWLLx9. Heat treatment. Step 2: MaterialFor manufacture AS3777-2008 Clause 5 Steel Used in hook shall comply with AS 1442. AS 1444.AS 1721-1985 Step 1: Quality Grade Selection AS3777 Clause 4.2 Type M P S Low carbon steel normalized. AS1448.81 .05% Step 3: Manufacture AS 3777-2008 Clause 6 Hooks shall not be welded.81 (WLL+20)x9.45% (ii) Phosphorus 0.AS 2318-2006.

.

15493 Mpa 230.1593 mm^2 1.7747 MPa l shall lhave a trust 500 MPa 193.4 20 N mm mm^2 mm mm^4 mm MPA Work load limit 2900 Nm 46. AS1448. AS1443. Step 2: Bearing Selection Bearing specification Bearing thrust load OD ID Thinckness Life cycle n from figure below according Step 3: Shaft Design Total load diameter of shaft Cross-section area Design Length Factor of safty Area moment of inertia y Moment Shear stress Bending stress Material Yield of material Permissible shear shear stress Permissible comp.7 . 1444.tensil stress Step 4: Trust Bearing Block Pin Total load diameter of shaft Cross-section area Factor of safty Area moment of inertia y Stress Concentration Factor 58000 40 1256.AS 1721-1985 Sample Calculation Step 1: Thrust load calculation Use live load from previous Load calculation Work Load Limit Bearing Thrust Load Thrust or other suitable bearing can be used 58000 N 77140 N nts quenched and tempered.4123 MPa 335 MPa 58000 N 20 mm 314.2 15707.AS 2318-2006.637 200 1 251327.96 mm^4 10 mm 1.

Shear stress Material Yield of material Permissible shear shear stress Permissible comp.4123 MPa 335 MPa .7723 Mpa 500 MPa 193.tensil stress 130.

.

.

.

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Wire rope Selection Clause 7 AS 1418. AS 2759-2004 Step 1: Determine the work load limit(WLL) Live load Dead load WLL 58000 N 1000 N 59000 N Step 2: Determine the minimum diameter of the rope .AS3569-2010. AS 1418.3-2002.1-2002.

Step 3: Determine the minimum wire rope breaking force F0:Minimum wire rope breaking force Step 4: Selection of wire rope from manufacture Note: The wire rope must comply with AS3569-2010 Step 5: Application of wire rope Note: application of wire rope must comply with AS2759-2004 .

this is a 4 fall hoist. AS 2759-2004 Sample Calculation Note: Base on the design aim. rope manufacture provides minimum break force data Step 2: Minimum Brake force on rope Sump of load minimum coefficent of utilization Minimum break force 59000 N 4.Noble-Casar Alphalift 8mm Grade 1960 in this example Diameter of wire rope Estimate length of wire 8 mm 34 m The Fleet angle should be <5 degree The drum rope should be mechanical anchorage at least 2 or more clamp .AS3569-2010. For dangerous and heave lifting Grade not smaller than M5 Step 1: Minimum Diameter of rope Not neglect. only a quarter of the loads exert on wire. Theoretically.5 66375 N From A.

.

etically. only a eave lifting .

AS 1418. DIN 15061.Sheave Design Clause 7 Step 1: Sheave Sizing AS 1418.3-2002.1-2002. DIN 15020-1 .

Diameter of Sheave Ds: diameter of Shear De: Pitch diameter of rope equalizer sheave hs: Minimum ratio for sheave he: Minimum ratio for rope equalizer sheave .

Step 2: Material Selection .

DIN 15061.2 mm mm mm mm mm mm mm Material selection must comply with Australian Standards . DIN 15020-1 Sample Calculation Base on previous calculation Rope in 8mm diameter obtain fromtables wit a M4 Grade Nominal diameter of rope Minimum ratio for equ sheave Minimum Pitch diameter Design pitch diameter hg m i r 8 20 160 160 15 4 18 4.

.

.

in fromtables .

AS1403-2002 Step 1: Diameter of Drum Diameter of the drum = hd*dmin hd: minimum ratio of for drum dmin: minimum diameter of rope Step 2: Theoretical Thickness of drum shell d .1-2002.3-2002.Drum & Drive shaft design AS 1418. AS 1418.

.

for D>250mm Ks=1.AS 3678 Note: The groove shall be an arc of minimum radius 0.AS1830. The minimum two dead turns is required on a drum Step 4: Drum Drive shaft Ks: size factor.535 times the nominal diameter of the rope and subtending an included angle no less than 130 degree For on e or two layers of rope.Step 3: Material Specification Grey cast iron . grade not laess than Grade 200 Nodular graphite cast iron.8 for Ks<250mm refer to figure .AS 1831 Steel castings AS-2074 Steel plate . the groove pitch shall be not less than 1.06 times the nominal rope diameter.

detail refer to AS-1403-2004. depends on the geometric on shaft. Clause 8.K: stress raising factor.0 Mq: Bending Moment at shaft crossing section Tq: Torque at shaft Pq: maximum axial tensile force on shaft .

52504 2 705.018741 3.2 500 Mpa .67773 3.3893 904.5 4 1 31 0.7787 70.AS1403-2002 Sample Calculation Step 1: Diameter of Drum Calculation Nominal Diameter of rope Classificaton of mechanism Minimum diameter ratio Minimum diameter of Drum Design diameter of drum Step 2: Theorectical Length of Drum Lifting Height Number of Falls extra length Theoretical minimum length minimum radius of groove Perimetero of drum Dead turns length Theoretical turns Groove gap Theoretical length of drum Design Drum length 8 m5 18 144 144 mm mm mm mm 7.726391 mm MPa(steel plate) Mpa Mpa 1.8 4.535 452.2504 730 m m m m mm mm rev mm mm mm Step 3: Bending Moment and Static force Combine loading 58000 Maximum Bending moment 21170 maximum loading rope angle 30 Maximum unfactored tension on rope 15.87713 Step 4: Theorectical thickness of Drum Rope layer factor Pitch of rope coil Permissible stress of material Yield stress of material Permissible bending stress TDC Guess thickness of drum TDB Theoretical Thickness Step 5: Torsion check Step 5: Diameter of drive shaft estimation Safty factor Tensile strength of material N Nm degree KN 1 152 200 500 335 -0.

87666 mm 50 mm .4 2 1143.154 Nm 52.Endurance Limit Size factor K (guess) Stress rising factor (Ks) Torsion Diameter of shaft design diameter 225 MPa 1.

he nominal t .

.

.

(KN) Cc: group calssification coefficient Cw: Wheel-speed coefficient Dw: wheel-tread diameter (.. AS 1418.) Bwe: effective wheel-tread width is equal to Bte Fpw: permissible unfactored bearing street between wheel and rail .Drive wheel design Clause 7 AS 1418.1-2002. Step 1: Determine the Wheel loading Step 2: Calculate the load capacity of wheel Pw: Permissible wheel loading.3-2002.

.

20 .Step 3: Profile of wheel TF: Flange thickness Dw: wheel tread diameter The height of flange shall be not less than Dw/50+10 Note: for other not common wheel profile refer AS1418.1-2002 Clause 7.

Thus the profile of the wheel choose as follow Dw< 400mm Flange thickness Flange Heigh Effective tread width 10 mm 12 mm 40 mm .Sample Calculation Step 1: setup general condition Grade M5 Diameter of wheel assume perimeter of wheel Speed of wheel rotation ratio step 2: determine maximum unfactory wheel loading Out of balance factor Pw max:Maximum wheel loading Pw min: Minimum wheel loading Pw mean: Maximum unfatored wheel loading Step 3: Determine the permissible wheel loading Speed of travel Bwe:Effective wheel-tread width Cc: group classification Dw: wheel-tread diameter Fuw:tensile strength of material Fpw:permissible unfatored bearing stress Cw: Wheel speed coefficient Pw:Permissible wheel loading Step 4: Profile of the Wheel Because of the bottom flange of the crane brigde are generally flat.

.

.

3 18813.59458 m/s mm mm MPa MPa KN enerally flat.91 14.1 110 mm 345.34 KN 0 KN 12.86 0. Thus the t .5752 mm 333.333333 30 1 110 480 4.54223 KN 0.964575 1.3333 rev/s 0.

0003142 92.3333333 110 0.17262 Nm 6.3-2002.309867 500 193.969 1330.2 Tensile strength of material 800 Mpa Endurence Limit 360 MPa Diameter of drive shaft 14.036726 Step 2: Diameter of Drive Shaft (details refer to drum design) Safety factor 1.4113 0.AS1403-2002 0.95 m/s mm N N 73.1-2002.7284 w 450 w 1440 rpm 23.Input value Drive system Sample Calculation: Step 1: Power of Motor Travel Speed Diameter of Drive wheel Rolling coefficient of friction Total vertical load Rolling resistance force Efficiency of Motor Torque to overcome resistance Angular velocity Power Power of motor selected from manu' stardard output rpm Gear ratio AS 1418.023 57843.1 Stress raising factor 1.2 Size factor (guess initial) 1.5139389 rad/s 501. AS 1418.41234 N m^2 Mpa Mpa Note : as the distance in between fixed support is minimized.14981 1. moment can be neglected Step 5: bearing selection .074856 mm Design shaft diameter 20 mm Step 3: Shear stress on shaft Shear force Cross-section area of shaft Shear stress at shaft Yield stress of material Permissible shear limit 58000 0.

Step 5: Key and Keyway-.BS 4235-1-1972 .

rev/s 62.20353 rpm .

.

Input value Hoisting system Sample Calculation: Power of Motor Diameter of drum Speed of Lifting Number of Falls Speed of wire rolling design load Lift angle actural Load at rope Motor efficiency perimeter of drum Torque angular speed of drum na Power Factor Of Safety 150 4.7109951 4 38 4660.471238898 978.528548 1.888862 0.15 5.84 0.5 4 0.360 mm m/min m/s kg degree kg Nm Rad/s rev/s W W Power of motor select from manu' standard rmp Gear ratio 5500 w 1440 rpm #DIV/0! .3 5000 20 5320.

601252 3.15 0.777778 919.471239 0.375 m/s m rev/s rad/s .rpm load wire speed Diameter of drum perimeter Turns angular velocity Torque Power 5000 0.6875 3474.283333 0.

66842 Mpa Yield stress of material permissible com.66842 Mpa 300 kg 1189.5539 63.3187 mm^2 63. due to pin joint at both side.4123 MPa .81059 2 32 800 N MPa mm mm^4 mm^4 mm M32 Shear stress Calculation Area moment of inertia cross-section area Shear Stress Bending Stress Calculation Bending force cause by comp Bending Moment Bending stress Compressive Stress Calculation Compressive Stress Calculation 98154.574 15.9 mm^4 785.2 Nm 191.Input value Cage Design Tie Rod Buckling calculation Note: minimal moment occur.tension stress Permissible shear stress 500 Mpa 335 MPa 193. Compression force Elastic Modular Length of tie rod Effective Length factor Area of moment of inertia Diameter of tie rod Factor of safty design diameter design length of tie rod 50000 200000 1000 0.5 6332.

539063 Mpa 250 MPa 237 Mpa Refer to class & load calculation .2 7.5 Nm 4 mm 102.Web Length of web 1000 mm Thick (design guess) 8 mm Height 350 mm Nomber 2 Tensile Stress cross-section area Stress concentration factor Stress Bending stress Calculation Bending force area moment of inertia 1 Moment Y Bending stress Material Grade Eeffective stress 8000 mm^2 1.5 Mpa 12500 85333.3333 2187.

9545 49050 .16E+08 222.Area moment of Inertia A Length(mm) Height(mm) Ixx Total 300 12 43200 2.

B 6 600 108000000 mm^4 C D 300 6 20 600 200000 108000000 157216000 0 23211.441 .

.

078171 2193.516 10801.45335 4181.2 13709.2717 0.68484 9794 355392.46903 4427.26279442 93600 1.5162703 Mpa 250 MPa 165 95.9134 17 5000 1.1 28783.4 1.09067 6.023 1261.hoist weigth seft weigth total weight dynamic factor deadload length WL Dynamic factor hoisting load sum of vertical load rolling resistance force coefficient of friction minimum drive wheel load minimum drive boggie wheel load traction force on boggie wheel ls 250 2417.8134 0.353 boggie wheel base moment lateral force due to long tracel lateral load due to off centre Sum of lateral load 3 26562.4 2667.065771445 Maximum moment bending stress Yield of material permissible bending stress permissible shear stress top Flange .475 20905.707 109.118 54837.9 83621.

.

1*0.537622786 .534809 mm MPA mm^4 mm length 1 2 3 4 5 6 28.727042324 2.773220635 0.span E I maximum deflection Maximum allowable force Maximum allowable weight 17000 207000 1242878400 20 50271.05 3.68647 5124.33333333 300 6 300 6 0 6 height 16 600 20 600 0 0 sum y height area 4800 3600 6000 3600 0 0 18000 334 717 load Q t Shear stress Frequency 83669 64800 6 0.

.

59992 7053 23.24E+09 Length Ad^2 Volume 510124800 0.21024 6.28673 83669 y 8 308 626 308 0 0 area*y 38400 1108800 3756000 1108800 0 0 6012000 Ixx are moment of inertia d=y-ypiece 102400 -326 1.5 41.4317 0.3 390625 1926.6263682 5.028333 55037.0.102 2433600 0.08E+08 -26 200000 292 1.16E+08 1.64178 6043 .31736 5.39 60.4 17 m Moment y Bending 355593.08E+08 -26 0 0 0 0 2.6280146 30.306 Weight 2417.306 61.30836 0.66667 30.028333 Deflection Force 33.814815 37.0816 2433600 0.030666667 5.0612 0 0 1026576000 0.3333 57554 2014.3664063 21.0612 511584000 0.33752 76.3 302 86.88 65.25 58.56391 15.7554 82.40359 333333.

33333 .28.93082 61.

66248 61.338307 25.33333 .7.

538462 .6.

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