PULLEYS, SPROCKETS, DRUMS

&
LOAD HANDLING ATTACHMENTS
INTRODUCTION

• Pulleys are either fixed or movable in design.

• Fixed pulleys: are used to change the direction
of the flexible appliance while
• movable pulleys: are used to gain mechanical
advantage or speed.

Single Fixed Pulley

FIXED PULLEY

• Theoretically, Z 0  Q but due to the pulley

resistance, being partly due to the stiffness
of wire rope and partly due to frictional
resistance in the bearings Z 0> Q,.
FIXED PULLEY

a. Due to the stiffness


of the wire

b. Resistance due to Total pulling

friction force
c. Live load
e
e
P d

z(zo) Q

The Deflection of the Wire

Rope on a Pulley
Due to the stiffness of the wire

R cos   e Q  R cos   e F
 F R cos   e


Q R cos   e

e
1
R cos 
e
e 
P d e
1
z(zo) R cos 
Q

The Deflection of the Wire  2e 

Rope on a Pulley
F  Q1  
 R cos  
Resistance due to friction

P  Q  F0  2Q

d'
 M  P 
 2
d' d'
N  Q  F     Q
e
2R R
e
P d

z(zo) Q

The Deflection of the Wire

Rope on a Pulley
 CONT’D
Total pulling force

F  Q1  resistance due to regidity  resistance due to friction 

 2e d'  F 2e d'
F  Q1        1 
 R cos  R Q R cos  R

1



2e d
 0.1
R cos  D  10
MOVABLE PULLEYS
a. Pulleys for gain in force:
Single Movable Pulley for a Gain in Force
Where: c = speed of force
v = speed of load
s = distance the force moves
Z(Z)
h = distance the load moves
0

s 0

s s=2h
c
c=2v
F + So = Q , F =  So =  (Q –F)
v
F = Q -F
h Q
Q
 F
 o  2 
1 
F Q F  2
1  Q
1 
 CONT’D
b. Pulleys for gain in speed

h
s
v
2
h z(z) v
c
0

s
2
0
s
Q
c
F  Q  S 0  Q  Q  Q1   
Single Movable Pulley for
Fo 2Q 2
a Gain in Speed   
F Q1    1  
 PULLEY SYSTEMS
Pulley systems for gain in force
Rope running off a fixed pulley
• The number of parts of the line on which the weight is
suspended is also equal to the number of pulleys z.
• The transmission ratio i of the system is equal to z.
 CONT’D

z(z)
0 z(z) 0

s 2 s 1 s 1 s 2 s 3

Q
Q
1 n 1
Q  S1 
Total tension in the rope  n 1  1
Q  S1  S 2  S 3    S n Q n   1 
F  S1   Q  n 
1   n 1    1
S1 S 1 S  
 S1   2    n11  n 1    1 
  
1 1   n 1
 S1 n 1
 n 1
 n2
   1    n  
  z   1 

DESIGN OF SHEAVES AND SPROCKETS
Rope sheaves
• The minimum diameter ( Dmin) of the sheave should be
at least ten times the diameter of the hemp rope.
Whereas Dmin for wire rope should be
Dmin  e1  e2  d
• Where: e1= factor depending on the hoisting device
and its service
e 2=factor depending on the rope
construction
d = wire rope diameter
 CONT’D

2 tan 
tan  max 
D
1
0.7 K
 max is the allowable angular
deviation of the wire rope

h=1.5d to 2d
 CONT’D
• Depending on the peripheral velocity of the sheave
hub hole surface, unit pressure should not exceed the
following values:

V[m/s] 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

P[kgf/cm] 75 70 66 62 60 57 55 54
V[m/s] 0.9 1.0 1.1 1.2 1.3 1.4 1.5 -

53 52 51 50 49 48 47 -
P[kgf/cm]
 CONT’D
Rope Drums
Drums for steel wire rope are made of cast iron.
Helical grooves are always used for wire ropes.
Number of turns on the drums (z)

Hi
z 2
D
i = ratio of the pulley system
D = drum diameter
H = height to which the load is raised
The value 2 in the equation is added to account for the idle (or holding) turns
 CONT’D
• Length of the helix on the drum:

l  zt
• Leaving a length of about 5t for both sides flanges,
the full length of the drum L is:
 Hi 
L  7 t
 D 
•If two ropes are coiled on the drum, the full length of
the drum will be
 2 Hi 
L  9 t  1
 D 
 CONT’D

• The wall thickness of cast iron drum can be

approximated by using the following formula:
w= 0.02D  (0.6 to 1.0) cm

• Strength of the Drum: During operation the drum is

subjected to the combined action of torsion bending and
compression, where the effect of the latter is much
larger.
 CONT’D
p

S
w

From Lames formula: At the inner surface

D 2  d0 2 D2
 in  p in 2
 2 p out
D 2
 d0 D 2  d0 2
At the outer surface
D 2  d0 2 D2
 out  2 p in 2
 p out
D 2
 d0 D 2  d0 2
 CONT’D
Considering the forces in we have:

pin = 0 , pout = p , do = D  2 w

D2
 in comp   2 pout 2
D 2  d0
 CONT’D
Allowable compressive stresses:

For cast iron 15-32  all= 1,000 kgf/cm2 cast steel

Cast steel  all= 1,600 kgf/cm2 welded drums (St 42)
welded drums  all = 1,800 kgf/cm2
(St 42)
Allowable bending stresses:
 all
For cast iron = 230 kgf/cm2
Steel casting  all= 1,800 kgf/cm2
Welded drums  all = 1,400 kgf/cm2
FRICTION DRUMS
• Friction Drums for Ropes: are rope-driving
drums in which motion is transmitted by
friction between the rope and drum. There
are three types of friction drums.
a. Simple friction drums are provided with
helical grooves for the rope, which coils
around them in one or several turns.
 CONT’D
s 1 s 2

Gear Pinion

s
s
1
2

S1
Friction drum

Single Friction Drum

S1
 e  2 n S1
S2 where  on coming force
S
2  running off (can be regulated by hand)

μ  coefficient of friction
peripheral force on drum n  number of coils
F  S1  S 2 e  2.718 the base of the natural logarithm
 CONT’D
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 motor.
S S1 S1
S2 
S1 S 3   1 2
e 1
S 
; n e    n 1 ; S n 1  
e  n
e   1 ;
s 1 sn+1

s 1

sn+1

Double Friction Drum I II

 CONT’D
Total peripheral force on both drums
F  S 1  S n 1
The load on drum shaft I is QI  S 1  S 2  S 3    S n

on drum shaft II is Q II  S 2  S 3  S 4    S n 1

d
Losses in the bearings are W  Q I  Q II  1
D

Where, 1
= coefficient of friction in the bearings
d = diameter of the bearing journal
D = diameter of the drum.
 CONT’D

The total efficiency of the drive is

S1
 
F W
 CONT’D
c. Capstan: are usually arranged vertically, driven by an
electromotor through a worm gear drive and used to
move railway cars.

S1 s

S2 
2

s 1

 2 n
e
LOAD HANDLING ATTACHMENTS

• The load is usually handled by means of chain

or rope slings attached to hooks of which the
two most popular designs are standard (single)
and Ramshorn (double) hooks.
 CONT’D
Forged Standard Hooks
 CONT’D
Hook Dimensions
• For the shank:
4Q
t  2
  all  500kgf/cm
d 1

The unit stress on the saddle of the hook.

Q M M 1 
     
A Ar Ar x   r
 CONT’D
r  R2  R2 
  1   b2  b1  b2   ln  b1  b2 
A  d  R1 

1 y
A yr
 dA

R2
M  Q .r  Q0.5 a  e1  R1

d
d2 d1

The Critical Cross-section I-II b2 b1

r
Tensile Stress in the Inner Fibre

Substituting
M  Q0.5 a e1  r  0.5a  e 1 Y  e1 and h=a

Q Q 0.5 a  e1  0.5  e1   1  y
I   Q
 r Ar  yr

Q  0.5a  e1   1 y 

 1   1   
A  r   y  1 

Q 1 2e1
I      safe all - maximum tensile stress
A x a
 Compressive Stress in the Outer Fiber
Substituting
M  Q 0.5 a  e1  ; r  0.5 a  e1 ; h  e1  e 2 ;

r  0.5 a  h  e 2 and y  e2

Q 1 e2
 II    
A  a
<  all maximum compressive stress
h
2  all should not exceed 1500 kgf/cm2.
Solid Triangular Eye Hooks
• Solid triangular eye hooks are usually employed in
cranes with high lifting capacity (over 100 tons) and
occasionally in medium power cranes.

Bending moment in the bow (from investigation):

Ql
M1 
6
Bending moment where the sides adjoin the bow
Q
M2 
13
 CONT’D

Solid Triangular Eye Hook

 CONT’D
Tensile force acting on the sides:
Q
P

2 cos
2
Compressive force P1 acting on the bow is
Q 
P1  tan
2 2
Maximum stress in the bow
M bend P Ql
  1   all M bend   P1 x
w A ;w 6
= Sectional modulus[cm3]
W
here A = Cross-sectional area [cm2]
x = moment arm of the compressive force
 all = 800kgf/cm2
Hinged Triangular Hooks
• Unit stress in the links (assuming the bow in
suspended on four links)
Q
t 

4 cos  A'
2
Three-Joint Built-up Hooks
 t ,all =1,200 kgf/cm2
 CONT’D
The unit stress in the bow (assumed as a curved beam)

p1 M M e1 Q
    M   P1  x
A AR xAR R  e 2 2
;
Q 
P1  tan
2 2

where e1 = distance between the neutral axis

and the fibers carrying the greatest load.
 CONT’D
2 4 6

For an ellipse, 1 a  1 a 
x      
4 R 8 R
5 a
 
64  R 

Where a is the major axis of the ellipse or the diameter of a

circle. The shank eye stress is check by Lame Formula.

p D 2  d 2  Whe Q
t  p

D2  d 2 re , 4 cos bd
2

b = eye width
Crosspieces for Hooks
The crosspiece is forged from steel and provided
with turned trunnions at the ends.

Crosspiece for Hooks

 CONT’D
The maximum bending moment is
 Q Q d1 Q  d 
M max      1 
2 2 2 4 = 4  2 
M max
b 
W I h
where W = section modulus  ; c
c 2
1 bh 3 1 d2h3
W  -
12  h  12  h 
 
2  
2
h 2b h2d2 h2 6 M max
  = b  d 2  , b    all
6 h 2 b  d 2 
6 6
 all = 600 – 1000 kgf/cm2 for carbon steel