Assignment 5 Solutions

Problem 1

(a) The system is sketched in Figure 1.1

Hoist Dum
Winch Pulley

Pulley Bearing
Shaft

Steel Cable
Motor Shaft

Drive Motor

Support
Structure

Guiding Pulley

Escape
Hatch

Soil Reinforcement
Cylinder
Human
Capsule

Oxygen
Supply
Capsule (Cage)
System

Figure 1.1 A preliminary sketch of the system.

The human capsule (cage) is operated using a cable over a winch pulley. It is driven by a
dc motor of adequate torque-speed-power capability, with proper speed control. The
motor turns a hoist drum which winds or unwinds the cable, as required. During most
operations, the capsule is empty when lowering into the mine. However, in the beginning,
a rescuer may be transported into the mine along with supplies. In a typical operation, the
capsule is pulled up with a human occupant. The speed of lowering may be faster than
the speed of raising. Typically, in the beginning of the operation the capsule is slowly
accelerated to a steady speed. Much of the operation is carried out at this steady speed.
Then toward the end of the task, the capsule is slowly decelerated to a smooth stop. A
trapezoidal speed profile may be used in a typical operation.

(b)

The main structural components of the system are: cable; human capsule; winch pulley
and its shaft and bearings; a guiding pulley for the vertical segment of the cable and its
shaft and bearings; supporting structure for the winch pulley; hoist drum with its shaft
and bearings; soil reinforcement and cylinder for evacuation tunnel; stops for the
allowable lowest and highest positions of the capsule. Basic design approaches are
indicated below.

Cable: Consider the weight of the heaviest allowable payload, capsule, and accessories in
determining the maximum cable tension. Note that friction at the cable and pulley
interface will increase the required cable tension particular during transient periods of
motion, above what is needed to support the weight under static conditions. Use the yield
strength or the ultimate strength with appropriate factors of safety, for normal stress in
the cable to obtain the cable diameter for the chosen material (e.g., cable steel). Check for
fatigue based on the number of cycle of operation during the design life and endurance
limit. Also, check the total cable extension, which should not be extensive even when it is
near yield strength (to avoid vibration problems, etc.).

Pulley Shaft: For the maximum allowable cable tension and the orientation of the two
segments of the cable, determine the maximum allowable load on the shaft. Design the
shaft based on the allowable shear stress. Check the normal stresses due to shaft bending.

Pulley: These may be approximated as disks. Loading includes the tensions in the two
cable segments, frictional force along the rim in the segment that touches the cable, and
the shaft reaction force. Design for thickness and radius of the pulley, based on the
chosen pulley material (e.g., high-carbon steel or cast iron). Formulas for radial and
tangential stresses in disks may be used, with proper safety factors with respect to
fracture strength.
Bearings: bearing reaction loading can be computed based on the pulley shaft loading.
Then the design may be done based on the bearing stresses. Deflection allowances should
be made to avoid cogging (in the case of roller bearings, journal bearings, etc.)

Human Capsule: It may be treated as a cylinder or a shell. The dimensions and wall
thickness may be designed using appropriate formulas for stress, and strength (yield or
ultimate) and safety factors. Connection hooks of the cable to the capsule should be
carefully designed by considering their structure/configuration, size, and material. The
inertial loading due to acceleration and deceleration in the speed profile must be included
in the design.

Support Structure: the load on the support structure depends on the loads of the
bearings that carry the pulley unit. The structure may be formed using two-force
members. Corresponding loads may be computed by the joint method and the section
method. Cross-sectional dimensions can be selected based on yield strength (e.g., of
structural steel) and a suitable safety factor (say, 3). Also compute tensile deflections and
make sure that they are not excessive that can create unpleasant motions and vibrations in
the pulley (and hence the capsule).

Hoist Drum: This may be considered as a solid cylinder (made of high-carbon steel). Its
loading includes: Motor torque; Cable tension (P2); Bearing reactions. Formulas for stress
(normal and shear) at various critical locations of the drum are available in the literature
to carry out the design. Its shaft and the bearings may be designed in the same as the
pulley shafts and bearings. The inertial loading due to acceleration and deceleration in the
speed profile must be included in the design.

Reinforcement Cylinders for Soil: Internal diameter of the cylinder is constrained by

the diameter of the human capsule. The external diameter is roughly equal to that of the
drilled tunnel. For the worst-case soil pressure, which is applied on the outside of the
cylinder, maximum stresses (axial, tangential, and radial) in the cylinder cross-section
may be computed. Cylinder thickness may be designed in this manner using allowable
strength for the material (with proper safety factor). Check for buckling as well.

Limiting Stops for Capsule: there will be impact forces and shock at the limiting
positions of lowering and raising the capsule. These may be estimated based on the mass,
highest velocity, and momentum of the capsule and its contents. Sufficiently high safety
factors should be used (say, 5). Impact buffers (say rubber pads) should be provided.
They may also be designed using the principles of shock and vibration absorption.

(c)

The most critical components of the system are the cable, the pulley shaft, bearings
and pulley (for the drive pulley, not the guiding pulley), human capsule, support
 structure, hoist drum, drive motor, and the reinforcement cylinder. The less critical
components are the guiding pulley with its shaft and bearings, limiting stops, and
shock absorber units.

Problem 2

(a) Cable Design

30o
120o
P2

P1 = Mg

P1 = Tension in the vertical segment of the cable

P2 = Tension in the segment of the cable leading to the drive motor (hoist drum)

When raising the capsule (cage), P2>P1. Under steady conditions P2 and P1 will be
related to the coefficient of friction μ between the cable and the pulley. The approximate
formula is

where, = angle of contact between the pulley and the cable (in radians)

Use a typical value for the coefficient of friction:

Also,

Use this value for in the cable design.

Cable stress
where, safety factor for yield strength =3

= cable diameter.

We get

Hence
√

Note: Typical steel cables are made of twisted multiple strands, each strand consisting of
multiple wires (For example, the following cable is commercially available: Diameter =
1.5 cm, Number of Strands = 7, Number of Wires Per Strand = 19, Load Capacity =
12,500 [Max], Coating = Galvanized Zinc, Type= Solid Braided Rope, Packing Type =
Reel, Weight = 5 kg/m, Safety Factor = 5). Diameter of such a cable is slightly greater
than that of a solid cable as computed above.

(b) Shaft Design

The resultant force R from the two cable segments may be determined using the
parallelogram of force:

P1 =
P2 = 12000 N
6000 N 60o
120o
R

By the cosine rule, we have

( )

Hence √

From the free-body diagram of the shaft, we have for equilibrium:

(assume symmetry)
R

R1 R2
Allowing for possible non-symmetrical reaction loading, use

Shear stress in the shaft

where, factor of safety wrt fracture in shear = 5

d s = shaft diameter

Hence

We get
√

We will use