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Wire rope excavator

Problem statement:

´ This is a practical problem the main
bj ti off which
hi h is
i to
t replace
l th presentt day
the d Hydraulic
H d li
operated excavator or JCB with Wire rope operation in order
to minimize the hydraulic network. This system may also prove
to be simple rather than a complex and cumbersome design as
usually observed in the hydraulic operated machines.
To perform a given work using an Excavator Hydraulic
systems were used. The present day excavator has the following
¾ The hydraulic system incorporates complex arrangements for
pressurizing the fluid.
¾ It uses Diesel Engine (6 or 12 cylinders type ) which consumes lot of
¾The engine structure and design are complex.
The present day engine need also to be eco friendly and
so we look far ward for a better system which minimize the draw backs.
The present idea may help in this regard
Figure shows the usual Excavator using
hydraulic systems which include cylinders, ram, valves, fluid.
Figure shows the basic arrangement of the wire rope arrangement
Black lines – Wire arrangement for first arm
Rose lines – Wire arrangement for second arm
The mechanism uses rope drums just as we observe in
hoist machines. The rope drum is supposed to be arranged inside the body
of the machine particularly in front of the cabin where the driver or the
operator sits. The bucket movement may be obtained by the regular
(hydraulic ) arrangement.
arrangement This is necessary because the rope arrangement
cannot handle the work in such locations.
F ibilit
This is to verify whether the use of ropes are feasible or not.
That is whether the ropes are capable of handling the large loads.
Consider the following examples -

Example1 – Dam with gate Example2 – Cranes
Mechanism for the first arm:
Mechanism for the second arm:
The difficulties that may arouse when the rope mechanism
acts on only one side can be understood from the following figures

Difficulty – 1 Difficulty – 2
Yellow – actual position
Grey – deflected position
Difficulty – 3

Y ll – actual
Yellow t l position

Grey - deflected position

In order to eliminate the difficulties (as shown above) that
may arouse when
h the
th ropes acts
t on only
l one side,
id we employ
l a double
d bl
side acting mechanism which may work effectively.
The basic operation that is involved in this type of
mechanism can be understood from the figures

(Movement of arm to which (movement of arm to which first
bucket is connected) arm is connected)
Essential Requirements:
9 The mechanism should not cause any miss function, for this
purpose it is necessary to employ double side acting mechanism.
9 Whatever the amount of rope wound on one side, the same amount of
rope should be unwound (released) on the other side. It means the
length of the rope on both sides should undergo equal changes when in
This is the one most essential condition to be satisfied by the
proposed mechanism. Else stresses may develop and also the possibility
of wire breaking occurs along with miss function.
Figure shows the result of
unequal changes in length.

D i Considerations:
Design C id ti
1. Pins that are used to connect ropes with the arms should be designed
to withstand the large loads without being stressed.
2.The rope should have the capacity to carry the maximum load carried
by the machine.
3. The pulleys are supposed to offer less friction
4. The proposed mechanism should use less power to handle a given
task, than that consumed by a similar sized Hyd. Operated machine.
Use of motors:
Factors like difficulty in the availability of diesel, gases
that are released during combustion, cost etc. makes us to look for a
better fuel (alternate fuel) or if possible a motor. It can be easily
verified that a diesel engine consumes more input to develop a given
rated power than that consumed by an electric motor. Cost incurred is
also low. But what required in this case is the ability to store large
amounts of power and also to discharge it whenever required.
Bucket motion:
The bucket attached to the arm is necessary to be operated by
hydraulic system. The wire rope arrangement in such locations may not
handle work effectively and may not do expected job. The following
problem may arise when the bucket is operated by rope (one side )
The following arrangement may sounds good but may not handle

•The system eliminates much of the hydraulic network.
•The losses incurred in this case may be reduced since the hydraulic
system which offers viscous resistance are minimized and only few
parts may be encountered.
The advantages of the above system can be experienced
y when the system
only y is studied well and pput into real workingg model.
Some drawbacks:
1 The unit may not be effective.
1. effective
2. System is not recommended for heavy duty applications.
3 Separate arrangement for the hydraulic system in addition to the wire
rope system is needed and hence it seems to be quite in comfort.
4 In case if motor were used in place of diesel engine the difficulty in
storing and supplying electric energy is the main draw back.
Although the development of the wire rope mechanism
seems to be difficult, it may be confirmed about the usage by making a
prototype of the above said mechanism, evaluating all the constraints and
possible limitations. Also the performance of both the diesel engine and
motor helps us to decide the suitable type of power input to the system.
All we need is to develop a suitable system capable of storing large
amounts of electric energy. Results of any idea will be found only when it
is put into practical model and hence the above said model may be
prepared, as there is no harm in trying.
Dedicated to…..

Lord Sri Venkateswara

Thank yyou….

Th E
The Endd