MATERIALS HANDLING EQUIPMENT

LECTURE Three
Hoisting Equipment
Outlines
 Theory of hoisting equipment
 Flexible hoisting appliance
 Pulleys, sprockets, Drums and
 Load handling attachments
 Arresting gear and brakes
 Hoisting and travelling gear
By: Yonatan T.
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 Theory of hoisting equipment
• The hoisting is a device used for lifting or lowering a load
by means of drum or lift – wheel around which rope or
chain wraps.

• It may be done with a wide range of equipment from the

small hand operated simple screw or hydraulic – jack to
modern high powered cranes and elevators.

• It may be manually operated, electrically or pneumatically

driven and may use chain, fiber or wire rope as its lifting
medium.

• Hoisting equipment can be a stationary, portable or travelling.

• There are different types of hoisting equipment whose

accurate classification is difficult.
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Cont..
• There are three groups of hoisting having the
equipment following main distinctive features.
i. Hoisting machines
- a group of periodic action devices as self-
designed lifting
gears for hoisting and moving loads.

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Cont..
ii. Cranes
- a combination of separate hoisting mechanism with a
frame for lifting and/or moving loads

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Cont..
iii. Elevators
- a group of periodic action machine intended for raising
loads with guide – ways.

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Cont..
• The main technical parameters of hoisting machines
are:
– lifting capacity : the maximum safe load a machine
is
designed to handle

– Dead weight of the machine : the total weight

of the machine without load

– Speed of various movements: this may be the

hoisting speed, the bridge travel speed and the
trolley traveling speed

– lifting height : the height to which the load is intended to be

raised;
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 Flexible hoisting appliances
- Hemp – rope
- Welded loaded
chains
- Roller chain
- Steel wire ropes

Fastening of
chains and ropes Load handling attachments
- Hook’s
- Electric lifting magnets
- grabs
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 Flexible hoisting appliances
• The needs of hoisting machinery in flexible members are met
widely by hemp rope, welded and roller chains, and steel
wire ropes.
1. Hemp – Ropes
 Because of their poor mechanical properties (rapid
abrasion, inadequate strength, rapid damage from sharp
materials and atmospheric effects, etc), they can be recommended
only for hand- operated hoisting machinery (rope pulleys).
 The diameters of the sheaves over which the rope runs should be
at least 10d,where d is the nominal rope diameter.

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Cont..
• By the mode of manufacture and number of strands,
hemp ropes are classified as
i. plain-laid
ii. cable-laid
• The latter being from twisted from three ordinary ropes
twisted from three ordinary ropes.

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Cont..
2. Welded loaded chains
 They are widely used in hoisting installations as
flexible members.

 Depending on the ratio between the pitch and the diameter of

the chain bar, welded chains are classified into
i. Short – link chains with t ≤ 3d
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ii. Long – link chains By:
with t ˃ 3d
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Cont..
 Manufacturing accuracy divides welded chains into:
i. Calibrated – with permissible deviation from the
nominal size within t +/- 0.03d and B+/- 0.05d
ii. Uncalibrated – with permissible deviation from the
nominal size within t +/- 0.1d and B +/- 0.1d
 Links for welded chain are formed most commonly
hammer (forge) and electric resistance welding.
 Because of the short comings, welded chains are used only in
some hand – operated mechanism (where Dmin > 20d)
and in few power drive mechanism (where Dmin > 30d)
 They are employed for low capacity hoisting machines
(hoists,
winches, hand – operated cranes, etc)
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Cont..
 Advantage of welded chain
– Good flexibility in all direction
– Possibility to use small diameter pulleys and
drums
– Simple design and manufacture
 Disadvantages of welded chains
– Heavy weight
– Susceptibility to jerks and overload
– Sudden failure
– Concentrated wear at the link joints and
– Low safe speed f movement.
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Cont..
3. Roller chains
 Roller chains are composed of plates hinge – jointed by pins
and rollers.
 For light loads, two plates are used. For very heavy loads
the
number of plates can be increased upto 12.
 The maximum allowable speed of roller chain is V = 0.25m/s
 Roller chains are used for hand operated hoists, power –
driven winches and hoisting mechanisms of high load lifting
capacity, operating at low speed, if the weight is lifted
between guide – ways.

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Advantage of roller chains
Roller chains are superior to welded chains in a number of ways
such as:
- The reliability of operation is higher since the plates are solid.
- Roller chain have good flexibility
- The friction in the joints is considerably less than that in
the joints of welded chains.

But roller chains should not be allowed:

– To carry weight acting at an angle to the plate(to
prevent excessive wear and pin breakage)
– To be used in dusty premises (unless the chain is sealed
by
cover which would cause excessive wear)

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Cont..
4. Steel wire Ropes
 The steel wire ropes are extensively used in hoisting machinery
as flexible lifting appliance.
 The wire is drawn cold and given heat treatment as well
as chemical treatment between the drawing stages in order to
obtain required strength, structure, appearance and surface finish.
 They are most popular types used in hoisting machinery.
 Normally steel wire ropes consist of 6 or 8 strands and a core.

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Cont..
 Comparing to chains they have the following
advantages:-
– Lighter weight
– Less susceptibility to damage from jerks
– Silent operation even at high speeds
– Greater reliability in operation

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Cont..
 Non –spinning wire ropes
 Each individual wire strand being laid is performed to
correspond
and to its disposition in the rope.
 As a result of unloaded wires are not subjected to internal
stresses and tend to spin.
 Advantages of non – spinning wire ropes over the
general purpose ropes:-
- Uniform load distribution over the individual wires,
which
reduces internal stresses to a minimum
- Better flexibility
- Less wear of the wire ropes running over drum or sheaves
- Greater operation safety.
 The disadvantage of non- spinning wire ropes is that it is
more
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Cont..
4. Fastening of chains and Ropes
• Various methods are used to secure the ends of chains
and ropes.

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 Pulleys
• A pulley is a wheel on an axle or shaft that is designed
to support movement and change of direction of a rigid cable or
belt, or transfer of power between the shaft and cable
along its circumference.
• Pulleys are used in a variety of ways to lift loads, apply force,
and to transmit power.

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 Classification of pulleys
• Pulleys are either fixed or movable in design.
1. Fixed Pulleys
• Fixed pulleys are used to change the direction of the flexible
appliance.
• Disregarding the resistance of the pulley, the pulling force
Zo equals Q (weight to be pulled) I.E Zo = Q, without
considering pulley resisting.

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Cont..
2. Movable pulley
• Movable pulleys are used to gain mechanical advantage or speed/force.
• Movable pulleys are classified into two
a. Pulleys for gain in force:
• Used to increase amount of force applied and it doesn’t change direction
of the force.
• The distance that effort moves is double that of the load, and the speed at
which the load is raised is half of that of the effort.

Where

C= Speed of force
v = speed of load
s = distance the force
moves h = distance the load
moves
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Cont..

b) Pulleys for gain in

•speed
Used to increase amount of load speed and it doesn’t
change direction.
• The effort is applied at the axle of the pulley and moves at half the
speed of the load.
• The distance moved by the load is twice that of the effort.
ℎ
s= 2
𝑣
c= 2
Z=Q = So
Where C= Speed of force
v = speed of load
s = distance the force moves
h = distance the load
moves
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Figure : Single movable By:
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Cont..
3. Block and Tackle pulley
• A block and tackle is a pulley system made up of fixed
and movable pulleys.
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Cont..
Pulley Systems
• Several fixed and movable pulleys are combined in order to form
a pulley system for a gain in force or a gain in speed.

Figure: pulley system for a gain in Figure: pulley system for a gain in
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Sheaves Flexible hoisting appliances
• Used for ropes and - Hemp – rope
welded chains - Welded loaded
chains
Sprockets
- Roller chain
• Used for welded chains - Steel wire ropes
and
Roller chain
Drums
• used for Hemp rope and steel
wire ropes
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 Sheaves
• A sheaves is a pulley with a grooved wheel for holding belt,
wire rope or rope.
• A sheaves are grooved rims used for guiding ropes or chains.
• The sheaves are usually mounted freely on their axles.

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Cont..
• Rope life depends on the material of the groove.
• Practical experience goes to show that ropes operating over
steel sheaves wear down more rapidly than those used in
conjunction with cast-iron sheaves apparently due to higher
contact stresses and poorer conditions of slipping of the
rope over the steel sheave.
• To increase rope life, sheave grooves are lined with aluminum,
rubber, and plastics.

 Sheaves for welded chains:

– These sheaves are usually made of cast iron.
– They are mainly used for hand operated hoists and rarely they
are used for power driven devices.

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 Sprockets
• A sprocket or sprocket-wheel is a profiled wheel with
teeth, that mesh with a chain, track or
other perforated or indented material.
• As a rule , sprockets are manufactured with a small number of
teeth and are small in size ensuring compactness and low
cost of the driving mechanism
.

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Cont..
Sprockets for welded chains:
• Sprockets are used as driving chain wheels of hand
operated hoists and winches.

Sprockets for rollers chains:

• Sprockets are manufactured from cast iron and forged steel
casting.
• They are mainly used for hand- operated hoists and
winches.

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 Drums
• Drums is a grooved wheel on which the rope is wound in
more than one layer.
• During operation the drum is subject to the combined action
of
torsion bending and compression.
• The machined grooves increase the drum bearing
surface, prevent friction between the adjacent rope
turns and consequently reduce the contact stresses and rope
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wear.

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Cont..

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 Friction Drums of ropes
• Friction drums are rope – driving drums in which motion
is transmitted by friction between the rope and drum.
• They have the advantage of being able to raise loads for
great
height.
• Are used for winches and railway cars.
• Friction drums are capable of handling long ropes by means of
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a small drum.
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Cont..
• There are three types of friction drums
a) Simple friction drums
– They are provided with helical grooves for the rope,
which coil around in one or several turn.
b) Double drum friction drive
– In this case the rope is wound several times around
two parallel drums rotating in the same direction and
driven by a single motors.
c) Capstan
– Capstans are usually arranged vertically, driven
by electromotor through a worm gear drive and used to
move railways cars.

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 • Sheaves
• Sprockets
• Drums

Flexible hoisting appliances

- Hemp – rope
- Welded loaded
chains
- Roller chain
- Steel wire ropes

Fastening of
chains and ropes Load handling attachments
- Hook’s
- Electric lifting magnets
- grabs
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 LOAD HANDLING ATTACHMENTS
• The load is usually handled by many various
methods.

2019

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Cont..
• They are three most commonly used load handling
attachment
i. Hook’s
ii. Electric lifting
magnets
iii. Grabs
i. The
Hook’s
load is usually handled by means of chain or rope
• slings attached to hooks.
• One – piece forged hooks are used for lifting loads upto
100 tons while triangular and laminated hooks can be
employed to carry over 100 tons.
• Hook are forged from low carbon steel.
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Cont..
• In the process of production hooks are carefully annealed
after forging and machining.
• Generally hooks have trapezoidal section made wider on the
inside for better material utilization.

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Cont..
ii. Electric Lifting Magnets.
– Lifting magnets are used to handle magnetic materials
of diverse form (ingots, beams, rails, steel sheets and
plates, scrap, metal chips etc.).
– These drastically reduces the time required for
manual suspension of loads.
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Cont..
iii. Grabs
• These are the holding attachments which are special type of
buckets which mechanically grab and automatically dump
the materials.
• The grabs are designed considering the type of material to
be bold.

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 • Sheaves
• Sprockets
• Drums

Flexible hoisting appliances

- Hemp – rope
- Welded loaded
chains
- Roller chain
- Steel wire ropes

Fastening of
chains and ropes Load handling attachments
- Hook’s
- Electric lifting magnets
- grabs
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 Arresting gear and brakes
Arresting Gear
• Arresting gear is used to hold the being lifted
without interfering in the hoisting process but preventing the
load from coming down due to gravity.
• They are three most common arresting gear types:-
i. Ratchet gearing
ii. Friction arresters
iii. Roller ratchets

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Cont..
i. Ratchet gearing
• Ratchet gearing consists of ratchet gear and pawl.
• The teeth in the ratchet(internal teeth or external teeth) and
so arranged that the ratchet gear runs free when the load is
being raised.
• The pawl engaging the ratchet assist its motion when the load
is being lowered.

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Cont..
ii. Friction Arresters
• Friction arresters operate noiselessly compared to the operation
of toothed arresting gear.
• However, the pressure on the pawl pivot and shaft is
considerably high. They have a limited application.
• Toavoid unidirectional action, the arrester is always
provided with two pawls arranged at diametrically opposite points.

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Cont..
iii. Roller Ratchets
• This mechanism arrest the load within a minimum distance.
• The whole system relies on friction for its successful operation.
• A roller wedged between the follower and the driver
is subjected to the action of normal forces N1 and N2 and
tangential friction forces µ1N1 andµ2N2.
• With the roller in equilibrium, the resultant force R1 = R2. for
equilibrium N1= N2

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 Brakes
• A brake is a mechanical device that inhibits motion by
absorbing energy from a moving system.
• It is used for slowing or stopping of moving vehicle, wheel
axle or to prevent it’s motion, most often accomplished by
means of friction.
• In hoisting machinery, brakes are employed for controlling
the speed of load lowering and holding the suspended load at
rest.

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Cont..
• Depending on the purpose, brakes can be classified as
i. Stopping brakes – These bring the drive at rest at
the end of motion.
ii. Regulating brakes – These are serving to maintain
the
speed of motion within prescribed limits.

• From operational aspect they can be classified as

i. Automatic brakes – These brakes are
applied automatically irrespectively of the operator’s
will at the- instant the motor of the mechanism is de-
energized.
ii. Controlled brakes – These are set and released by
the operator irrespectively
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 Hoisting and Travelling Gear
– In any lifting drive the hoisting mechanism is considered to
be the vital element.
– Hoisting mechanisms are subdivided into three groups
a) Hand power drives
b) Individual power drives
c) A common drive for several mechanisms

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Cont..
a) Hand power drives
• A hand drive" is employed in mechanisms with a low lifting
capacity, or where the load has to be moved a short distance,
or for occasional lifts;
• Application area of Hand drives are:- winches with small
lifting height, in jacks, and sometimes in travelling overhead and
gentry cranes and in light-duty rotary cranes.

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Cont..
b) Individual electric drives
• An electric motor driven hoist has one or two rope
drums for coiling and uncoiling the hoisting wire rope.
• The hoisting motor drives the drum through a
planetary gearing system.
• Electrically driven cranes designed to handle up to 2000
tons are available. The drives can be hydraulic drive ,
pneumatic drive , diesel electric drives etc.

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Cont..
 Electric motor is generally in hoisting
installations
preferred owing to the following advantages.
most
1) Immediate readiness for operation.
2) Possibility of driving every motion by a separate
3) motor.
Higher economic efficiency as with other
compared drives.
4) The ease of speed control over a wide range.
5) Convenient reversing of motions.
6) Safe operation, simplicity of and
construction,
reliability of safety devices. high
7) Ability to cope with short-timeoverloads of
significant magnitude.
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