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PART TWO

1 Mamaru w. & Agmuas A. 07/07/2023

 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 (IF WIRE NOT DEFLECTED)

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 (IF WIRE DEFLECTED)

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 rope-from torque rule ;

 M  0 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
( Z ) F  Q1  
6
 R cos  
Resistance due to friction Resistance due to friction
P  Q  F0  2Q


Resisting moment due to frictional
 resistance is
d'
 M  P 
2
Frictional resistance in bearings:
e
e
P d
d' d'
N  Q  Fo    Q  
z(zo) 2R R
Q
where,
The Deflection of the Wire d’=pulley axle diameter
7
Rope on a Pulley
 = Coefficient of friction
 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  
Z
Where  is the pulley efficiency and, Q is called pulley factor of resistance.

WHERE
2e is stiffness or rigidity of rope and it can be empirically determined by experiment and was
R cos  found to be

2e d
 0.1
R cos  D  10
Where, d=rope diameter and ,
8
D= pulley diameter
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 Resistance : F + So = Q ,
c F =  So =  (Q –F),
F = Q -F
 Q
F Q F 1 
v 1   o  2 
F  2
h
Q
Q s=2h 1 
Where,
for Q ,   1.05   0.975
c=2v zo 
2
 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
 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  1 n
   1
S1 S 1 S1  
 S1   2    n 1  n 1    1 
  
1 1   n 1
 S1 n 1
 n 1
  n2      1    n  
  z   1 

 EXAMPLE
It is required to determine the power requirement of the electromotor used in
the operation of the elevator Given that - Cabin weightF ( A ) = 800kg, Counter
weight ( FC ) = 450kg, Tensioner ( FT ) = 1820kg,Pulley diameter ( D) = 500mm and
Velocity (V) = 0.75 m/s. Determine the power requirement
i). Neglecting the rigidity of the wire rope
ii). Considering the rigidity of the wire rope. Take e=5mm) C m 

Finally, compare the power requirements obtained in both cases. O r1

FA
Fc

O2

FT
 SOLUTION:

a) the system configuration without considering the stiffness of the power rope and taking into
account the rigidity of the wire rope may be schematically represented in fig. bellow.

Cm
O1 r

F1 F2 Cm

e e O1 r

FA
Fc

O2 O2 r e e

F3
FT F4
FT

a) b) c)

15
|. Neglecting the rigidity of the wire rope ||. Considering the rigidity of wire rope, the value
In the lower pulley with tensioner fig.a Of e may be safely assumed to be equal to 5mm.
F1+F2=FT On the lower pulley with tension fig.a
-FT(r)+F2(2r)=0
F1 +F2=Fr
F2=8927N
F1=FT-F2=8927N Ft*(r-e)+F2*(2r)=0
Further more from fig.d F2=8749n
F3=FA+F1=16775n F1=9106n
F4=Fc+F2=13341n From fig.d we have,
Taking moment about o1, F3=Fa+F1=16954n
F3*r-cm-f4*r=0 F4=Fc+F2=13164n
After inserting the value and solving cm, we get
Taking moment about center of the above wheel,
Cm=858.5nm
F3*(r+e)-cm-F4*(r-e)=0
V=w*r
W=v/r=0.75/0.125=6rad/s From which, cm=1098nm
The required power cm*w=5151 watt=5.2 kw W=v/r=0.75/0.125=6rad/s
The required power cm=6588watt=6.6kw

16
 CONT’D

• Comparing the two values obtained, we can clearly see

that the power requirement has increased by about
20% when the rigidity of the wire rope is taken into
consideration.
DESIGN OF SHEAVES AND SPROCKETS
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

Where: Dmin  e1  e2  d
e1= factor depending on the hoisting device
and its service table, 4.2
e 2=factor depending on the rope
construction table, 4.1
d = wire rope diameter
 .
.

19 Mamaru w. & Agmuas A. 07/07/2023

 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
Sheaves are freely mounted on roller bearings of
bronze bushing.
The bushing of the sheaves can be checked for unit
pressure by:

Q
p
d .l Where
l =length of bushing
d=diameter of the sheave axle
Q=acting load
 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
 .
.

24 Mamaru w. & Agmuas A. 07/07/2023

 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

Where,
σ In=internal stress
σ Out=external stress
Pin=internal pressure
S
w Pout=external stress
S do=internal diameter
D=outside diameter
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 p out 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 = 230 kgf/cm2
For cast iron
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

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.
S1 S1 S1
S1 S 3   S n   ; S n 1  
S2 
e   12 ; e  n
e 
1 ; e   n 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
Where,
n = the number of turns
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0.5a 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  e2 ;

r  0.5 a  h  e2 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 P1 Ql
M bend   P1 x

w

A
  all
;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  e2 2
;
Q 
P1  tan
2 2

where e1 = distance between the neutral axis

and the fibers carrying the greatest load.
 CONT’D

For an ellipse,
2 4 6
1 a  1 a  5 a
x        
4 R 8 R 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.

t 

p D2  d 2  Whe p
Q
re , 
D2  d 2 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  d1 
M max      
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 b 2
h d2 2
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
EXAMPLE

Selecting by calculation the ropes, pulleys and drum required for an electric overhead
traveling crane With a lifting magnet of the hoisting equipment shown bellow in fig.
Given data:
Lifting capacity, Q=5000KG
lifting height, H=8M
weight of lifting magnet, G=2000KG
weight of lifting tackle, Go=120KG
number of rope parts, Z-4 2
medium service duty

50
51
52
53
54
55
Example 2 ( refere to the text book)
Which is permissible.
Assignment

61