WINCH & DRUM WINDER

Design and Analysis of Single Drum

Refer : Handbook WINCH, WIRE AND CABLE TECHNOLOGY (2001) & Guideline for Design Commissioning and Maintenance of Drum Winders.

Calculate by moon.near76@gmail.com

DATA INPUT
Load / Line Pull = 17714.1 Lb 8035 Kg 78796.4 N
Line Speed (V) = 58 Ft/min 0.29 m/s
Output Torque = 2256.0 In.Lb 2599.2 Kg.cm 254.9 N.m
Ø Head Drum = 99 Inch 2520 mm
Input Speed = 1420 Rpm
Output Speed = 2.2 Rpm

SPEED CALCULATION
Selection of the Gear unit & V = speed = 0.29 m/s
the variable speed gear unit. Ø Head Pulley = 2520 mm

Refer to CEMA
nN Input speed = 1420 rpm
na Output speed = 2.2 rpm

Output speed na = V.60000 . iv

π.D = 2.2 min⁻¹ (rpm)

WINCH DRIVES
Power Determination
With the pulls and speeds selected, the basic “drum output power” comes from the two well-known relationships:

H.P. out = Line Pull (lb.) x Line Speed (ft/min) = 31.13 Hp 22.90 kW
33,000

H.P. out = Output torque (in-lb.) x Output Speed (rev/min) = 0.08 Hp 0.06 kW
63,000

Mechanical efficiencies for machines with spur or planetary reducers and fairleaders will range between 80% and 85%.
If worm gearing is involved, an efficiency of 70% to 75% is appropriate.
Each manufacturer will have his own design values, ranging from hopeful to conservative.

H.P. Input = H.P. out x overall winch efficiency = 26.53 Hp 19.51 kW

ROPE SELECTION
A vertical single drum winder is required to carry 20 persons from the surface to an underground seam located at 400 metres deep.
High of head sheave 15 meter
Select a rope suitable for the winder :
Mass of a miner and equipment = 88 Kg
Factor of Safety required on rope = 10 10
Mass of personnel in cage = 1760 Kg
Estimated cage = 4000 Kg
Estimated attachments mass = 200 Kg
Estimated rope mass 5 Kg/M = 2075 Kg

∴ Mass on rope at drum = 8035 Kg

78.8 kN

∴ Minimum rope breaking strain = Mass on rope x Safety factor

788.2 kN

For shaft over 400 metres deep. use Non-rotating rope

(Ref section 2.3.1)
From AS1426 Steel wire ropes for mines Select ø 36 Gd 1770 Non-rotating rope.
Breaking Strain 891 kN
Mass 5.49 kg/M.

Recalculate with actual rope mass = 2278.35 Kg

Difference of rope mass 203.35 Kg
Mass on rope at drum = 8238.4 Kg
Total static load at drum = 80.82 kN

∴ Rope Factor of Safety = Breaking Strain / Static load

11.02 > 10
DRUM PARAMETER SELECTION
For a vertical single drum winder with a surface to underground seam depth of 400 metres
Select the drum dimensions necessary to correctly coil and store the rope.

Assume a rope diameter of 36 mm

Assume a rope angle from drum to sheave of 45 °
Assume the drum will have parallel rope grooves.

Fleet angle required = 1.5° 1.5 ° Tan 14.10

Distance from drum to sheave = 17 m 17 m

Drum Width = 2*(Distance to sheave*Tan 1.5) 479448 mm 34000 479448

2* 17* Tan1.5* 1000 = 890.4 mm

Drum to Rope Ratio = 70

Minimum Drum Diameter = 70*36 2520 mm

Pitch of rope groove = Ø + Ø *0.04 37.44 mm 6.69 0.1787

Number grooves = Drum width / pitch of rope groove 23.78 24 groove

Drum width = 24*37.44 890.4 mm

= 898.56 mm

Actual fleet angle = Tan-1 (449.28/17000) 14.1014 °

= 1.514°

Allow 3 dead coils on drum at all times

1st Layer
Working rope Dia = 2556 mm
Working rope length = 166.9 m

2nd Layer
Working rope Dia = 2617.5 mm 2569.4 mm
Working rope length = 187.4 m 183.9 m

3rd Layer
Working rope Dia = 2679.0 mm 2630.9
Working rope length = 200.1 m 196.5 m

Total drum capacity with 3 Layers = 559.75 metres 554.3 m 547.3 m

Capacity required = 400+50 449 m < 554.3