CHAPTER SIX

Hoisting and Traveling Gear

Power is required in order to drive the
travelling and hosting mechanisms of a
hoisting equipment.

Power sources are classified depending on

the energy used to produce the motive
force or torque. The two principal
sources of motive power are.

• Power drive
• Hand/ manual drive
The power drive can be provided by electric
motor, stem engine, internal combustion engine,
hydraulic or pneumatic system.

On most hoisting installations preference is

given to the electric motor because it has the
following advantages.
• Immediate readiness for operation
• Possibility of driving every motion by a
separate motor.
• High economic efficiency
• Ease of speed control
• convenient reversing of motion.
• ability to cope with short time overloads of
significant magnitude
Steam engine has become obsolete due to its
low efficiency.

The IC engine is mostly used on travelling

mechanisms and has the advantage of
immediate readiness for operation,
comparatively small dimension and weight, high
efficiency and the possibility of speed control.
But it has the following disadvantages.

• Impossibility to start up the engine under

load
• Vulnerability to overloads
• Reversing gears and extra brakes have to be
used to operate in the reverse.
The hydraulic drive provides for speed
control, ensures smooth operations,
simple means of protection against
overloads and is compact.

Some of the difficulties in using

hydraulic drives are: when it is used to
operate a moving mechanism difficulties
are experienced in connection with
feeding fluid to the drive, low
temperatures impair the operation of the
drive and loss of pressure head and
leakage of operating fluid.
Pneumatic drives are characterized by
smooth operations, simple construction,
easy and convenient control and simple
maintenance and repair. On the other
hand, it displays low efficiency in handling
light loads and limits the radius of action
of movable machines by the length of the
air hose.

They are also prone to fire accidents and

are not suitable in explosive surrounding.
I. Hoisting Gear
a) Hand Power Hoisting Mechanisms
Motion is transmitted from the handle I
through three pairs of speed reducing
gears to a drum fitted on shaft IV.

Useful work: A0 = Qh Where, Q = weight of load

h = distance travelled
by load

Work done:
A = Ks where;
K= actual effort
Applied by operator
 Cont’d
s = path of the force K corresponding to the
path of Q
Qh Qv
Efficiency:  = A0 = =
A Ks Kc
Ko Ko
= =
K K o +W

Where, W = total resistance due to friction in

the mechanism
c = the speed of the point of application
of the drawing effort (30 to 45 m/min)
Effort applied by operator:
Qh Qv
K= =
s c
Total efficiency:  =  pull . drum . 3
gear

where  = pulley efficiency  0. 94

pull

 drum = drum efficiency  0. 98

 gear = efficiency of one pair of gears  0. 99

The total transmission ratio of the mechanism i is:

moment of load M Q QR
i= = =
moment of force   M k Ka
 Cont’d

with pulley available Q should be replaced

by the tension in the rope

Q
S=
2
b) Hoisting Mechanism with an Individual
Electric Drive
• At a constant lifting speed, (v =
constant) the power in hp developed by
the electric motor is:
Qv
N=
75

The torque on the motor shaft

N
M  = 71,620
nmotor

Where,
n motor = motor shaft rpm
 Cont’d
The transmission ratio between the motor
and the drum is:
motor speed nmotor
i= =
drum speed ndrum

The speed of the rope on the drum is:

vdrum = v  i pull
Where, i pull = pulley transmission ratio ( i pull >1 for
gain in force)
V
Drum Speed [rpm]: ndrum = drum
D
Where, vdrum= speed of the rope on the drum
[m/min]
D = drum diameter [m]
 II. Travelling Gear

a) Rail Travelling Mechanisms (Hand Trolleys).

Motion is transmitted from wheel I due to the effort K
through two pair of gears to the travelling wheels,
wheel III.

Travelling Mechanism of Crane Trolleys

 Cont’d
Wheel load:
a) P max =
Q + Go
4
Where, Q = weight of the load
Go
= weight of trolley

b) When the load is suspended asymmetrically

in trolleys with two hoists, the force exerted
on the wheels is approximately equal to:
Go Q b2
Pmax = A  + ; .
4 2 b

G o Q b1
P min = B  + .
4 2 b
Moment of Resistance
If the resistance to motion in a horizontal
direction is denoted by W- the moment of
resistance relative to the axle of the wheel
at steady motion is:
d
M = WR = (Q + G o )  + (Q + G o ) k
2
d
= (Q + G o ) (  + k)
2
Where, d = diameter of wheel journal [cm]
 = coefficient of friction in journal
k = coefficient of rolling friction
 traction force:
Q + Go d Q + Go
W= (  + k)= ( d + 2k)
R 2 D
Coefficient of resistance to motion(traction factor)

=
W d + 2k
= [Kgf/ton]
Q + Go D

Where, D = diameter of traveling wheel

There is additional resistance due to the
friction on the flanges of wheels:
W =  (Q + Go )tons . w
where,  = 1.25 - 1.4 for sliding bearing
 = 2.5 - 5.2 for rolling bearing
Values of Traction Factors (Coefficient of Resistance to Motion)
The total efficiency of the mechanism  is
given by:

 =  o . 2
gear
tw
Where,
o = efficiency of operating wheel  0.93
 gear = efficiency of one pair of gear

 tw = efficiency of traveling wheel  0.97

 b) Crane Trolley with an Individual
Electric Drive
The motion transmission principle is
similar to that of hand operated crane
trolley except that the manual effort K
is replaced by an electromotor.

Travelling Mechanism of an Electrically

Driven Crane Trolley
 Cont’d
The power developed by the motor is
Wv
N=
75
Where,  = total efficiency of motionthe machine
W = resistance to =  (Q + Go )tons  

The transmission ratio is:

motor speed n
i= = mot
travelling wheel speed ntw
v
The speed of the travelling wheel is n=
D
where v = speed in [m/min]
D = wheel diameter in [m]
 Travelling Mechanisms of Overhead
Travelling Cranes

Hand Propelled Overhead Travelling

Cranes

In an ordinary four-wheeled crane, the

maximum force acting on the wheels arises
when the loaded trolley is located in the so-
called dead section of the span.
 Cont’d

Travelling Mechanism of a
Hand-propelled
overhead Travelling Crane
 Cont’d
The maximum force acting on a travelling
wheel of a four-wheeled crane
G L (Q + G o )
L P max -  - (L - e)= 0
2 2 2

G Q + Go L - e
P max = + ( )
4 2 L

Similarly, Pmin = +
G Q + Go e
.
4 2 L
where G = weight of the crane
(without trolley) and
Go = weight of the trolley
 Cont’d
• The resistance to motion:
W =  (Q + Go + G )tons 

Where, d + 2k and  = 1.4 to 1.8

=
D
The transmission ratio:
i=
M
=
WR
 =  o  gear  t
 M o  KR o
60KcRo
Speed of the traveling mechanism: v= [m/min]
WR
where c = mean peripheral speed of the operating wheel (0.8 to 1 m/s)
Ro = crank handle radius
M = moment of resistance to motion referred to the shaft of
the traveling crane [kg-cm]
 Electrically Driven Overhead Travelling
Cranes

Resistance to motion is: W =  (Q + G + G o )

 Cont’d
The maximum moment arises when the
loaded trolley is in the dead section of
the span.
 G Q + Go
M '
dII = + (L − e )R
2 L 
G Q + Go e
P min = + 
4 2 L
To overcome friction:
d Wv
Z > W -  F N=
D 75
Travelling Mechanisms of Cantilever and
Monorail Cranes

The maximum force

acting on the vertical
travelling wheels is:

max V Q + Go + G
F ver = =
2 2

Where V = vertical thrust

Q = weight of the load
G = weight of crane (without trolley)
Go = weight of trolley
 Cont’d
• The maximum force acting on the
horizontal rollers is:
H (Q + G o ) a + G e1 V e
F
max
hor = 1
= = 
2 2 h1 2 h1

where H 1 = horizontal thrust

The resistance to motion W is:

Q + Go + G d1 (Q + G o ) a + G e1 d
W= (  + k) + 2 (  2 + k)
R 2 R2h1 2
Ve
= V + 
h1
= V (1 +
e
) where d 1 and d 2 are diameter
h1 of the hinges
 Operation of Hoisting Gear during
Transient Motion
Dynamic Load
If a body with a moment of inertia I
revolve with a variable angular speed,
the dynamic torque causing the change
in speed is:
dw
M dyn = I
dt
where ,
dw
= angular acceleration
dt
 Cont’d
According to d'Alambert's principle, the motor
torque is expressed by:
dw
M = M st + M dy = M st + I
dt

where, M st = moment of static resistance

referred to the motor shaft.
2
GD
I = mr 2 =
Using the moment of gyration: 4g

Where, r = radius of gyration

D = diameter of gyration
g = 9.81 m/s2
 Cont’d
2

The product GD is known as the moment

of gyration: dw GD 2 dw
M dyn = I = .
dt 4g dt
Considering only rotating links, the kinetic
energy of the equivalent system equals:
2 2 2 2 2
I rr w = Iw + w
I1 1 w
I2 2 I n wn
+ + ..... +
where 2 2 2 2 2
I rr = moment of inertia of the equivalent system referred to the
motor shaft.
w , I = angular speed and moment of inertia of the motor armature,
clutch, and other components on the motor shaft.
 Cont’d
w1 , w2 , w3 , , wn = angular speeds of gears, shafts and
other rotating parts of the mechanism mounted on
their respective shafts.
I 1 , I 2 , I 3 , , I n = moment of inertias of the different parts
of the mechanism

(a) Hoisting (b) Travelling,

Fig. 6.10 Diagrams of Mechanisms:

1-Electric Motor Armature, 2- Worm Drive,
(c) Slewing
3- Pulley System, 4-Turning Wheel,
5-Slewing Axis, 6-Boom, 7- Motor Shaft
 Introducing the corresponding moments of
gyration,
n1 2 n 2 n 2
( GD 2 )rr = GD 2 + G1 D12 ( ) + G 2 D 22 ( 2 ) + .... + G n D 2n ( n )
n n n

n n n
= i1 , = i2 ,...., = in
n1 n2 nn
2 2 2
G G G
( GD )rr = GD + 1 2D1 + 2 2D 2 + .... + n 2D n
2 2

i1 i2 in

Since in  i2  i1 , the further the link is removed from the motor shaft,
the less it will contribute to the moment of gyration.

( GD )   GD
2
rr
2

where  = coefficient for accounting the effect of the

parts of the transmission mechanism ,1.1 - 1.25.
 Denoting the rectilinear mass by m ' , weight
by G ' and velocity by v, the kinetic energy is:
1 ( GD )   2
m v 2 =
2 r ,rect

2 4g  2
where (GD ) 2
r , rect
= moment of gyration of the equivalent system
used instead of the rectilinear system.

Accounting for the losses in the mechanism,

m v2 ( GD2 )r ,rect   2
=
2 4g  2
G 2n
m = ,  =
g 60
365 G  v 2
( GD 2 )r,rect = [Acceleration]
n 
2
 Upon retardation, the kinetic energy of
the link in rectilinear motion is
transmitted to the motor shaft and is
partly absorbed in the drives.
m v2 ( GD 2 )r,rect   2
=
2 4g  2

365 G  v 2
( GD 2 )r,rect = 2
 [Retardation]
n
For the whole system, the moment of gyration
of the equivalent system is
( GD2 )r = ( GD2 )r,r + ( GD2 )r,rect
 The dynamic torque for acceleration or
retardation of the whole system with rotary
parts and parts with rectilinear motion, as
referred to the motor shaft, is

( GD 2 )r dw ( GD 2 )r dn 2n
M dyn = = . , where  =
4g dt 375 dt 60

The motor torque in starting M mot is used to

overcome both the static resistance and the
inertia forces, in travelling and hoisting
mechanisms.
M mot = M st + M dyn
For hoisting mechanism, in braking,
M br = M st + M ' dyn
For travelling mechanism, during braking,
the moment of forces resisting motion
acts opposite to the direction of rotation
and helps in retarding, so that
M br = M '
dyn −M '
st

Where,
M br = actual braking torque comprising the electric braking torque and
mechanical braking torque
= moment of static resistance referred to motor shaft
'
M st

N
M ' st = 71620 mot kg.cm (Starting)
nmot
nmot = motor speed [rpm]
N mot = motor power developed at steady motion [hp]
For hoisting gear: N mot =
Qv
75

For travelling gear: Wv

N mot =
75
where Q = weight of load being raised [kg]
W = resistance to motion [kg]
v = speed [m/s]
 = total efficiency of mechanism
M ' st = moment created by load in hoisting mechanism or
moment created resisting forces in travelling mechanism

N mot
M '
st = 71620 kg-cm
nmot
 Cont’d
For hoisting gear:

Qv
N br =  hp
75

For travelling gear

Wv
N br = hp
75
 Starting and Braking Time
Considering that M st is constant,
independent of the speed and considering
M mot and M br as constant values we obtain
M dynand M '
dynto be constant. Then from the
equation for M , we obtain that
dyn

dn is constant. ( GD 2 )r dw ( GD 2 )r dn
=
M dyn = .
dt 4g dt 375 dt
For starting: dn n where = starting time
=
ts
dt t s
For braking: dn n where
= t br = braking time
dt t br
 Cont’d
( GD2 )r dn ( GD2 )r n
M dyn =  = 
375 dt 375 t

For starting: ts =
( GD2 )r . n
375 M dyn

The braking time for hoisting gear is:

( GD 2 )r . n
t br =
375 ( M br − M ' st )

and for travelling gear

 GD 2 n 0.975 G  v 2

2
( GD )r . n M dyn +
t br =
375 ( M br + M ' st ) 375 t s n t s
and the dynamic torque in retardation is:

 GD2 n 0.975 G  v2 
M ' dyn  +
375 t br n t br
where ts = 1.5 to 5 seconds for hosting machine
t br = 5 to 8 seconds for bridge travelling mechanisms
ts = 1 sec for mechanisms with lifting speed v <12 m/min

t br = 1.5sec for mechanisms with lifting speed v >12 m/min

Moments of Inertia of Various Elements of Mechanisms
Approximate Values of the Moments of Inertia of Couplings

Outer Shaft Hub Rim Weight Moment

Diamet Diam Lengt Widt [kg] of
er eter h h Inertia
[mm] [mm] [mm] [mm] [Kg.cm/s2]
150 30 120 60 10 0.003
200 40 160 80 20 0.01
250 50 200 100 40 0.03
300 60 240 120 70 0.08
400 70 280 140 140 0.28
500 80 320 160 250 0.78