• Hoisting equipment are usually powered

equipment used for lifting and lowering unit

and varying loads intermittently.
• In certain equipment while lifting and
lowering, shifting of the load can also be
accomplished, within an area known as the
reach of the equipment.
• The component parts and units of hoisting equipment
include:
o Flexible hoisting appliances;
o Pulleys and pulley systems;
o Sprockets and drums;
o Load handling attachments;
o Stopping and braking devices;
o Drivers (motors), Transmission components (axles,
shafts, bearings, clutches, etc.);
o Rails and travelling wheels;
o Machine structures (crane frames) and Control devices.
• There are three groups of hoisting equipment having
the following main distinctive features.
i. Hoisting machines: designed as self-lifting gear
and for hoisting and moving.
ii. Cranes: a combination of separate hoisting
mechanism with a frame for lifting and/or moving
loads.
iii. Elevators: a group of periodic action machine
intended for raising loads with guide- ways.
• The main technical parameters are:
o Lifting capacity: the maximum safe load the
machine is designed to handle;
o Dead weight of the machine: the total weight of
the machine with out the load;
o Speed of various movements: hoisting speed, the
bridge travel speed and the trolley travel speed;
o Lifting height: the height to which the load is
intended to be raised;
o Geometrical dimension of the machine.
• Hoisting machines are periodic-action machines and
their hourly capacity can be determined from:

Qhr  n  Q
• Where n = number of machine cycles per hour
Q = weight of live load [tons]
Qhr = hourly capacity [tons/h]
• When handling bulk material, the weight of live loads is:
Q = V   

• Where V = capacity of bucket, grab etc [m3]

 = filling factor
 = specific weight [t/m3]
• The total load lifting capacity of the machine will be:
Qtot  Q  G

• Where: Q = live load [tons]

G = weight of bucket, grab, etc. [tons]
• The number of cycle per hour is:
3600
n
t
• Where:  t   t op  t idle
• Factors acting on the operating conditions are:
1. Load on the machine
2. Its annual and daily utilization
3. Relative duty factory (DF)
4. Ambient temperature
• Mean lifting capacity utilization:
Qm
K load 
Qn
Where: Qm = mean value of load [tons]

Qn = nominal load [tons]

• Yearly utilization factor:

Days in operations per year

K year 
365

• Daily utilization factor:

Hours in operations per day

K day 
24
• Hourly utilization factor:
Time - on in an operationa l hour(min)
K hr 
60

• Mean utilization of the machine per working cycle:

top
DF  100%
top  tidle

• The total time-on, T, of a mechanism throughout its

life, h (in years)
DF
T  365K year  24 K day  K hr  h
100
• Duties of Hoisting Machinery
Duty Mean Utilization of Mechanism
By Time Duty Factor Temperature
K load (DF) 0
C
K year K day %
Light L 0.5 0.25 0.33 15 25
Medium M 0.5 0.5 0.67 25 25
Heavy H 0.75 0.75 0.67 40 25
Very Heavy VH 1.0 1.0 1.0 40 45
• Hoisting machineries use different flexible hoisting
appliances for handling materials some of which are:
o Hemp ropes
o Welded load chains
o Roller chains
o Steel wire ropes
• Hemp ropes have poor mechanical
properties (rapid abrasion, inadequate
strength, rapid damage from sharp
materials and atmospheric effects).
• They can be recommended only for
hand-operated hoisting machinery (rope
pulleys with diameters at least 10d).
 Cross-sections of Hemp Ropes
• Load on the rope [kgf]

F =
d
2
 br
4
For white rope  br  100 kgf/cm2 and
For tarred rope  br  90 kgf/cm2.
• They are widely used in hoisting installations
as pliable members.

Where t - pitch
d - diameter
B - chain outside width
“A chain is no stronger than its weakest link”
• Depending on the ratio between the pitch
and the diameter
i. Short-link chains with t  3 d
ii. Long-link chains with t > 3 d
• Depending on manufacturing accuracy
i. Calibrated - t  0.03d and B  0.05d
ii. Un-calibrated - t  0.1d and B  0.1d
• Welded chains are formed from oval steel links by
a number of methods.
i. Hammer (forge) welding: the chain bar is
formed by forging to chain shape, then the ends
are forge welded.
ii. Electric resistance welding: the link is made
of two butt-welded half links.

Sequence in the Manufacturing of Welded Chains

Disadvantages
- Heavy weight
- Susceptibility to jerks and overload
- Sudden failure
- Intensive wear at the link joints and
- Low safe speed of movement
Advantages
– Good flexibility in all directions
– Use small diameter pulleys & drums
– Simple design and manufacture
Selection
Fbr
Fs 
K

Where , Fbr = breaking load [kgf]

K = factor of safety (3 to 8)
Fs = Safe load [kgf]
 Chains Drive Factor of Ratio Minimum
Safety, K (D/d) Number
of Teeth on
Sprocket
Welded calibrated and Hand 3 20 5
uncalibrated Power 6 30 5
Welded calibrated on sprocket Hand 4.5 20 -
sheaves Power 8 30 -
Welded uncalibrated (sling) - 6 - -
passing around the load

Welded uncalibrated (sling) not - 5 - -

passing around the load

Roller - 5 - 8
• They are composed of plates hinge-jointed by pins and
rollers. For light loads, two plates are used; for very
heavy loads, the number of plates can be increased up
to 12.

Simple Roller Chain with Two Plates

• The plates can be secured on the pins by
several methods like retainer rings, pins, etc
• Roller chains are used for hand-operated hoists and
power-driven winches and hoisting mechanisms of high
load lifting capacity.
• They are superior to welded chains
 The reliability of operation is higher since the plates are solid.
 Roller chains have good flexibility and therefore they can be
used on small diameter sprockets.
 The friction in the joints is considerably less.
• However, they should not be allowed:
 To carry weight at an angle
 To be used in dusty premises
 To wind on a drum
 To a speed greater than 0.25m/s
• They are extensively used in hoisting
machinery as flexible lifting appliances.
• Comparing to chains they have the following
advantages.
 Lighter weight
 Less exposure to damage from jerks
 Silent operation even at high speeds
 Greater reliability in operation

(a) (b) (c)

Steel Wire Rope Construction
• Wire ropes are manufactured first
by twisting separate wires, cold
drawn and given heat treatment
between drawing stages, into
strands and then into a "round"
rope.
• Wire ropes consist of 6 or 8
strands and a core. Each strand
consists of 19 or 37 wires.
The lays of the rope classifies the wire ropes into:

i. Cross-of regular lay ropes: the direction of the

twist of the wires in the strand is opposite to that of
the strands in the rope.

ii. Parallel or long lay ropes: the direction of twist of

wire and strand is the same. They are more flexible
and resist wear better, but tend to spring and are
used in lift.

iii. Composite or reverse laid ropes: the wires in two

adjacent stands are twisted in the opposite
direction.
Steel Wire Rope Lays
1. General Purpose Steel Wire Ropes
a. Ordinary construction: the strands are twisted of
wires of the same diameter. The repeatedly cross
over of the inner wires create zones of increased unit
pressure, which shortens life.
b.Warrington type compound rope: is twisted of strands
with different wire diameters keeping the proportional
pitch of every layer, thus crossovers are eliminated.
2. Wire Ropes with Flattened Strands
They are usually made from five flattened
strands with a flattened wire core; the
strands are laid on the hemp core.
They experience more uniform pressure and
are used where the rope is subjected to
intensive abrasion and wear.

Ropes with Flattened Strands

3.Locked-coil Steel Wire Ropes
A locked coil rope consists of an outer layer
formed of specially shaped wire and an inner
single lay spiral rope.
Locked-coil wire ropes are used in cable-ways and
cable cranes; they are never met within hoisting
machines.

Locked-coil Ropes
• They have the advantage over the other
wire ropes because they have specific
features of smooth surface, tightly
packed wires and little wear.
• However, their shortcoming is due to
their little flexibility.
Selecting Steel Wire Ropes
• Wires in a loaded rope experience complex stress
consisting of tension, bending, twisting and
compression.
• Thus the total stress can be determined
analytically only to a certain degree of
approximation.
• Experiments have shown that life of a rope is
greatly affected by fatigue and can withstand only
a definite number of bends during service life
• Investigations have shown that the rope life
is inversely proportional to the number of
bends where one bend equals the transition
of the rope from a straight position into a
bent position or vise versa.
• Reverse bending reduces the rope life
approximately double of the single bend.
• The number of bends is obtained by the
number of points where the rope runs on
and off over a pulley/ drum surface.
• Depending on the number of bends, the
corresponding rope life can be found from the
ratios
Dmin / d and Dmin / 
Dmin= minimum diameter of pulley/drum
d = diameter of rope
 = diameter of one wire
No. of bends 1 2 3 4 5 6 7 8

Dmin /d 16 20 23 25 26.5 28 30 31

No. of bends 9 10 11 12 13 14 15 16

Dmin /d 32 33 34 35 36 37 37.5 38

Values of Dmin /d as a Function of Number of Bends

Total stress
S Mc
    ten   ben  
A I
M 2E

I Dmin

 Mc 2E  E
c   ben    
2 I Dmin 2 Dmin

 br S E '
 
  +
K A Dmin
 3
E'  E= Corrected rope elastic modulus  800,000kg/cm2
8
E = elastic modulus of rope wire material = 2,100,000kg/cm2

d 2  2
4

4
i  2.25 d  1.5 i

Thus:  d 
E'  
S E'   br
  
S 1.5 i  S E'
 
    
A Dmin A Dmin A Dmin K
1.5 i 
d
• Rewriting the equation for the required useful area:
S
A
 br d E'
 
K Dmin 1.5 i

• Ropes subjected to only tensile forces

where
Fbr Fbr =
Fs  breaking strength [kgf]
K
Fs= maximum force [kgf]
K = factor of safety
Values of K for Different Operating
Conditions
Drive Duty K
Hand Light (L) 4.5
Light (L) 5.0

Medium (M) 5.5

Power
Heavy (H) 6.0
Very Heavy (VH) 6.0
 Given data:
S = 1800kgf
i = 222
 b 160kg / mm 2

K=6
Dmin/d = 23
S Nearest value of the area A is 174.4mm2
A( 222)   172.5mm 2
d= 22mm
 b
K D 
d
 36000


 = 1mm
 min  Breading load(F)= 27900kgf
Wire ropes for Materials Handling Equipment (According to DIN 655)
Design (DIN655) Rope dia. Wire dia. Metal cross- Weight (kgf/m) Strength of the wire rope in (kgf) if the strength of
d 5% (mm)  (mm) section 5% the wire in (kgf/mm2)
(mm2)
130 kgf/mm2 160 kgf/mm2 180 kgf/mm2
6x19=114 wires 6.5 0.4 14.3 0.15 1860 2300 2550
+1core
8.0 0.5 22.4 0.21 2900 3600 4050
A
9.5 0.6 32.2 0.30 4200 5150 5800
12.5 0.8 57.3 0.54 7450 9150 10300
16.0 1.0 89.5 0.85 11650 14300 16100
19.0 1.2 128.9 1.22 16750 20600 23200
22.0 1.4 175.5 1.66 22800 28050 31600
6x37=222 wires 10 0.45 35.3 0.34 4600 5650 6350
+1core
13 0.60 62.8 0.59 8150 10050 11300
B
16 0.75 98.1 0.93 12750 15700 17650
22 1.00 174.4 1.65 22650 27900 31400
24 1.20 251.1 2.38 32650 40200 45200
30 1.50 392.3 3.72 51000 62750 70600
40 1.80 564.9 5.36 73450 90400 101700
8x37=296 wires 16 0.6 83.7 0.84 10900 13400 15050
+1core
19 0.7 113.9 1.14 14800 18200 20500
C
21 0.8 148.8 1.49 19350 23800 26800
27 1.0 232.5 2.32 30250 37200 41850
32 1.2 334.8 3.35 43500 53550 60250
40 1.5 523.1 5.24 68000 83700 94150
• Various methods are used to secure the ends of
chains and ropes to the load suspension appliance.
a) Fastenings of Welded Load Chains

Split yoke and a bolt Cross piece and forked eyes

b) Fastenings of Roller Chains

A special link having bigger pitch and hole

for bolted connection
c) Fastenings of Wire Ropes
Geometry of a Tapered Wire Rope Socket
 Q
F 
2sin 
pA where p = unit pressure
F   115kgf/cm2
2
A = bearing area [cm2]
l (d1  d 2 )
A
2
Hence We have
pl (d1  d 2 )
F 
4 Q p( d 1  d 2 )( d 1  d 2 )
F  
l 
r1  r2 d  d2
 1
2 sin  4  2sin
sin  2sin
 4Q
p( d 12  d 22 ) p
Q (d 12  d 22 )
4
Assuming d 2 = d (wire rope diameter)

4Q
d1  d2
p

Where  sh =125kgf/cm2
Q
h
d   sh
• The tension in the slings are functions of included angle
between the sling legs.
• If the load is suspended from two legs of sling, the tension in
each leg will be .
Q
S 
2 cos 
For a four leg sling loaded symmetrically
Q
S1  S 2  S 3  S 4 
4 cos 
We know that
h
cos  
l

Thus
Ql
S1  S 2  S 3  S 4 
4h

For m legs
1 Q Q
S   K
cos  m m

Where, K 
1
cos 
Various Types of Knots of Hemp Ropes