Crane Calculations

Page: 1
DC Motor/Gearbox Safety Factor
t
motorstall
.070kgf cm := (motor stall torque)
t
maxpower
t
motorstall
2
:= (availible motor torque at max power)
v
noload
9400
rev
min
:= (motor no load speed)
(motor speed @ max power)
v
maxpower
v
noload
2
:=
r
gear
64.8 := (motor gearbox ratio)
r
bevelgear
4 := (bevel gear ratio)
w
fuelrod
2.0lbf := (fuel rod weight)
r
gearpitch
0.5in := (lift gear pitch radius)
(torque required from motor)
t
design
w
fuelrod
r
gearpitch

r
gear
r
bevelgear

:=
t
gearboxstall
t
motorstall
r
gear
:= (stall torque from gearbox)
t
shaftstall
t
gearboxstall
r
bevelgear
:= (stall torque on main shaft)
SF
motor
t
maxpower
t
design
7.874 = :=
Lifting Rod Vertical Speed
v
gearbox
v
maxpower
r
gear
:= (speed output from gearbox at max power)
v
rod
v
gearbox
r
bevelgear
2 r
gearpitch
5.965
in
s
= := (vertical speed of crane rod)
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 2
Stress and Elongation in Crane Rod (not including gripper section)
r
rod
0.5in := (radius of lifting rod)

rodyield
7500psi := (yield strength)
E
pvc
550 10
3
psi := (modulus of elasticity)
l
rod
6in := (length of lifting rod)

rod
t
shaftstall
r
gearpitch
r
rod
2

40.103psi = := (stress in lifting rod)

rod

rod
E
pvc
7.291 10
5
= := (strain in lifting rod)
SF
rod

rodyield

rod
187.02 = :=
rod

rod
l
rod
4.375 10
4
in = :=
Shear Stress in Rack Bolts
n
bolts
5 := (number of bolts holding rack to rod)
(bolt diameter)
d
bolt
.073in :=
(max allowable shear stress for rack bolts)

maxbolt
85000
2
psi :=
(cross sectional area of bolt)
a
bolt

d
bolt
2
|

\
|
|
.
2
:=

bolt
t
shaftstall
r
gearpitch
n
bolts
a
bolt
1.505 10
3
psi = := (shear stress in bolt)
SF
rackbolts

maxbolt

bolt
28.238 = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 3
Main Lifting Gear Tooth Stress
n
teeth
16 := (number of teeth on gear)
w
gear
3
8
in := (width of gear)
r
rootlength
0.134in := (length of gear tooth)

maxnylon
12000
2
psi := (max shear stress in nylon gear)
L
tooththick
2 r
gearpitch

n
teeth
:= (tooth thickness)

geartooth
t
shaftstall
r
gearpitch
w
gear
L
tooththick

427.762 psi = := (shear stress in gear tooth)

SF
liftgear

maxnylon

geartooth
14.026 = :=
Rack Tooth Stress
w
rack
5
16
in := (width of rack teeth)
L
racktooth
0.1404in := (thickness of teeth at root)

acetal
9500
2
psi := (max shear stress of acetal)
(shear stress in rack teeth assuming
all weight beared on one tooth)

racktooth
t
shaftstall
r
gearpitch
w
rack
L
racktooth

717.871 psi = :=
SF
rackteeth

acetal

racktooth
6.617 = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 4
Torsional Shear Stress in Crane Shaft
d
shaft
.25in := (diameter of crane shaft)
(max shear stress for steel drill rod)

steel
1030
2
MPa :=
(radius of crane shaft)
r
shaft
d
shaft
2
:=
(polar moment of inertia for crane shaft)
J
shaft
d
shaft
4

32
:=
(torque seen by crane shaft)

shafttorsion
t
shaftstall
r
shaft

J
shaft
5.133 10
3
psi = := (torsional shear stress in crane
shaft)
SF
shafttorsion

steel

shafttorsion
14.551 = :=
Deflection of Crane Shaft
l
shaft
.694in := (distance between supports)
(modulus of elasticity)
E
shaft
2910
3
ksi :=
(moment of inertia)
I
shaft

64
d
shaft
4
:=
(deflection of shaft assuming point
load)
Deflection
shaft
t
shaftstall
r
gearpitch
l
shaft
3

48E
shaft
I
shaft

3.944 10
5
in = :=
Shear Stress in Crane Shaft
a
shaft
r
shaft
2
:= (cross-sectional area)

shaft
t
shaftstall
r
gearpitch
a
shaft
641.643 psi = := (shear stress in crane shaft)
SF
shaft

steel

shaft
116.411 = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 5
Shear Stress in Crane Shaft Pins (lift gear and large bevel gear)
d
pin
.125in := (diameter of pin)
l
pin
0.75in := (length of pin)

maxpin
85000
2
psi := (max shear stress of material)
a
pin

d
pin
2
|

\
|
|
.
2
:= (cross-sectional area of pin)

pin
t
shaftstall
r
shaft
2a
pin
5.133 10
3
psi = := (shear stress in pin, divided by 2 because
pin goes
through both sides of shaft)
SF
pin

maxpin

pin
8.28 = :=
Shear Stress in Small Bevel Gear Pin
d
smallpin
.0625in := (diameter of pin in small bevel gear)

smallyield
50000psi := (yield strength of small bevel gear pin)
r
gearboxshaft
.0785in := (radius of gearbox output shaft)
a
smallpin

d
smallpin
2
|

\
|
|
.
2
:= (cross-sectional area of small pin)
(shear stress in small pin, divided by 2
because pin goes through both sides)

smallpin
t
gearboxstall
r
gearboxshaft
2a
smallpin
8.174 10
3
psi = :=
SF
smallpinshear

smallyield
2

smallpin
3.059 = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 6
Pin Bearing Stress on Lift Gear
l
pinengage
.25in := (length of pin engagement in main shaft gears)

liftgear
t
shaftstall
r
shaft
d
pin
l
pinengage

2
|

\
|
|
.
2.567 10
3
psi = :=
SF

maxnylon
2

liftgear
4.675 = :=
Pin Bearing Stress on Large Bevel Gear
r
bevelpitch
1in := (pitch radius of large bevel gear)
w
bevelgear
5
16
in := (width of bevel gear)

bevelgear
t
shaftstall
r
shaft
d
pin
l
pinengage

2
|

\
|
|
.
2.567 10
3
psi = :=
SF
bearingbevel

acetal
2

bevelgear
3.701 = :=
Pin Bearing Stress on Small Bevel Gear
r
Sbevelpitch
0.25in := (pitch radius of small bevel gear)
l
smallpinengage
.14025in := (length of engagement for pin on small bevel gear)

Sbevelgear
t
gearboxstall
r
gearboxshaft
d
smallpin
l
smallpinengage

2
|

\
|
|
.
3.643 10
3
psi = :=
SF
smallbevelpin

acetal
2

Sbevelgear
2.608 = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 7
Bearing Stress on RP from Main Crane Shaft
w
rpleft
.381in := (bearing width left side)
w
rpconnection
w
rpleft
2 := (total bearing width including both sides)

maxrp
3200psi := (max stress rp can handle)

rp
t
shaftstall
r
gearpitch
d
shaft
w
rpconnection

2
|

\
|
|
.
105.256 psi = :=
SF
rp

maxrp

rp
30.402 = :=
Large Bevel Gear Tooth Stress
w
Lbeveltooth
.217in := (width of teeth on large bevel gear)
L
Lbevelthick
.05in := (thickness of teeth on large bevel gear)

Lbeveltooth
t
shaftstall
r
bevelpitch
|

\
|
|
.
w
Lbeveltooth
L
Lbevelthick

1.451 10
3
psi = :=
SF
Lbeveltooth

acetal
2

Lbeveltooth
6.545 = :=
Small Bevel Gear Tooth Stress
w
Sbeveltooth
0.234in := (width of teeth on small bevel gear)
L
Sbevelthick
.059in := (thickness of teeth on small bevel gear)

Sbeveltooth
t
gearboxstall
r
Sbevelpitch
|

\
|
|
.
w
Sbeveltooth
L
Sbevelthick

1.141 10
3
psi = :=
SF
Sbeveltooth

acetal
2

Sbeveltooth
8.328 = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 8
Gripper Calculations

liftpinmax
1030MPa :=
(diameter of lifting pin)
d
liftpin
1
8
in :=
(length of exposed pin in gripper)
l
liftpin
0.44in :=
l
pinengagement
0.39in := (length of pin engagement in rod)
Bearing Stress on Crane Rod from Lifting Pin
(bearing stress on rod due to
lift pin)

bearing
t
shaftstall
r
gearpitch
d
liftpin
l
pinengagement

2
|

\
|
|
.
411.31psi = :=
SF
bearing

rodyield

bearing
18.234 = :=
Shear Stress in Lift Pin
a
liftpin

d
liftpin
2
|

\
|
|
.
2
:= (cross sectional area of lift pin)
(shear stress in lifting pin at stall, divided
by 2 because of double shear)

liftpin
t
shaftstall
r
gearpitch
2a
liftpin
1.283 10
3
psi = :=
SF
liftpin

liftpinmax
2

liftpin
58.206 = :=
Deflection in Lift Pin
I
pin

64
d
liftpin
4
:=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013
Crane Calculations
Page: 9
Deflection
pin
t
shaftstall
r
gearpitch
l
pinengagement
3

48E
shaft
I
pin

1.12 10
4
in = :=
Kevin Winstead
MEGR 3156 (Team6)
12/3/2013