‫‪MDP2130‬‬

‫‪Mini project 1‬‬

‫‪Hoist mechanism‬‬

‫‪Submitted by:‬‬

‫‪Name‬‬ ‫‪Sec‬‬ ‫‪Student code‬‬

‫اسراء ممدوح عباس ابراهيم‬ ‫‪1‬‬ ‫‪9220143‬‬
‫جمال وائل الصادق عبدا‬ ‫‪1‬‬ ‫‪9221683‬‬
‫عمر عصام الدين مختار مصطفى‬ ‫‪4‬‬ ‫‪9220543‬‬
‫محمد احمد محمد الحسن حفظ ا‬ ‫‪4‬‬ ‫‪9221478‬‬
‫محمد اسامة محمد الحسن‬ ‫‪4‬‬ ‫‪9221480‬‬
‫نهال عمرعثمان سليمان‬ ‫‪6‬‬ ‫‪9221744‬‬
‫هبة محمد سلمة السيد‬ ‫‪6‬‬ ‫‪9220943‬‬
Abstract:
It is one of the most important tools in various industries, ports
and machine shops when it comes to lifting, unloading and moving
heavy materials are hoists, and its use allows to minimize the
effort and the energy necessary to carry out these movements.

History and development:

The modern-day crane evolved from the early pulley mechanism.
Ancient construction workers used these primitive devices to manoeuvre
weighty objects more quickly than by hand. The pulley works by changing
the direction of force, reducing the effort required to lift an object.
The people of Mesopotamia (present-day Iraq) were the first to invent a
pulley system in 3,000 BC. Known as the shadouf, this lever-style
mechanism enabled the Mesopotamians to lift water buckets more easily
to aid irrigation.
Records show the Ancient Greeks began using lifting tongs and Lewis irons
in their temples around 515 BC. Innovations in winches and pulleys began
replacing ramps as a means of moving objects vertically.
These new lifting mechanisms saw Ancient Greek construction trend
towards using more small stones rather than fewer large building blocks.
Moreover, crane innovations saw the practice of erecting large monolithic
columns replaced by smaller column drums.
Renowned for their architectural prowess, the Romans constructed
thousands of enormous buildings,The simplest Roman crane was the
trispastos, a single-beam jib with a winch, rope, and three pulleys,The
Romans later invented the more advanced pentaspastos system, which
had five pulleys.
The present-day hydraulic crane relies on the same mechanical principles
developed by Armstrong almost two centuries ago. However, superior
materials—notably steel and iron—and better specifications allow us to lift
heavier loads to dizzying new heights.
A critical modern advancement was replacing water with an
incompressible fluid such as oil. This new liquid type allowed us to more
accurately transfer pressure between pistons, thus enhancing capacity and
efficiency.Another crucial innovation was the mobile crane. While mobile
cranes lift smaller loads, their agile nature offers significant benefits in
many construction scenarios.

Introduction:
Hoist (or rigging) is defined as the mechanism used to lift or move a load
mechanically, applying a lesser force than the weight to be moved. It is used for
lifting or lowering a load by means of a drum or lift-wheel around which rope or
chain wraps. It may be manually operated, electrically or pneumatically driven
and may use chain, fiber/lifting slings or wire rope as its lifting medium. These
units are typically used in an industrial setting and may be part of an overhead
crane.
They are usually attached by a lifting hook to a rotating arm that is attached to a
machine. They can also be mobile guided by rails placed on ceilings of industrial
buildings. Small hoists can be handled by hand, but heavier hoists are electrically
powered by motors, which is essential to establish their lifting power.

Types of Hoists:
Manual Hoists:
Manual hoists are lever-actuated, or hand chain operated lifting devices. A
manual lifting hoist uses two different chains: the hand chain used to control the
lifting and lowering action and the load chain, which supports the load.
The manual chain hoist is characterized by having a compact, lightweight and
easy-to-handle design that allows the lifting of up to approx. 2 tons of weight. It
is ideal for vertical load lifting.
Powered Hoists:
Powered hoists come with 3 different settings: electric, air/pneumatic and
hydraulic.Electric hoists follow the same principle as manual ones, only the chain
drive is replaced by an electric control. Pneumatic chain hoists or otherwise
known as air hoists are very similar in features to an electric hoist except the hoist
is powered by a compressed air feed as opposed to being restricted by the need
for a suitable electric power supply. Finally, hydraulic chain hoists are very similar
in features to pneumatic hoists except the hoist is powered by hydraulic oil as
opposed to being powered by a compressed air line.
Design calculations:
1- Hook:

We chose this specific hook to be able to deal with 3 tons load; its safety of factor
will be 3.
Check:
Designing a hook involves considering the specific requirements of the application
and ensuring that the hook is capable of safely and efficiently performing its
intended function, First We will assume some dimensions for the hook so we can
calculate the stresses because of the bending moment:
 To Determine the bending moment, we must set the location of the Neutral axis:

� 800
�= = = 36.409��
�� 60
20��
� 20

Calculations of spending stress will be at the most far point of the center of
rotation of the hook That will assure that the calculations would be at the stress
concentration point, because this is a 180 degrees hook, this point will be
horizontally at the left of the center of rotation The hook is under tensile and
bending stresses, a part on the inner radius is the one that is under tension:

M =m� × r = 1000 × 9.81 × 40 = 392.409Nm

N =mg N = 9810

The maximum tensile stress at R inner :

� � − ��� �
� max = +
� × ��� � − � �
392400 36.409 − 20 9810
���� = + = 124.329 ���
800 × 20 × 40 − 36.409 800
we will choose a material that meets the strength and durability requirements for
this application. Common materials include steel, stainless steel, or other alloys
depending on factors like strength, corrosion resistance, and cost, assume ASTME
A331Q+T (Sy=367Mpa).
Calculating the safety factor using Tresca:

�� 387
�1 − �3 = 124.33 = �� = 2.952
�� ��

Sigma 3 will = 0 because at the status of no load is hanged there's no stresses

applied on the hook .
A safety Factor is relatively low but according to Mazzella companies a hook with
dimensions smaller than this dimensions can undergo a load of almost 3.5 tons,
So we will consider that the design is safe under a load one ton.

Design against cyclic load:

σmax=124.329 Mpa , σmin=0
σm=(σmax + σmin) /2 =62.164 Mpa
σa=(σmax + σmin)/2 =62.164 Mpa
Se`=0.5 Su=0.5*384 =192 Mpa
Kf=4.51*(384^-0.265)=0.932 , Kr=0.82(for 99% reliability)
Assume:Kt=Ks=1
Se=Kf*Ks*Kr*Kt*Se`=146.7 Mpa
According to goodman:((Kf*σa)/Se)+(σm/Su)=1/ns
The hook has many curves and fillits , so we will assume Kf=1.3
((1.3*62.164)/146.7)+(62.164/384)=1/ns
ns =1.42
2- wire:

The safety factor will be near 3.

3- Drum:

This is the smallest standard drum available. It can handle the torsion if this
application, we will use 316 L Stainless Steel to ensure strength and durability.
4- shaft:
Shaft is made of AISI 1030 (Sy=648).
Assuming the following:
1) Gears at end D are neglected.
2) The dimensions are doubled as the drum requires more space.
3) Drum is connected to the shaft by interference fit.
4) The drum has a rope guide that rotates the steel wire around the drum over.
two sets (wire length is 40 meter).
5) Bearings are fixed in the system and their reactions don't vary over time.

Calculation of masses and torque:

A- Steel cable mass= 91.6*.4 = 36.64 Kg. (with a diameter =15mm)
B- Drum mass= 508.111 Kg.
C- Mass down= 508.111+36.64= 544.75 Kg.
Adding 1 ton =1544.75 Kg.
Neglect hook’s mass.
D- Torque= (36.64+1000) *315= 3.2*10^6 N.mm.
E- Load= 15.15*10^3 N.
 - The critical section is at B.
1

1
3
32�� 3
The diameter of the shaft = ���
× �2 + 4 × �2

s.f=3 M=3*10^6 T=3.2*10^6

D=58mm

To design against cyclic loading:

 1
3
2 2
32 × �� �� ��
× �� + × �� × �� + �� + × ��� × ��
� × �� �� ��

Sf=3 Sy=648Mpa Se=324Mpa Kf=1.5 Kfs=1

Mm=M=3*10^6Nmm Ma=0 Tm=0 Ta=3.2*10^6Nmm
D=70mm

5- deflection:

Maximum deflection is at A .
−�� − −15.15×103 ×2003
�� = 3��
= �
3×200×103 × ×704
=.17mm (very small deflection).
64

6- Critical speed:

2×9810×15.15×103 ×.17
Wcr =
2×15.15×103×.172
= 240 rad/s = 2294 rpm .

7-Detailed design:
From preliminary design phase: dmin=70mm
Assume d=100mm and using AISI 1050:
Su=1120 Mpa ,Sy=807 Mpa ,E=200*10^3 Mpa
The density of steel=8 g/cm^3
The weight of the shaft=8*(π/4)*(10^2)*(20+30+20)*9.81=431.64 N
So for 700 mm: W=0.6 N/mm
Since the load due to shaft weight and gear reaction at end D will be neglected.
Dynamic analysis:
σ =(3*(10^6)*50)/((π /64)*(100^4))=30.56 Mpa
Ꚍ xy= (3.2*(10^6)*50)/((π /32)*(100^4))=16.3 Mpa
Since the loading Alternating(completely reversed)
σm =0 , σa =σ =30.56 Mpa
Ꚍ m =Ꚍ xy =16.3 Mpa , Ꚍ a=0
σm` =square root(σm^2+3*(Ꚍ m^2))=28.23
Mpa σa`=square root (σa^2+3*(Ꚍ a^2))=36.56
Mpa Se`=0.5*Su=560 Mpa , Kf=4.51*(1120^-
0.265)=0.7 ,
Ks=1.248*(100^-0.112)=0.7451 , Kr=0.7 (99.99 Survival percent) , Kt=1
Se= Kf*Ks*Kr*Kt*Se` =204.5 Mpa
By using Soderberg equation: ((Kf*σa)/Se)+(σm/Sy)=1/ns
Kf=1
(36.56/204.5)+(28.23/807)=1/ns
ns =4.7 ( higher than 3 but suitable for the dangers of this application)

8-Pin design:

Assume the material is AISI 1006 Q&T: Su=300 Mpa , Se=150 Mpa
According to the load and application ,we will assume that the pin diameter is 7
mm
Calculation of stress for the load P:
Pmax=hook’s weight +1000*9.81=0.934*9.81+1000*9.81=9819.163N
Pmin=hook’s weight=9.1625=0 N
Ꚍ max=Pmax/2A=9819.163/(2π *7^2)=31.893 Mpa
Ꚍ min=0
Ꚍ m=15.946 Mpa , Ꚍ a=15.946 Mpa
Se`=0.5 Su=150 Mpa
Assume Kf=1.3
According to goodman: ((Kf*Ꚍ a)/Se)+(Ꚍ m/Su)=1/ns
(1.3*15.946/150)+(15.946/300)=1/ns
ns=3.22

9- Power:

From previous calculations we chose this motor for our application:

10- Drawings:
11- References: 1-Fineworks cranes. 2-Mazzella companies.
3-McMaster carr. 4-Lafia Lift. 5-shigley textbook.