Stage Winch Design Techniques

Motor Winch Physics

Dan Eslinger Dan Eslinger Assistant Technical Director Assistant Technical Director Seattle Repertory Theatre Repertory Theatre

Sample Winch Design Application:

Rules of thumb: Velocity: 3 ft/sec standard top speed 4 ft/sec for fast applications Acceleration: 1 ft/sec2 4 ft/sec2 Decide how long for it to reach top speed.

Wagon: 3000# Max velocity: 3.5 ft/sec Acceleration: 2 ft/sec2 Casters: 6 diameter soft rubber running on a flat wood deck.

Wagon: 3000#

v: 3.5 ft/sec

a: 2 ft/sec2

6 diameter soft rubber casters

First, find the Force required to move the wagon: Forcetotal = Faccel + Ffriction + Flift

Faccel = m a Faccel

m : mass =

weight 32.2ft/sec2

3000 # = 2 ft / sec 2 = 186.3# 32.2 ft / sec 2

Frolling friction

N r = rc

N: normal force, perpendicular to motion, here: the load r: casters coefficient of rolling friction hard rubber on wood: 0.003 soft rubber on wood: 0.008 rc: radius of caster

3000 # 0.08" Ff = = 80 # 3"

Ftotal = 186.3# + 2 80 # = 346.3#

Double the friction to be safe.

Wagon: 3000#

v: 3.5 ft/sec

a: 2 ft/sec2

6 diameter soft rubber casters

Force to move wagon: 346.3# Size the Motor (hp):

1hp =

Power 550lb ft / sec

Power = F v = 346.3# 3.5 ft / sec = 1212lb ft / sec

hp = 1212lb ft / sec = 2.20hp 550lb ft / sec
Round up to 3 hp motor. sample: 1750 rpm

Size the Drum: at least 30 times the cable diameter.

"

cable : 1

30 = 7.5" min. drum diameter 4

"

Choose 8 diameter drum.

circumference = d = 8" = 25.13" = 2.09'

Wagon: 3000#

v: 3.5 ft/sec

a: 2 ft/sec2

6 diameter soft rubber casters 2.09 per drum rev.

Force to move wagon: 346.3#

3 hp motor 1750 rpm

Size the Reducer & Sprockets: match desired top speed (3.5 ft/sec)

speed =

3.5ft 60 sec 1rev = 100.48 rev at drum min sec 1 min 2.09ft
Choose 15:1 reducer.

1750 motor rpm = 17.42 reduction needed 100.48 drum rpm 17.42 = 1.161 reduction needed in sprockets 15

Drum sprocket teeth = 1.161 x reducer sprocket teeth. e.g. 12 teeth on reducer & 14 teeth on drum.

Wagon: 3000#

v: 3.5 ft/sec

a: 2 ft/sec2

6 diameter soft rubber casters 2.09 per drum rev.

Force to move wagon: 346.3#

3 hp motor 1750 rpm

15:1 Reducer 12 teeth 14 teeth sprockets Verify Amount of Torque:

hp =

rpm 5252

T: torque in ft lbs

1750 = 9.0 ft lbs 3= 5252

drum = motor gear reduction effeciency sprocket reduction

15 14 teeth = 126 ft lbs = 1512 in lbs at drum = 9.0 ft lbs 80% 1 12 teeth

drum = Fcable rdrum 1512 in lbs = Fcable 4" Fcable = 378#

> 346.3

Force is great enough to move wagon!

Compact Manual Winch

Loren Schreiber Technical Director
San Diego State University

Compact Manual Winch Price List

Item Drive Pulley Drive Gear Drive Gear Bushing 5/8" Shafting Acme Nuts (2) Acme Coupling Nut Acme 1 X 10 Screw Thrust Bearing Bearings (4) Tension Pulley (2) In-feed Sheaves (2) Shoulder Bolt Shoulder Washers Shaft Collar Keyless Bushing Misc. Steel Misc. Hardware Vendor Martin Sprocket Martin Sprocket Martin Sprocket Martin Sprocket McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr McMaster-Carr NA NA Part Number 3 3V 1060TB C16160 S1664 2517-5 1497K41 94815A118 93023A680 98935A866 60715K15 6361K21 9466T89 9466T83 91264A798 91140A266 6166K29 5926K18 NA NA Total: Cost $92.01 $80.82 $36.76 $17.83 $26.94 $9.28 $16.30 $19.00 $15.28 $118.20 $25.88 $17.04 $4.70 $7.75 $0.97 $32.76 $25.00 $10.00 $556.72

Less Gears: $380

Jon Lagerquist
Technical Director South Coast Repertory Theatre

Hand crank winch with pneumatic disc brake

Disc brake detail

Square shaft end for removable crank

Winch for chain driven turntable

Cable tension device with welded end

Torque tamer (Dodge) with quick pins for disconnecting sprocket from shaft

Winch farm on midrail

Design for new winch yet to be built

Friction Drive Winch

Chris Fretts Technical Director
Indiana Repertory Theatre

Friction Drive Winch

Motorized or manual operation Does not use a Grooved Drum Uses a keyed four groove Multi-sheave above and five idler sheaves below Cable is either an endless loop or both ends terminate at wagon

Drive: 2HP Motor with 25:1 Gear Reducer Motor Output: 1750 RPM Gear Reducer Output: 70RPM Top Cable Speed: 3ft./sec. Shafts: 13/16 Roller Chain: #50

Operation of the winch can be changed from motorized to manual by shifting the roller chain from the sprocket on the Gear Reducer to the idler sprocket on the motor mount. By pulling the lower pins on the mount and pivoting the motor mount on the upper bolts, the roller chain can be shifted to the idler.

A handle for manual operation can be attached to either end of the two shafts on the top of the winch unit. In its current configuration, we have installed a additional 1.5:1 output reduction with the installation of a 20 tooth and 30 tooth sprocket on the two top shafts. This allows some choice of mechanical advantage if the winch is operated manually. This additional reduction decreases the motorized top cable output to 2ft./sec.

Proper tension on the drive cable is controlled by drawing back the idler sheave assembly on the two threaded rods. This is done by using an impact wrench on the welded nuts on back end of each threaded rod.

A rotary encoder is attached with #25 roller chain and sprockets to the drive sheave to enable positioning control with our PLC system. This can be interchanged with a mechanical counter if needed for manual operation

Major Parts List

Baldor # 2HP Motor #VM3558T ebay Buy it now price $120 25:1 Gear Reducer #GF2532BG ebay Buy it now price $199 Grainger # Pillow Blocks (4) #5X685 Multi-sheave 11.25OD #2L371 Sheave 7OD (5) #3X923 #50 Roller Chain 10 #2W095 15 Tooth #50 Sprocket (3) Varies with Bore 30 Tooth #50 Sprocket # 6G021

www.surpluscenter.com Friction Drive Winch

Indiana Repertory Theatre

Peter Pan Winch

Developed and designed by Stephen Henson at California State University Fullerton

with special thanks to Bill Meyer, Matthew McKinney and Scott Shiba for various creative influences during the process of development

Prototype winch -Form followed function purely -Used with a sprocket instead of three-grooved sheave, for direct chain-drive -Two plates punched to be bolted to the gear box, welded to a cross member punched for hangers Version 2.0 winch -Rotated motor 90 degrees -Added two vertical angle irons for pushing motor away from batten -Allowing for three-grooved sheave with a double sheave hung above directly from batten (not shown) -Crudely mounted mule blocks for directing cables along batten to scenery -Rotary Limit Switch and Junction box mounted to motor mount

View of completed winch frame

-Top plate is designed to facilitate standard Batten hangers, as well as suspend a swivel double sheave -Slotted flat bars accommodate multiple positions for head blocks as well as twisting into alignment with three-grooved sheave -Center plates are punched accordingly for mounting gear box with encoder and motor suspended from gearbox -Bottom of frame has additional steel structure for mounting rotary limit switch and junction box containing RJ45 connectors. -Head block assembly is punched with extra holes to allow for flexibility with parts

CAD MODEL IMAGES

Matthew McKinney
Graduate Student San Diego State University

Frankenwinch

Traveler winch Built from equipment on hand 2HP AC Vector Motor Drive Mounted to winch Massively over powered (Opera Capable) Cost: Priceless

Winch hanging from

Shipping Crate Top is removed to attach directly to batten and lift out of box

Bill Meyer
Technical Director Cal State Fullerton

Basic 1 HP DC Winch with dolly and strap Frame design version 8ish Setup to be used in either direction

Winch box/case with carpet sound profingish Built as a Parallel

Top Easily removable for adjustment and inspections Gaps at both end for cable in / cable out

Breaks down for easy storage

Old version with jack shaft with squared end for hand crank

New version without hand crank option but holes punched if necessary (And they werent necessary)

Set Screw for adjustment of chain tension

Cable clamp x 1 bolt with 7/32 hole

Cable tensioning device All-thread and removable guides

Complete pillow block, drum, sprocket and shaft assembly for ease in changing between endless cable and drum setups

Endless cable turntable winch

Easy access limit switch location

Good location and labeling for limit and encoder connections

A list of winch prices for a 1 1/2 HP DC winch 180 v DC 1 1/2 HP motor Grainger 4Z379 $480.00 Gear reducer w/ base Grainger 1L426 $360.00 Dynaper Series R45 Encoder # R4500602222 $285.00 Furnas Rotary limit switch 72:1 54EB23FC $360.00 Chain & Sprockets Grainger $125.00 1 1/4 shafts, pillow blocks, $125.00 10 d grooved drum x 11 long Est. $550.00 6 sheaves for Tension assembly @ $50.00 each 3 Groove Sheave w/ hub for Turntable drive $150.00 Misc Hardware, bolts, all thread etc $75.00 Misc Electrical $48.00 Steel for frame $30.00 TOTAL $2464.00

Variations on a Theme

San Diego State University Stock Winch 5HP AC Vector Drive Drive Mounted on Winch
Shorter Encoder Cables Shorter Limit Cables

Creative Conners Control System MCued Servo System

Drive Line Reactors Brake Resistor E-Stop Relay Amp Enable Relay Disconnect Embedded Controller

Dan Eslinger
Seattle Rep Standard 5HP Winch

Seattle Reps 5HP Winch

Slick Features:
Cable Tensioning Drive Chain Tensioning Overtravel Limits & Encoder Built-in

Seattle Reps 5HP Winch

Equipment
Motor Reducer Drum Sprockets Chain Sheaves Sheave Shaft Threaded Rod Pillow Blocks Rotary Limits Encoder Limit Enclosure Limit Gearing Steel Frame Hardware

Specs
Baldor 5HP 3-phase AC, 1725 rpm, 184 TC Grove Gear 20:1, dual shaft right angle 25-tooth on reducer, 30-tooth on drum, #60 chain #60 + connecting links, etc. McKissick 6-1-B, 1 1/4" bore bushing, 6" dia. 1 1/4" cold rolled steel 3/4-10, 36" drum: Browning VPS 228 sheave shaft: Browning 1A116 VF2S 100 series Albrect #589W switch assemblies 12F9766 10K Potentiometer (being replaced) NEMA 1 enclosure spur gears & belt 2"x2"x3/16" angle, 1/4" x 4" strap Bolts, nuts, etc $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ Total $ 12" Sch.80 pipe, 9" wide, grooved for 1/4" cable $

Cost
255.00 560.00 1,250.00 65.00 30.00 65.00 9.00 9.00 38.00 23.00 295.00 95.00 26.00 4.00 40.00 40.00 12.00 2,816.00

Limit & Enc.Plugs 3-pin & 4-pin XLR

Seattle Reps 5HP Winch

Stirling Shelton
Technical Director Cincinnati playhouse in the park

www.fishertechnical.com

& Spiderman 2
Joseph Champelli Professor of Entertainment Technology University of Tennessee

www.fishertechnical.com

Typical FTSI flying winch

900 feet/minute)

rated for 500 lbs @ 15 fps (4.5 meters per second -

2006 Fisher Technical Services, Inc.

www.fishertechnical.com

FTSI flying winch for the film Spiderman 2 300 lbs @ 43 fps (2580 fpm, ~30mph)

2006 Fisher Technical Services, Inc.

www.fishertechnical.com

Design
2006 Fisher Technical Services, Inc.

Details
Parts List:

www.fishertechnical.com

SEW Servo Gearmotor 16 Diameter Drum Dual coil holding brake Custom Control Enclosure

2006 Fisher Technical Services, Inc.

www.fishertechnical.com

Assembled Drive Train

2006 Fisher Technical Services, Inc.

www.fishertechnical.com

Controls

2006 Fisher Technical Services, Inc.

On location in NYC

www.fishertechnical.com

2006 Fisher Technical Services, Inc.

On location in NYC

www.fishertechnical.com

2006 Fisher Technical Services, Inc.

On location in NYC

www.fishertechnical.com

2006 Fisher Technical Services, Inc.

Winches on Truss

www.fishertechnical.com

2006 Fisher Technical Services, Inc.

www.fishertechnical.com

& Spiderman 2

Standards for Winch Design and Fabrication

ESTA: E1.6-1 watch for public review in 2006 German:

www.esta.org

BGV C1
www.vplt.org/en/index.html

BS 7905-1:2001
http://www.ihs.com.au/standards/bsi

Website

www.creativeconners.com

Email info@creativeconners.com. Phone 401.862.2980 Mail Creative Conners, Inc. 48 Wabun Ave. Providence, RI 02908