7 T Manual Rope Drum Hoist R1
7 T Manual Rope Drum Hoist R1
7 T Manual Rope Drum Hoist R1
foroperationofUnderSluiceGateofWajooNallah
1.0 GeneralDescription
An manually operated Rope drum hoist of 7 t capacity is provided for operation of
Under Sluice Gate for Check dam on Wajoo Nallah. The hoisting mechanism mainly comprises
of central drive unit having an manual reduction and worm reducer. Two end gear boxes,
p gear
each with one sets of spur g p
/ pinion p drum are connected to the gate
and a rope g byy rope.
p
One end of the rope is fixed to the drum and other end after passing over gate pulley is
connectedtohoistbridgestructure.
2.0 TechnicalDetails
Number of Hoists
NumberofHoists 4 Nos
HoistCapacity 7t
Totallift 9m
TypeofHoist RopeDrumHoist
3.0 EfficiencyoftheSystem
Efficiency
SlNo. Components Type Pairs
St ti
Starting Running
R i
i RopeDrum Bush 1 0.93 0.95
ii Pulleys Bush 1 0.93 0.95
iii Gear/Pinion Spur 1 0.93 0.95
iv CentralReduction Spiral 3 0.95 0.97
OVERALLEFFICIENCY 0.69 0.783
StartingSystemEfficiencywithoutpulley 0.742
RunningSystemEfficiencywithoutpulley 0.883
4.0 Materials
Shafts IS:2004
2
YP 3264 Kg/cm
UTS 6324 Kg/cm2
2
BendingStressWithoutKeyway(0.2*UTS) 1264 Kg/cm
2
BendingStressWithKeyway(0.75*0.2*UTS) 948 Kg/cm
2
ShearStressWithoutKeyway(0.3*YP) 979 Kg/cm
2
ShearStressWithKeyway(0.75*0.3*YP) 734 Kg/cm
2
EquivalentBendingStress(1.2*0.2*UTS) 1517 Kg/cm
Equivalent Shear Stress (1.2*0.3*YP)
EquivalentShearStress(1.2 0.3 YP) 1174 Kg/cm2
2
CombineStressforBendingandTorsion 1517 Kg/cm
(0.6*YPor0.24*UTSwhicheverisless)
NoofDrums
oo u s 2
NoofFallsoneachsiden 2
W 1
MaximumRopeTension T=
1
n
2
FactorofsafetyunderNormalcondition 7.6
>6Hence,OK
60
6.0 Rope Drum
RopeDrum
RopeDiameterd 16 mm
ThicknessofDrum@bottomofGroove(minCS16&CI20mm)t 16 mm
MaterialForRopeDrum CastSteelIS:1030Gr230450N
2
Having YP 230 Mpa 2346 Kg/cm
2
UTS 450 Mpa 4590 Kg/cm
2
PermissibleCompressiveStresses(N) 918 Kg/cm (AsperCl4.3.3.1ofIS:6938)
2
PermissibleCompressiveStresses(BDT) 1876.8 Kg/cm
2
CrushingStrengthofDrum(Normal) 606.42 Kg/cm
2
< 918 Kg/cm HenceOK
NumberofTurnsondrum
Lift FallEachSi de
NoOfTurn
DrumP.C.D.
TotalnoofGroovesonDrum 18 Nos.
GroovedLengthofDrum 333 mm
Adoptoveralllengthofdrumas 450 mm
Corediameterofdrum 352 mm
TurnDiameterofDrum 396 mm
Pitch
FleetAngle = tan 1
PCD
FleetAngleofGroovesondrum 0.843 degree
<5,HenceOK
FleetAnglewhenthegateis@Top FleetAnglewhenthegateis@Sill
100
00 mm 233
33 mm
1500
mm 9000 mm
6.2 BendingStressinDrum
Normal
BendingMomentinDrum(rope@centre) 20193.75 kgcm
SelfweightofDrum(Approximate) 250 Kg
3
SectionModulusofDrumZ 1633.9633 cm
2
BendingStressinDrum 13.22 Kg/cm
6.3 TortionalStressinDrum
2
TortionalShearStress 11.57 Kg/cm
2
CombinedEquivalentStresses 607.01 Kg/cm
2
< 918 Kg/cm HenceOK
6.4 DesignofGearWheel&DrumConnectionbolts
ate a o o ts
MaterialofBolts C ass 8 o S 36
Class4.8ofIS:1367
2
Having YP 320 Mpa 3264 Kg/cm
2
UTS 420 Mpa 4284 Kg/cm
NumberofBolts 6 Nos
ProposedDiameterofBolts 16 mm
ShankDiameterofBolts 17 mm
2
ShankAreaofBolts 2.27 cm
PCDofBolts
PCD fB l 450 mm
MaximumDeadloadonBolts =(1795+250)= 2045 Kgs
MaximumShearloadonEachBolts
=(2045x400)/(450x6)= 303 Kgs
2
ShearStressinBolts 134 Kg/cm
ShearStressinBoltsare WithinLimit.
7.0 CentralDriveUnitReduction
Adopt ThreeStageHelicalGearReductionUnit
ReductionRatio 28 :1
8.0 ManualOperation
NoofPersonrequiredforoperation = 2 Nos.
Crankradius = 400 mm
Effort/Forceappliedperman = 10 Kgs
CrankRPM = 24 rpm
SystemEfficiency = 0.742
WormReducerRatio = 28
OpenReductionRequired = 4.45
ProvidefollowingReduction
9.0 TorqueTransmission
Torqueinkgcm
Sl.No. Componentset
Output
O Input
I
1 DrumGear/Pinion 1795x40/2= 35900 35900/0.95= 37790
2 1stPinionShaft 37790x19/85= 8448 8448/0.95= 8893
10.0 Gear&PinionDetails
10.1
0. Detail
eta
DrumGear
NoofTeethonGearN = 85
No.ofTeethonPinionN = 19
ModuleofGear&PinionSetm = 8 mm
FaceWidthofGearF = 80 mm
FaceWidthofPinionF = 90 mm
TypeofGear/Pinion = Spur
10.2 MaterialforGears&Pinions
YPMpa UTSMpa
GearMaterial CaststeelIS:1030,Gr280520 280 520
10.3 AllowableStresses
2
GearStresses = 1060.8 Kg/cm
2
PinionStresses = 1264.8 Kg/cm
10.4 RootStressesforGearsandPinions
f
Therootstressingearandpiniontoothisgivenby
Pq
root =
F m
RootStressesUnderNormalCondition
2
MaximumGearStress 451.55 islessthan 1060.8 Kg/cm OK
2
MaximumPinionStress 573.17 islessthan 1264.8 Kg/cm OK
11.0 DrumShaft
11.1 DirectionofToothLoadonGearandPinion
F2 F3
DRUM
F1 F2
416
80 mm
450
A 60 60
60 X Y
60
C D
450
20
A 570 B
11.2 LoadingComponentsForDrumAxle
i)) RopeTensionF1
ope e s o 1795
95 Kgs
gs Downward
o ad
ii) ToothloadofgearF2 1111.5 Kgs Downward
iii) HorizontalLoadF3 404.6 Kgs Horizontal
DeadWeights
RopeDrum 250 Kgs Downward
DrumGear 75 Kgs Downward
iv) DeadWt.onGearSide@B 200 Kgs Downward
Dead Wt. on Drum Side @ A
v) DeadWt.onDrumSide@A 125 Kgs Downward
X 1795
BendingMoment&ReactionsforDrumShaft
Loading@A
Loading@B
11.3
11 3 Stresses in Drum Axle
StressesinDrumAxle
Provide YP UTS
ShaftMaterial ForgedSteelIS:2004,Class4,45C8 320 620 Mpa
DrumShaftDiameter@Support 60 mm
DrumShaftDiameter@Centre 50 mm
3
SectionModulusofDrumShaftZ(D3/32) 12.27 cm
2
AreaofDrumShaftZ(D2/4) 19.63 cm
t Gea d(@ )
AtGearEnd(@B)
2
BearingStress 33.39 Kg/cm
2
<204 Kg/cm HenceOK
AtDrumFlangeEnd(@A)
2
BearingStress 35.01 Kg/cm
2
< 204 Kg/cm
<204 Hence OK
HenceOK
12.0 PinionShaft
1197.8336
Pinion 90
155 30
200 75
R1 275 R2
SelfWeightofPinion 15 Kgs
SecondPinionResultantToothload(F2/Cos20+selfWt.) 1197.8336 Kgs
a u o que
MaximumTorque 8 8 kgcm
8448 gc
Provide YP UTS
ShaftMaterial ForgedSteelIS:2004,Class4,45C8 320 620 Mpa
DrumShaftDiameter@Support 40 mm
DrumShaftDiameter@Centre 50 mm
3
SectionModulusofDrumZ(D3/32) 12.27 cm
2
TorsionalShearStress(Tmax/2.Z) 344.25 Kg/cm
AlltheStressesare
All th St areWithinLimit
Withi Li it
12.1 CheckforCombinedBendingandTwisting
CombinedTwisting Te = M 2
+T 2
2
AllowableStress 881.28 Kg/cm
CombinedBending M e = 0.5 ( M + M 2 +T2 )
2
AllowableStress 1138.32 Kg/cm
HenceOK
12.2
12 2 Bearing for Pinion Shaft Support
BearingforPinionShaftSupport
Provide
PlummerBlockHousing SNH509TC
AdapterSleeve H309
Bearingno 22209EK ofSKF@eitherEndsofShaft
I.D.ofBearing 40 mm
O.D.ofBearing 80 mm
SSupportwidthofBearing
id h f B i 23 mm
StaticCapacityofBearing 81500 N
DynamicCapacityofBearing 73600 N
MaximumloadunderBDTCondition 8546 N
DynamicCapacityofBearingis morethanrequiredHenceOK
13.0 FloatingShaft
Provide YP UTS
ShaftMaterial ForgedSteelIS:2004,Class3,30C8 270 490 Mpa
ShaftDiameter@Flange 45 mm
ShaftDiameter@Centre 45 mm
3 3
SectionModulusofDrumZ(D /32) 8.95 cm
2
Torsional Shear Stress (Tmax/2 Z)
TorsionalShearStress(Tmax/2.Z) 96 Kg/cm
471.96
471
HenceOK