GTS, PTS & Technical Data Sheet of Pakaldul H.E.project

DESIGN CALCULATION OF 7.5MT ROPE DRUM HOIST FOR HEAD PAGE : 1 of 42..............
REGULATOR VERTICAL LIFT GATE SIZE 3500MM X 2900MM

CHENANI H. E. PROJECT, STAGE-I(5X4.66MW) REV. : 0
UDHAMPUR, JAMMU & KASHMIR
1. DESCRIPTION
The proposed Electrically Operated Rope Drum Hoist shall be designed for 7.5 tonnes capacity
for the operation of 3.0 M x 2.9 M size Head Regulator Vertical Lift Gate as per provisions
contained in IS: 6938-2005.
The Head Regulator Vertical Lift Gate shall be lowered by means of proposed rope drum hoist
under flowing water conditions & raised under balanced condition created by crack opening of
gate. The rope drum hoist shall be installed on the deck duly supported on concrete slab.
2. TECHNICAL REFERENCES
a. Technical Specifications
b. IS: 6938 – 2005 – Code Practice for Design of Rope Drum Hoist & Chain Hoist for
Hydraulic Gates.
c. IS: 800 – Code of Practice for General Construction in Steel.
d. IS: 807 – 2007 Code of Practice for design, manufacture, erection and testing of cranes and
hoists.
3. TECHNICAL DATA :-
a. Capacity of Hoist - 7.5 MT
b. Type - Electrically Operated Rope Drum Hoist
c. Lifting speed - 0.5  5% m / min.
d. Lift - 5.0 Mts.
e. No. of Hoists required -2
f. Number of Rope Drum - 2 Nos.
g. Number of fall on each Drum - 2 Nos.

4. MATERIAL SPECIFICATIONS
1. Structure Structural Steel IS2062 E250 (Fe410W)
2. Rope drum Structural Steel IS:1030 Gr.340-570W
3. Sheaves & Pulleys Cast Steel IS:1030 Gr. 280-520W
4. Shafts Forged Steel IS: 2004 Class 5, 55C8/En9
5. Bushes for rope drum Al. Bronze IS: 305 Gr: AB2
6. Wire rope Steel IS: 2266
7. Gear Wheel Cast Steel IS:1030 Gr.340-570W
8. Pinions Forged Steel IS: 2004 Class 5, 55C8/En9
9. Threaded Fasteners Mild Steel IS: 1363 / IS: 1367

5. MECHANICAL STRENGTH
SL.No. Material & Strength

1. Structural Steel – IS2062 E250 (Fe410W)
Y.P. = 250 N/mm for thickness < 20mm
2
Y.P. = 240 N/mm for thickness > 20mm and <40mm

2
Y.P. = 230 N/mm for thickness > 40mm

2
U.T.S = 410 N/mm

2
2. Forged Steel-
IS:2004 Class 4 IS:2004, Class5 IS:1570, 55C8
Y.P. = 320 N/mm
2 Y.P.
= 350 N/mm
2 Y.P.=
540 N/mm2
U.T.S = 620 N/mm U.T.S = 710 N/mm U.T.S =
2 2
800 N/mm
2
3. Cast Steel –
IS:1030 Gr. 280-520W IS:1030 Gr.340-570W
Y.P. = 280 N/mm
2 Y.P. = 340 N/mm
2
U.T.S = 520 N/mm

2 U.T.S = = 570 N/mm
2
4. Aluminium Bronze –
IS: 305 Gr. AB2
U.T.S = 600 N/mm2
5 kg/cm
2
65Si7 IS:3431 Y.P 12025
6. ALLOWABLE STRESSES
A. Rope drum :
IS:1030 Gr.340-570W
Compressive stress:
a. Normal Condition = 0.2x5810.4 = 1162.08 kg/cm
2
b. Break down condition:-

80% of YP = 0.8x3465.85 = 2772.68 kg/cm
2
Bending Stress
a). Normal Condition = 0.2 UTS = 0.2x5810.4 = 1162.08 kg/cm
2
b). Brake Down Condition –

80% of YP = 0.8x3465.85 = 2772.68 kg/cm
2
Combined stress
a). Normal Condition - 0.24 UTS = 0.24x5810.4 = 1394.5 kg/cm
2
b). Brake Down Condition:-

80% of YP = 0.8x3465.85 = 2772.68 kg/cm
2
B.Type-1 & 2 Gears : IS:1030 Gr.340-570W

Root Stress
a. Normal Condition 0.2x5810.4 = 1162.08 kg/cm
2
=
b. Break down condition = 0.8x3465.85 = 2772.68 kg/cm
2
C. Pinion : IS:2004, Class5

Root Stress:
a. Normal Condition 0.2x7237.51 = 1447.5 kg/cm
2
=
b. Break down condition
80% of YP = 0.8x3567.79 = 2854.23 kg/cm
2
D. Bushes : IS 305Gr.AB2
Bearing stress:
a. Normal condition 0.04x6116.21 = 244.65 kg/cm
2
=
b. Break down condition
133% of Allowable Stress = 1.33x244.65 = 325.38 kg/cm
2
E. Pin for Sheave : IS:2004, Class5

a. Bending Stress under Normal Condt.= 7237.51x0.2 = 1447.5 kg/cm
2
b. Shear Stress under Normal Condition = 3567.79x0.3 = 1070.34 kg/cm

2
c. Bending Stress under BDT condition= 3567.79x0.8 = 2854.23 kg/cm

2
d. Shear Stress under BDT condition = 3567.79x0.8 = 2854.23 kg/cm

2
F. Key for Shafts : IS:2004 Class 4

a. Shear Stress : 3261.98x0.3 = 978.59 kg/cm
2
b. Crushing Stress : 6320.08x0.3 = 1896.02 kg/cm

2
b. Shear Stress under BDT Condition : 6320.08x0.8 = 5056.07 kg/cm

2
b. Crushing Stress under BDT Condition : 6320.08x0.8 = 5056.07 kg/cm

2
G. Cheek Plate / Structural Steel : IS 2062
i). Direct Compression and Compression in Bending
Direct Tension and Tension in Bending
Normal conditions
Plate < 20 mm = 0.55x2548.42 = 1401.63 kg/cm
2
Plate < 20 mm < 40 mm = 0.55x2446.48 = 1345.57 kg/cm

2
Plate < 40 mm = 0.55x2344.55 = 1289.5 kg/cm

2
Break down condition:-

80% of Y.S or 1.33% of allowable stress, which is = 1.33x0.55of YS = 0.73 OF YS
Plate < 20 mm = 0.73x2548.42 = 1860.35 kg/cm
2
Plate < 20 mm < 40 mm = 0.73x2446.48 = 1785.93 kg/cm

2
Plate < 40 mm = 0.73x2344.55 = 1711.52 kg/cm

2
ii). Shear Stress

Normal condition = 0.4 XYS
Plate < 20 mm = 0.4x2548.42 = 1019.37 kg/cm
2
Plate < 20 mm < 40 mm = 0.4x2446.48 = 978.59 kg/cm

2
Plate < 40 mm = 0.4x2344.55 = 937.82 kg/cm

2
Break down condition = 1.33 X Allowable stress

Plate < 20 mm = 1.33x1019.37 = 1355.76 kg/cm
2
Plate < 20 mm < 40 mm = 1.33x978.59 = 1301.52 kg/cm

2
Plate < 40 mm = 1.33x937.82 = 1247.3 kg/cm

2
iii). Bearing Stress

Normal condition = 0.4 x UTS = 0.4x4179.41 = 1671.76 kg/cm
2
B D T condition= 1.33 X Allowable stress = 1.33x1671.76 = 2223.44 kg/cm

2
iv). Combined Stress

Normal condition = 0.75 x YS
Plate < 20 mm = 0.75x2548.42 = 1911.31 kg/cm
2
Plate < 20 mm < 40 mm = 0.75x2446.48 = 1834.86 kg/cm

2
Plate < 40 mm = 0.75x2344.55 = 1758.41 kg/cm

2
v) Bending stress
Normal conditions = 0.5 X YS = 0.5x2548.42 = 1274.21 kg/cm
2
B D T condition= 1.33 X Allowable stress = 1.33x1274.21 = 1694.7 kg/cm

2
G. Shafts : IS 2004 CLASS 4
a. Normal Condition
Bending stress without keys = 0.2x6320.08 = 1264.02 kg/cm
2
Bending stress with keys = 0.75x1264.02 = 948.02 kg/cm

2
Torsional stress without keys = 0.3x3261.98 = 978.59 kg/cm

2
Torsional stress with keys = 0.75x978.59 = 733.94 kg/cm

2
Combined stress without keys = 0.24x6320.08 = 1516.82 kg/cm

2
Combined stress with keys = 0.75x1516.82 = 1137.62 kg/cm

2
Equivalent bending stress without keys = 1.2x1264.02 = 1516.82 kg/cm

2
Equivalent bending stress with keys = 1.2x948.02 = 1137.62 kg/cm

2
Equivalent Torsional stress without keys = 1.2x978.59 = 1174.31 kg/cm

2
Equivalent Torsional stress with keys = 1.2x733.94 = 880.73 kg/cm

2
b. Break Down Condition

80% of YP
2

2

2

2

2

2

2

2

2

2
H. Shafts : IS 2004 CLASS-5
a. Normal Condition
2

2

2

2
Combined stress without keys = 0.24x7237.51 = 1737 kg/cm

2
Combined stress with keys = 0.75x1737 = 1302.75 kg/cm

2
Equivalent bending stress without keys = 1.2x1447.5 = 1737 kg/cm

2

2

2

2
b. Break Down Condition
80% of Allowable Stress in normal condition

2

2

2

2

2

2

2

2

2

2
J. Spring : 65Si7
a. Shear Stress under Normal Condition : 12025x0.4 = 4810 kg/cm2

b. Shear Stress under BDT condition : 12025x0.8 = 9620 kg/cm2
7.0 DESIGN OF HOIST MECHANISM
Hoist Capacity = 7.5 MT
Lifting lowering speed = 0.5 m /min. ± 5%
No. of falls of wire rope = 2 falls / drum (side)
No. of drums = 2 (TWO)
Total lift provided = 5 meters
7.1 MOTOR
Total load on Rope = M= 7.5 + 0.25 (Weight of wire rope)
= 7.75 T
Lifting Speed = V= 0.5 M/min
Rope Drum Running effy. = 0.95 as per IS:6938-2005 for Bronze Bearing
Pulley running efficiency (A.F.
0.95 as per IS: 6938-2005
Bearing) =
(Total 1No. of Pulley per side) – Pulley efficiency = 0.95^1 = 0.95
Worm reduction efficiency = 0.6795
Gear Running efficiency = 0.95 per stage. As per IS: 6938-2005
Number of pair of open spur gears used = 2
Total open gear running efficiency = 0.95^2 = 0.903
Overall running efficiency = Rope drum efficiency x Open gear Efficiency x Pulley
efficiency x Worm gear box efficiency.
E = overall running efficiency = 0.95x0.95x0.6795x0.903 = 0.55
MVS 7.75x0.5x1
Motor KW Required = = = 1.15 kW
6.12 E 6.12x0.55
Motor selected 2.2 kW ( 3 HP), 700 r.p.m, sq, cage, 40% CDF,
150 Starts / hr., TEFC, Fr. Size 112M Make: Bharat Bijlee. POT 2.3
Rope Drum Starting effy. = 0.93 as per IS:6938-2005 for bronze bearing
Pulley starting efficiency (A.F. Bearing) = 0.95 as per IS: 6938-2005
Worm reduction Starting efficiency = 0.4
Gear starting efficiency = 0.93 per stage. As per IS: 6938-2005
Number of pair of open spur gears used = 2
Total open gear starting efficiency = 0.93^2 = 0.86
(Total 1No. of Pulley per side) – Pulley efficiency = 0.95^1 = 0.95
Overall starting efficiency = Rope drum efficiency x Open gear Efficiency x Worm gear
box efficiency.
Es = overall starting efficiency = 0.93x0.4x0.86x0.86 = 0.3
Overall running eff. Starting torque
Ratio = <
Overall starting eff. Running torque
0.55 Starting torque
Ratio = <
0.3 Running torque
Ratio = 1.83 < 2.3
7.2 HOIST BRAKE
1.5x3x716.2 1.5x3x716.2
Required Torque rating of brake = =
r.p.m 700
= 4.6 kg-m
BRAKES SELECTED -
Electro magnetic Brake , Model No. IPB- 150 , 50% CDF
Having Torque Rating- 7.6 Kgm. Make: Electromag
7.3 Brake Drum Coupling
a. Between Motor & worm gear box
1.5xHPx100 1.5x3x100
H.P. /100 r.p.m. = = = 0.64
r.p.m 700
Coupling selected Model N53P3D6 150 Dia. Brake drum.
Allowable HP/100rpm : 1.5 Make – MARK-ACE IND/MECO.
7.4 Flexible Coupling (B/w G.B O/P Shaft & line Shaft & b/w line shaft & pinion shaft)
1.5xHPx100x70x0.6795 1.5x3x100x70x0.6795
H.P. /100 r.p.m. = = = 15.29
2xr.p.m 700x2
Required Torque rating of 1.5x3x716.2x70x0.6795 1.5x3x716.2x70x0.6795
= =
coupling 2xr.p.m 2x700
= 109.5 kg-m
Coupling selected – Flexible Geared coupling-size 102
H.P. /100 r.p.m. 35 Max. Torque rating 250 kgm
Make: - New Allenberry
7.5 DESIGN OF WIRE ROPE
WIRE ROPE:-
Total Load on Ropes = Capacity + wt. of wire rope = 8+ 0.25 = 7.75 T
No. of falls on each drum = 2 Nos
Pulley efficiency, η = 0.95 per Pulley with A.F. Bearing
Wire rope tension = W/2 {(1- η)/ (1- η )}
n
= 7750x(1-0.95)/2x(1-0.95^2) = 1987.18 kg
= 19.49 kN
Min breaking strength required, = FOS XRope Tension = 6x19.49
= 116.94 kN
Proposed 20 mm dia. wire rope, 6X36 construction, right hand lay,
fiber core, Improved Plow steel, UTS= 1770N/mm or 180 kg/mm ,
2 2
, having breaking Load of 234 KN/ 23853.21 kg

MAKE: USHA MARTIN/FORT WILLIAM INDUSTRIES LTD.
Factory of safety = 23853.21/1987.18 = 12 > 6 Hence safe.
7.6 DESIGN OF ROPE DRUM
MATERIAL : IS:1030 Gr.340-570W
Proposed 2 drums with each 2 falls
Minimum Drum Dia: 20d = 20x20 = 400 mm
Proposed Drum Dia = 400 mm PCD
Circumference = 3.14x0.4 = 1.26 M
Total Lift = 5M
No. of Grooves required = 5x2/1.26+3 = 7.94+3 = 10.94 @ 11
Shell thickness below groove (t) = 3.55 cm (assumed)
Pitch of Groove = 20 + 2.5 = 22.5 mm = 2.25 cm
1. DESIGN OF SHELL
Proposed shell thickness = 3.55 cm
Compressive stress, sc = KXT/PXT
Where,
K = 1
T = 1987.18 kg
P = 2.25 cm
t = 3.55 cm
sc = 1x1987.18/(2.25x3.55)
= 248.79 kg/cm < 1162.08 kg/cm
2 2
3
11
35.5 7
400
309
394
2. GROOVES DETAILS
Wire rope dia = 20 mm
Depth of groove = 0.35x20 = 7 mm(min) Take 7 mm
Radius of groove = 0.53x20 = 10.6 mm(min) Take 11 mm
Inside Dia of drum = 400-2x(10+35.5) = 309 mm
Turned dia of drum = 400-2x(10)= 380 mm
Overall length of drum= 35 + 85 + 22.5x11 + 17.5 + 35
= 420 mm
CHECKING OF BENDING STRESS OF THE DRUM :-
1987.18 kg 5 kg/cm
A B
420
Wt. of drum = 210 kg. = w1

Wt. of drum/LG. = 210/42 = 5 kg/cm =W1
Wire rope tension = 1987.18 kg. = w2
Bending moment due to self wt. of drum = w1 x L/2 x L/2 = 5x42^2/4
= 2205 kgcm
Bending moment due to wire rope tension = w2 x L/4 = 1987.18x42/4
= 20865.39 kgcm
Total B.M.= = 2205+20865.39 = 23070.39 kgcm
Z for drum = π (D – d ) / 32D = 3.14(38^4-30.9^4)/(32x38)

4 4
= 3031.72 cm³
Bending stress = 23070.39/3031.72 = 7.61 kg/cm
2
Combined stress = (248.79^2+7.61^2)^0.5 = 248.91 kg/cm

2
< 1394.5 kg/cm

2
7.7 SELECTION WORM REDUCER
4XV where,
Motor r.p.m = 700 Drum R.P.M. = PXD V - is Velocity in m/min,
D - is Rope drum P.C.D.
Drum r.p.m. = 0.5x2/3.14x0.4 = 0.8
Speed of the motor proposed = 700.00 rpm
Total reduction required = 700/0.8 = 875
Service Factor for 12 hours/day Operation and Medium Impulsive load= 1.25 for NAV gears
Equivalent Power = Actual power x Service factor = 2.2x1.25= 2.75 kW
Selected central worm reducer: - Single reduction 70 :1 ratio,
Type ‘SNU” U Series, Size-6, I/p kW 3.61 @750 r.p.m., O/p Torque-2255.4Nm, with input &
output shaft extended on both sides
Make:ELECON/Shanthi Gear.
Reduction required for end gearing (open gearing) = 875/70 = 12.5
7.8 DESIGN OF END GEARING (SPUR TYPE- DOUBLE STAGE):-
Description No. of teeth Module in P.C.D. P.A. in Material

mm In mm Deg.
W1 85 8 680 20 IS:1030 Gr.340-570W
P1 19 8 152 20 IS:2004, Class5
W2 60 6 360 20 IS:1030 Gr.340-570W
P2 21 6 126 20 IS:2004, Class5
Actual lifting speed = 700x21x19x3.14x0.4/(70x85x60x2) = 0.5 M/min

Drum effy. = 0.95
Effy. Of W1 gear & P1 pinion set = 0.95
1987.18x20
Tooth load W1&P1 = = 1295.21 kg
34x0.95x0.95
Effy. Of W2 gear & P2 pinion set = 0.95

1295.21x7.6
Tooth load W2&P2 = = 575.65 kg
18x0.95
PxQ
Root Stress =
FxM
Where,
P = Tooth Load
Q = Strength factor
F = Face width
M = Module
Description Tooth Load Strength Face Width Module Root Stress Allowable
(in kg) Factor ‘Q’ ‘F’ in cm ‘M’ in Kg/cm
2 Stress
W1 1295.21 2.535 9 0.8 456.02 1162.08
P1 1295.21 3.6 10 0.8 647.61 1447.5
W2 575.65 2.5 5 0.6 479.71 1162.08
P2 575.65 3.43 6 0.6 658.16 1447.5
7.9 Design of Connection Bolts for Wheel W1 and Rope Drum

Proposed M- 12 Fit bolts @ 450 PCD – 8 Nos., As per IS:3640, 1367-3/
IS1363, Gr. 5.8
Rope Tension = 1987.18 kg
Total load on bolts = 1987.18x400/450 = 1766.38 kg
Load on each bolt = 1766.38/8 = 220.8 kg
Cross – Sectional Area of one bolt 3.14x1.2^2x0.85/4= 0.96 cm
2
=
Shear stress in bolt = 220.8/0.96 230 kg/cm
2
=
0.3XY.S 0.3x400X100/(1.2 x9.81)= 1019.37 kg/cm
2
Allowable Shear Stress = =
1.2 Hence safe.
Grade of Bolt is 5.8 YS of bolt is 400 N/mm . Material of Bolt will be as per
2
IS-1367, Bolt size M 12 x 90 mm Long.

8. DESIGN OF SHAFT
8.1. Design of Drum Shaft- Shaft 1
A) When Rope Tension Is On Gear Wheel Side
Vertical loads
3620.51 kg 105 kg
A1 C1 D1 B1
12.25 39.75 10.5

62.5 cm
RVA1 RVB1
Weight of drum = 210 kg
Weight of gear wheel W 1= 150 kg
Weight of gear wheel W 2 = 30 kg
Weight of pinion P1= 15 kg
= Vertical component of tooth load of W1+Wt. of W1+½ Wt of
Load acting at C1
drum+ rope tension
1295.21 210
= + 150 + + 1987.18
Cos 20 2
= 1378.33 + 150 + 105 + 1987.18
= 3620.51 kg
Load acting at D1 = ½ Weight of drum

210
=
2
= 105 kg
3620.51x50.25+105x10.5
RVA1 =
62.5
= 2928.53 kg
RVB1 = 3620.51+105-2928.53 = 796.98 kg
Horizontal loads:-
471.42 kg
A2 C2 B2
12.25
62.5 cm
RHB1
RHA1
0
Horizontal load at C2 due to load on w1 gear = 1295.21 x tan 20
= 471.42 kg
471.42x50.25
RHA1 = = 379.02 kg
62.5
RHB1 = 471.42-379.02 = 92.4 kg
Resultant load at A1 / A2 = (2928.53^2+379.02^2)^0.5 = 2952.96 kg
Resultant load at B1 / B2 = (796.98^2+92.4^2)^0.5 = 802.32 kg
Resultant B.M. at C1 / C2 = (2928.53^2+379.02^2)^0.5x12.25
= 36173.7 kgcm
Resultant B.M. at D1 = (796.98^2+92.4^2)^0.5x10.5
= 8424.34 kgcm
Proposed 90 Ø shaft confirming to IS 2004 CLASS-5 having UTS
7237.51 kg./cm² & YP = 3567.79 kg./cm²
π x 9^3
Zxx of shaft = = 71.57 cm3
32
π x 9^2
C.S. area = = 63.62 cm2
4
Bending stress in shaft = M / Z = 36173.7/71.57 = 505.43 kg/cm
2
< 1085.63 kg/cm

2
Resultant Load at C1 / C2 = (3620.51^2+471.42^2)^0.5
= 3651.07 kg
Resultant Load at D1 = (105^2+92.4^2)^0.5
= 139.87 kg
Shear stress = 3651.07/63.62 = 57.39 kg/cm
2
< 802.76 kg/cm

2
When the Rope Tension Is On Non-Gear Wheel Side

Vertical loads
1633.33 kg 2092.18 kg
A3 C3 D2 B3
12.25 39.75 10.5

62.5 cm
RVA2 RVB2
Vertical component of Tooth load of W1 + Wt. of gear wheel + ½
Load acting at C3 =
Weight of drum
1295.21 210
= + 150 +
Cos 20 2
= 1378.33 + 150 + 105
= 1633.33 kg
Load acting at D2 = ½ Weight of drum + Rope tension
210
= + 1987.18
2
= 2092.18 kg
RVA2 = (1633.33x50.25+2092.18x10.5)/62.5
= 1664.68 kg
RVB2 = 1633.33+2092.18-1664.68
= 2060.83 kg
Horizontal loads:-
471.42 kg
A4 C4 B4
12.25
62.5 cm
RHB2
RHA2
Horizontal load at C4 due to load on w1 gear = 1295.21 x tan 20 0
= 471.42 kg
471.42x50.25
RHA2 = = 379.02 kg
62.5
RHB2 = 471.42-379.02 = 92.4 kg
Resultant B.M. at C3 & C4 = (1664.68^2+379.02^2)^0.5x12.25
= 20914.22 kgcm
= 21660.45 kgcm
2
< 1085.63 kg/cm

2

= 1700 kg
Resultant Load at D2 = (2092.18^2+92.4^2)^0.5
= 2094.22 kg
Shear stress = 2094.22/63.62 = 32.92 kg/cm
2
< 802.76 kg/cm

2
Proposed 90 Ø shaft confirming to IS 2004 CLASS-5 having UTS

7237.51 kg./cm² & YP = 3567.8 kg./cm²
Shaft diameter at bearing 85 mm
8.2. DRUM SHAFT BEARINGS
Max load on Plummer block brg. = 2952.96 kg.
Min. capacity of bearing = 1.5X2952.96 = 4429.44 kg.
= 43452.81 N
Proposed Plummer Block SNL217 ,MAKE FAG/SKF with 22217 E
bearing and having dynamic capacity 285000 N
and static capacity 325000 N
Both static & dynamic capacity is much more than 43452.81 N
Max. Horizontal Load on Plummer Block = 379.02 kg.
Max. Vertical Load on Plummer Block = 2928.53 kg.
Proposed M 20 bolts as per IS:1367-3/ IS1363, Gr. 5.8
Number Bolt per Plummer Block = 2
Cross – Sectional Area of one bolt = 3.4x2^2x0.85/4= 2.67 cm²
Shear stress in bolt = 379.02/(2.67x2) = 70.98 kg./cm²
0.3XY.S
Allowable Shear Stress = = 0.3x400x100/(1.2x9.81)
1.2
= 1019.37 kg./cm² Hence safe
Tensile stress in bolt = 2928.53/(2.67x2) = 548.41 kg./cm²
100X400X120
Allowable tensile Stress =
235X9.81
Grade of Bolt is 5.8 YS of bolt is 400 N/mm2 . Material of Bolt will be as per
IS-1367-3/IS:3640, Bolt size M 20 x 150 mm Long.
8.3. Design of Shaft- P1W2

Vertical loads
642.59 kg 1393.33 kg
11.5 16 11
38.5 cm
Load acting at C5 = Tooth load of W2 + Wt. of W2

575.65
= + 30
Cos 20
= 612.59 + 30
= 642.59 kg
Load acting at D4 =Vertical component of tooth load of P1+ Weight of P1

1295.21
= + 15
Cos 20
= 1378.33 + 15
= 1393.33 kg
RVB3 = (642.59x11.5+1393.33x27.5)/38.5
= 1187.18 kg
RVA3 = 642.59+1393.33-1187.18
= 848.74 kg
Horizontal load:-
209.52 kg 471.42 kg
A6 C6 D5 B6
11.5 16 11
38.5 cm
RHA3 RHB3
Horizontal load at C6 due to load on W2 gear = 575.65 x tan 20 0

= 209.52 kg
Horizontal load at D5 due to load on P1 = 1295.21 x tan 20 0
= 471.42 kg
RHA3 = (209.52x27+471.42x11)/38.5
= 281.63 kg
RHB3 = 209.52+471.42-281.63
= 399.31 kg
= 675.89 kg
Resultant Load at D4/ D5 = (1393.33^2+471.42^2)^0.5
= 1470.92 kg
Resultant Load at RVA3/RHA3 = (848.74^2+281.63^2)^0.5
= 894.25 kg
Resultant Load at RVB3/RHB3 = (1187.18^2+399.31^2)^0.5
= 1252.54 kg
Resultant B.M. at C5/C6 = 894.25x11.5
= 10283.88 kgcm
Resultant B.M. at D4/D5 = 1252.54x11
= 13777.94 kgcm
Torque transmitted by P1W2 shaft = 575.65x18
= 10361.7 kgcm
Equivalent Torque = (M + T ) = (13777.94^2+10361.7^2)^0.5
2 2 ½
= 17239.39 kgcm
Equivalent Bending moment = 0.5x(13777.94+17239.39)
= 15508.67 kgcm
Proposed 70 Ø shaft confirming to IS:2004, Class5 having UTS
7237.51 kg./cm² & YP = 3567.8 kg./cm²
π x 7^3
32
π x 7^3
Zpp of shaft = = 67.35 cm3
16
π x 6^2
C.S. area = = 28.27 cm2
4
Equivalent Bending stress = 15508.67/33.67
= 460.61 kg./cm² < 1302.76 kg./cm²
Equivalent Torsional stress = 17239.39/67.35
= 255.97 kg./cm² < 963.31 kg./cm²
Direct Shear Stress = 1252.54/28.27
= 44.31 kg./cm² < 802.76 kg./cm²
Bending Stress = 13777.94/33.67
= 409.21 kg./cm² < 1085.63 kg./cm²
Torsional Shear Stress = 10361.7/67.35
= 153.85 kg./cm² < 802.76 kg./cm²
Combined Stress = (409.21^2+3x153.85^2)^0.5
= 488.33 kg./cm² < 1302.75 kg./cm²
8.4. Design of Shaft P2
Vertical loads
622.59 kg
A7 D6 B7
11.5 27
38.5 cm
RVA5 RVB5
Load acting at D6 = Tooth load of P2 + Weight. Of P2

575.65
= + 10
Cos 20
= 612.59 + 10 = 622.59 kg
622.59x27
RVA5 = = 436.62 kg
38.5
RVB5 = 622.59-436.62 = 185.97 kg
Horizontal loads
209.52 kg
A8 D7 B8
11.5 27
38.5 cm
RHA5 RHB5
0
Horizontal load at D7 due to tooth load on P2= 575.65 x tan 20
209.52 kg
RHA6 = 209.52x27 = 146.94 kg
38.5
RHB6 = 209.52-146.94 = 62.58 kg
Resultant Load at D6 / D7 = (622.59^2+209.52^2)^0.5
= 656.9 kg
= 460.68 kg
= 196.22 kg
= 5297.94 kgcm
Torque transmitted by P2 shaft = 575.65x6.3
= 3626.6 kgcm
2 2 ½
= 6420.31 kgcm
= 5859.13 kgcm
Proposed 50 Øshaft confirming to IS 2004 CLASS-5 having UTS
7237.51 kg./cm² & YP = 3567.8 kg./cm²
π x 5^3
32
π x 5^3
16
π x 4^2
C.S. area = = 12.57 cm2
4
= 477.52 kg./cm² < 1302.76 kg./cm²
= 261.63 kg./cm² < 963.31 kg./cm²
= 36.65 kg./cm² < 802.76 kg./cm²
= 431.78 kg./cm² < 1085.63 kg./cm²
= 147.78 kg./cm² < 802.76 kg./cm²
= 501.95 kg./cm² < 1302.75 kg./cm²
8.5. BEARINGS
(i) For Shaft P1W2
= 18431.13 N
Proposed Plummer Block SNL513 ,MAKE FAG/SKF with 22213EK
bearing and H313 adaptor sleeve having dynamic capacity 193000 N
and static capacity 216000N
Cross – Sectional Area of one bolt = 3.4x1.6^2x0.85/4= 1.71 cm²
Allowable Shear Stress = 0.3XY.S = 0.3x400x100/(1.2x9.81)
1.2
100X400X120
235X9.81
(ii) For Shaft P2
= 6778.91 N
Proposed Plummer Block SNL509 ,MAKE FAG/SKF with 22209 EK
0.3XY.S
1.2
100X400X120
235X9.81
8.6. DESIGN OF HOIST LINE SHAFT (DRIVING SHAFT)
Material: IS 2004 CLASS 4
Torque transmitted by P-2 shaft= 3626.6 kgcm
Min. Shaft diameter = 50 mm
π x 5^3
16
= 147.78 kg./cm² < 733.94 kg./cm²
619
Length of shaft / Dia. of shaft = = 12.38 < 50
50
So angle of twist need not be checked.
9 DESIGN KEY
PINION P1 & GEAR W2
Shaft Diameter(d) = 70 mm
Torque on P1W2 Shaft = 10361.7 kg-cm
Length of Key for Gear: 70 mm & for pinion : 100 mm
Width: 20 mm, Thickness: 12 mm Material of the Key : IS:2004 Class 4
Note: Design of key done based on shortes length
Shear Stress of Key=2T/(bdl)
= 2X10361.7/(2X7X7)
= 211.46 kg/cm < 978.59 kg/cm
2 2
Crushing Stress of Key=4T/(tdl)

= 4X10361.7/(1.2X7X7)
= 704.88 kg/cm < 1896.02 kg/cm
2 2
PINION P2
Shaft Diameter(d) at Pinion = 50 mm
Shaft Diameter(d) at Coupling = 40 mm
Torque on P2 Shaft = 3626.6 kg-cm
Length of Key for Pinion: 60 mm Width: 14 mm,
Thickness: 9 mm Material of the Key : IS:2004 Class 4
= 2X3626.6/(1.4X5X6)
= 172.7 kg/cm < 978.59 kg/cm
2 2

= 4X3626.6/(0.9X5X6)
= 537.27 kg/cm < 1896.02 kg/cm
2 2
Length of Key for Coupling: 65 mm Width: 12 mm,

Thickness: 8 mm Material of the Key : IS:2004 Class 4
= 2X3626.6/(1.2X4X6.5)
= 232.47 kg/cm < 978.59 kg/cm
2 2

= 4X3626.6/(0.8X4X6.5)
= 697.42 kg/cm < 1896.02 kg/cm
2 2
10. CHECKING OF HOIST MECHANISM UNDER BRAKE DOWN TORQUE CONDITION

OF MOTOR
Break down torque of motor = 230% of full load torque
Motor torque at break-down condition, T= 2.3x3x71620/(N)
= 2.3x3x71620)/(700) = 705.97 kgcm
a)Transmission/driving Shaft:-
Torque transmitted to driving shaft i.e. output torque of worm reducer
Tx Starting effy. Of worm reducer x reduction ratio of worm reduce
=705.97x0.4x70 = 19767.16 kgcm
Torque transmitted to driving shaft/side = 19767.16/2 = 9883.58 kgcm
b) END GEARS
Drum gear & Pinion (W1 & P1)
Tooth Load on W1 & P1 = 9883.58x60x0.93/(21x7.6) = 3455.54 kg
Stress at the root of Pinion P1, σ = P x Q / (F x M)
= 3455.54x3.6/(9x0.8)
= 1727.77 kg./cm² < 2854.23 kg./cm²
Stress at root of Gear W1, σ = P x q/ (F x m)
= 3455.54x2.535/(9x0.8)
= 1216.64 kg./cm² < 2772.68 kg./cm²
W2 gear & P2 Pinion
Tooth load on W2 & P2 = Torque on transmission shaft/P.C.R. of P2
= 9883.58/6.3 = 1568.82 kg
Now stress at root of pinion P2, σ = PXq/ (FXm)
= 1568.82x3.43/(5x0.6)
= 1793.68 kg./cm² < 2854.23 kg./cm²
Now , stress at the root of Gear W2, σ = P x q/ (Fxm)
= 1568.82x2.5/(5x0.6)
= 1307.35 kg./cm² < 2773 kg./cm²
c) Drum
Load on drum i.e. Rope tension = tooth load on drum gear x starting effy. Of Drum gear & pinion
x starting effy. Of drum x (P.C.D. of gear w1/P.C.D. of drum)
= 3455.54x0.93x680/400 = 5463.21 kg
Now Cr = Kt/Pt = 1x5463.21/(2.25x3.55)= 683.97 kg./cm² < 2772.68 kg./cm²
d) ROPE
Maximum pull per rope = 5463.21 kg
Now breaking strength of rope = 23853.21 kg
So Factor of safety = Breaking strength/Pull = 23853.21/5463.21 = 4.37 > 3
e) Drum shaft
i) When the rope tension is on gear wheel side.
Vertical loads
9395.52 kg 105 kg
A11 C11 D11 B11
12.25 39.75 10.5

62.5 cm
RVA11 RVB11
Weight of drum = 210 kg
Weight of gear wheel W 1= 150 kg
Weight of gear wheel W 2 = 30 kg
= Vertical component of tooth load of W1+Wt. of W1+½ Wt of
Load acting at C11
drum+ rope tension
3455.54 210
= + 150 + + 5463.21
Cos 20 2
= 3677.31 + 150 + 105 + 5463.21
= 9395.52 kg
Load acting at D11 = ½ Weight of drum
210
=
2
= 105 kg
RVA11 = 9395.52x50.25+105x10.5
62.5
= 7571.64 kg
RVB11 = 9395.52+105-7571.64 = 1928.88 kg
Horizontal loads:-
1257.71 kg
A21 C21 B21
12.25
62.5 cm
RHB11
RHA11
= 1257.71 kg
1257.71x50.25
RHA11 = = 1011.2 kg
62.5
RHB11 = 1257.71-1011.2 = 246.51 kg
Resultant B.M. at C11 / C21 = (7571.64^2+1011.2^2)^0.5x12.25

= 93576.1 kg
= 20417.97 kg
Zxx of shaft = 71.57 cm3
C.S. area = 63.62 cm2
2
< 2140.67 kg/cm

2

= 9479.33 kg
Resultant Load at D11 = (105^2+246.51^2)^0.5

= 267.94 kg
Shear stress = 9479.33/63.62 = 149 kg/cm

2
< 1337.92 kg/cm

2
When the Rope Tension Is On Non-Gear Wheel Side
Vertical loads
3932.31 kg 5568.21 kg
A31 C31 D21 B31
12.25 39.75 10.5

62.5 cm
RVA21 RVB21
Vertical component of Tooth load of W1 + Wt. of gear wheel + ½
Load acting at C31 =
Weight of drum
3455.54 210
= + 150 +
Cos 20 2
= 3677.31 + 150 + 105
= 3932.31 kg
Load acting at D21 = ½ Weight of drum + Rope tension
210
= + 5463.21
2
= 5568.21 kg
RVA21 = (3932.31x50.25+5568.21x10.5)/62.5
= 4097.04 kg
RVB21 = 3932.31+5568.21-4097.04
= 5403.48 kg
Horizontal loads:-
1257.71 kg
A41 C41 B41
12.25
62.5 cm
RHB21
RHA21
= 1257.71 kg
1257.71x50.25
RHA21 = = 1011.2 kg
62.5
RHB21 = 1257.71-1011.2 = 246.51 kg
Resultant B.M. at C31 & C41 = (4097.04^2+1011.2^2)^0.5x12.25
= 51694.8 kgcm
= 56795.55 kgcm
2
< 2140.67 kg/cm

2

= 4128.55 kg
Resultant Load at D21 = (5568.21^2+246.51^2)^0.5 = 5573.66 kg
Shear stress = 5573.66/63.62 = 87.61 kg/cm < 1337.92 kg/cm
2 2
f) DRUM SHAFT BEARINGS

= 112405.82 N
Proposed Plummer Block SNL217 ,MAKE FAG/SKF with 22217 E
bearing and having dynamic capacity 285000 N
Cross – Sectional Area of one bolt = 3.4x2^2x0.85/4= 2.67 cm²
0.3XY.S
1.2
100X400X120
235X9.81
g) Design of Shaft- P1W2
Vertical loads
1699.5 kg 3692.31 kg
A51 C51 D41 B51
11.5 16 11
38.5 cm
RVA31 RVB31
Load acting at C51 = Tooth load of W2 + Wt. of W2
1568.82
= + 30
Cos 20
= 1669.5 + 30
= 1699.5 kg
Load acting at D41 =Vertical component of tooth load of P1+ Weight of P1
3455.54
= + 15
Cos 20
= 3677.31 + 15
= 3692.31 kg
RVB31 = (1699.5x11.5+3692.31x27.5)/38.5
= 3145.01 kg
RVA31 = 1699.5+3692.31-3145.01
= 2246.8 kg
Horizontal load:-
571 kg 1257.71 kg
A61 C61 D51 B61
11.5 16 11
38.5 cm
RHA31 RHB31
0
Horizontal load at C61 due to load on W2 gear = 1568.82 x tan 20
= 571 kg
0
Horizontal load at D51 due to load on P1 = 3455.54 x tan 20
= 1257.71 kg
RHA31 = (571x27+1257.71x11)/38.5
= 759.79 kg
RHB31 = 571+1257.71-759.79
= 1068.92 kg
Resultant Load at C51 / C61 = (1699.5^2+571^2)^0.5
= 1792.86 kg
Resultant Load at D41/ D51 = (3692.31^2+1257.71^2)^0.5
= 3900.64 kg
= 2371.79 kg
= 3321.7 kg
Resultant B.M. at C51/C61 = 2371.79x11.5
= 27275.59 kgcm
= 36538.7 kgcm
Torque transmitted by P1W2 shaft = 1568.82x18
= 28238.76 kgcm
Equivalent Torque (M + T ) = (36538.7^2+28238.76^2)^0.5
=
2 2 ½
= 46179.04 kgcm
= 41358.87 kgcm

Zpp of shaft = 67.35 cm3
C.S. area = 28.27 cm2

= 1228.36 kg./cm² < 2140.67 kg./cm²
= 685.66 kg./cm² < 2140.67 kg./cm²
= 117.5 kg./cm² < 1003.44 kg./cm²
= 1085.2 kg./cm² < 2140.67 kg./cm²
= 419.28 kg./cm²
< 1003.44 kg./cm²
= 1305.77 kg./cm² < 2140.67 kg./cm²
h) Design of Shaft P2
Vertical loads
1679.5 kg
A71 D61 B71
11.5 27
38.5 cm
RVA51 RVB51
Load acting at D61 = Tooth load of P2 + Weight. Of P2
1568.82
= + 10
Cos 20
= 1669.5 + 10 = 1679.5 kg
1679.5x27
RVA51 = = 1177.83 kg
38.5
RVB51 = 1679.5-1177.83 = 501.67 kg
Horizontal loads
571 kg
A81 D71 B81
11.5 27
38.5 cm
RHA51 RHB51
0
Horizontal load at D71 due to tooth load on P2= 1568.82 x tan 20
571 kg
571x27
RHA61 = = 400.44 kg
38.5
RHB61 = 571-400.44 = 170.56 kg
Resultant Load at D61 / D71 = (1679.5^2+571^2)^0.5
= 1773.91 kg
= 1244.04 kg
= 529.87 kg
= 14306.49 kgcm
Torque transmitted by P2 shaft = 1568.82x6.3
= 9883.57 kgcm
2 2 ½
= 17388.52 kgcm
= 15847.51 kgcm
Zpp of shaft = 24.54 cm3
C.S. area = 12.57 cm2
= 1291.57 kg/cm² < 2140.67 kg./cm²
= 708.58 kg./cm² < 2140.67 kg./cm²
= 98.97 kg./cm² < 1003.44 kg./cm²
= 1165.97 kg./cm² < 2140.67 kg./cm²
= 402.75 kg./cm² < 1003.44 kg./cm²
= 1358.72 kg./cm² < 2140.67 kg./cm²
i) BEARINGS
(i) For Shaft P1W2
= 48878.82 N
Proposed Plummer Block SNL513 ,MAKE FAG/SKF with 22213EK

and static capacity 216000N

Hence safe
Hence safe
(ii) For Shaft P2
= 26103.09 N
Proposed Plummer Block SNL509 ,MAKE FAG/SKF with 22209 EK
Hence safe
Hence safe
i) DESIGN KEY
PINION P1 & GEAR W2
Torque on P1W2 Shaft = 28238.76 kg-cm
Note: Design of key done based on shortes length
= 2X28238.76/(2X7X7)
= 576.3 kg/cm < 5056.07 kg/cm
2 2

= 4X28238.76/(1.2X7X7)
= 1921 kg/cm < 5056.07 kg/cm
2 2
PINION P2
Torque on P2 Shaft = 9883.57 kg-cm
= 2X9883.57/(1.4X5X6)
= 470.65 kg/cm < 5056.07 kg/cm
2 2

= 4X9883.57/(0.9X5X6)
= 1464.23 kg/cm < 5056.07 kg/cm
2 2
Key for Coupling:

= 2X9883.57/(1.2X4X6.5)
= 633.56 kg/cm < 5056.07 kg/cm
2 2

= 4X9883.57/(0.8X4X6.5)
= 1900.69 kg/cm < 5056.07 kg/cm
2 2
j) Design of Connection Bolts for Wheel W1 and Rope Drum

Rope tension = 5463.21 kg
Total load on bolts = 5463.21x400/450 = 4856.19 kg
Load on each bolt = 4856.19/8 = 607.02 kg
Shear stress in bolt = 607.02/0.96 632.31 kg/cm
2
=
0.3XY.S 0.3x400X100/(1.2 x9.81)= 1019.37 kg/cm
2
Allowable Shear Stress = =
1.2 Hence safe.
11. DIAL CALCULATION:-
Total lift= 5 m
Drum circumference= 3.14x40 = 125.66 cm
Length of the rope winding = 5x2 = 10 m
No. of turn of drum for full lift = 10x100/125.66 = 7.96
Provide 1 sets of pinions & gears as follows:-
Material of gears – IS-2062
Material of pinions – IS-2062
No. of Module/ PCD

teeth Pitch
1 Gear
st 19 3 57
1 Pinion
st 73 3 219
Sprocket 1 26 9.525 79.0216
Sprocket 2 57 9.525 172.906
Total reduction of Gear/Pinion/Sprocket = 73x57/(19x26) = 8.42
Total angle of movement of dial = 7.96x360/8.42 = 340.33 0
Movement of Dial needle for one meter lift = 340.33/5 = 68.1 0
MAKE: - Sprocket - Rol-kobo/SKF
Chain –Rol-kobo/SKF
Limit Switch - Speed-O-Control/BCH
12. BALANCING PULLEY:-
PULLEYS IS:1030 Gr. 280-520W

i) Balancing Pulley (1 Nos. per side)
P.C.D. of pulley= 20 x rope dia. = 20x20 = 400 mm
Load / Pulley = 2x1987.18 = 3974.36 kg

3974.36 kg
43.5 43.5
87 cm
R1 = R2 = 1987.18 kg
Pin dia.= 50 mm
π x 5^3
32
π x 5^2
C.S. area = = 19.63 cm2
4
Max. B.M. = 1987.18x4.35 = 8644.23 kgcm

= 704.5 kg./cm² < 1447.5 kg./cm²
= 101.23 kg./cm² < 1070.34 kg./cm²
At B.D.T. Condition:-
Load / Pulley = 2x5463.21 = 10926.42 kg
R1 = R2 = 5463.21 kg
Max. B.M. = 5463.21x4.35 = 23764.96 kgcm
= 1936.83 kg./cm² < 2854.23 kg./cm²
= 278.31 kg./cm² < 2854.23 kg./cm²
Bush for Balancing Sheave
Sheave Pin Diameter = 50 mm
Minimum Thickness of the Bush = 0.08X50+3 = 7 mm
Proposed Thickness of the Bush = 8 mm
Proposed Bush of Outside Diameter: 66 mm , Inside Diameter : 50 mm
Length of Balancing Sheave Bush : 55 mm, , Material: IS: 305 Gr: AB2
Maximum Load on the Bush = 3974.36 kg

Bearing Pressure of the Bush = 3974.36/(5X5.5)
= 144.522 kg/cm < 244.65 kg/cm2 SAFE
2
Supporting Bracket for Balancing Sheave

Load on each Balancing Sheave Bracket = 50 kg
Proposed Sheave Bracket of Width: 200 mm 12
Thickness: 12 mm , Height: 274 mm
Material: : IS 2062
74
200
Bearing Stress = 1987.18/(5X1.2)
= 331 kg/cm
2
< 1671.76 kg/cm2 SAFE 200

Compressive Stress = 1987.18/((20-5)X1.2)
= 110.4 kg/cm2
< 1402 kg/cm2 SAFE
13. Rotary Type Double acting Limit Switch:-
Mounted on Drum Shaft
Total number of turns of rope drum for entire lift of operation is = 7.96
(85x7.96)
Rotation of P1 & W2 shaft for gear = = 35.61
19
No. of Pitch PCD
teeth
Sprocket 1 57 9.525 172.91
Sprocket 2 17 9.525 51.8369
(7.96x57)
Rotation of rotary limit switch = = 26.7
17
Used Rotary Geared limit switch having Gear Ratio 40: 1,

14. Manual Drive Mechanism:-

Load / Rope = 1987.18 kg
Torque on each drum = 1987.18x20 = 39743.6 kgcm
Torque on each cross shaft = 467555
39743.6x19x21/(85x60xeffy.
x (23/117) (21/98)/effy.Of
Ofdrum
drum&&end
endgears)
gears
= 39743.6x19x21/(85x60x0.95^3) = 3626.6 kgcm
Torque on output shaft of worm reducer = 3626.6x2 = 7253.2 kgcm

Torque on input shaft of worm reducer = 7253.2/(70xeff. Of worm reducer)
= 7253.2/(70x0.6795) = 152.49 kgcm
No. of Pitch PCD

teeth
Sprocket 1 27 12.7 109.395
Sprocket 2 27 12.7 109.395
Radius of arm of hand lever = 400 mm = 40 cm

Now, force required on hand lever = 152.49x27/(40x27xeff. Of sprocket)
= 152.49x27/(40x27x0.95) = 4.01 kg
One men required with total effort = 1 x100 = 100 N ( 10.1937 Kg.)
Breaking load of 12.7 mm pitch chain = 2950 kg. (Ref. IS: 2403)
Lifting speed of gate = 24x27x3.14x0.4/(27x70x4.47x2.86x2)
= 0.0168 M/min
= 1.68 cm/min

15.0 ROPE SLACKENING AND OVERLOAD PROTECTION DEVICE
Over load Slack Condition
Sheave
Normal
Condition
Balancing Sheave
Balancing Sheave
y
42
a
10
170
Over Load
Condition
850 850
1700
PCD of Overload Sheaves = 280 mm

PCD of Balancing = 400 mm
Rope Tension under Normal Condition = 1,987.18 kg
Overload Factor consider for Overloading = 1.25
Rope Tension under Overload Condition = 1987.18X1.25
= 2483.975 kg
Rope Slope under Normal Condition(y) = tan-1 (170-60)/850
= 7.37 0
Rope Slope under Overload Condition(a) = tan-1 (170-10-60)/850

= 6.71 0
Load on Pulley due to Rope Tension under Normal Condition= 2X1987.18 Xsin(7.37)
= 510.08 kg
Load on Pulley due to Rope Tension under Overload Condition= 2X2483.98 Xsin(6.71)
= 580.46 kg
Length of wire rope = 5 m
Weight of wire rope = 152 kg/100m
Self Weight of the Wire Rope on the Sheave = (5X152X2)/100
= 15.2 kg
Self Weight of Overload Sheave Arrangement = 50 kg
Total Weight on the Overload Sheave = 15.2+50
= 165 kg
Total Load on Sheave under Normal Condition(Pn)= 510.08 +165.2
= 675 kg
Total Load on Sheave under Overload Condition(Po)= 580.46 +165.2
= 745.66 kg
DESIGN/SELECTION PIN FOR OVERLOAD SHEAVE
Centre Line
of Sheave
A B C
58.5 59
117
Total Vertical Load on the Sheave under Normal Condition = 675.28 kg

Total Vertical Load on the Sheave under Overload Condition = 746 kg
Total Vertical Load On the Sheave Under Rope Slackening Condition = 165.2 kg
Vertical Reaction at A or C under Normal Condition = 337.64 kg
Vertical Reaction at A or C under Overload Condition = 372.83 kg
Bending Moment at B under Normal Condition = 337.64X5.85
= 1975.19 kg-cm
Bending Moment at B under Overload Condition = 372.83X5.85
= 2181.0555 kg-cm
Proposed Pin of Diameter : 50 mm, ## mm

Nos. Required : 1 , Material of Pin : IS:2004, Class5
Zxx = (3.14X5^3)/32
12.27 cm
3
Area = (3.14X5^2)/4
19.63 cm
2
Bending Stress(sb) under Normal Condition = 1975.19/12.27

= 100.62 kg/cm < 1447.5 kg/cm2
2
SAFE
Direct Shear Stress(sd) under Normal Condition = 337.64/19.63
= 17.2 kg/cm < 1070.34 kg/cm2
2
SAFE
Bending Stress(sb) under Overload Condition = 2181.0555/12.27

= 177.76 kg/cm < 2854.23 kg/cm2
2
SAFE
Direct Shear Stress(sd) under Overload Condition = 372.83/19.63
= 111.11 kg/cm < 2854.23 kg/cm2
2
SAFE
Bush for Overload Sheave
Sheave Pin Diameter = 50 mm
Minimum Thickness of the Bush = 0.08X50+3
= 7 mm
Proposed Thickness of the Bush = 8 mm
Proposed Bush of Outside Diameter: 66 mm , Inside Diameter : 50 mm
Length of Overload Sheave Bush : 55 mm,
Nos. Required:
1 , Material: IS 305Gr.AB2
Maximum Load on the Bush =746 kg

Bearing Pressure of the Bush = 745.66/(5X5.5)
= 27.1 kg/cm2 < 244.65 kg/cm2 SAFE
Connecting Rod for Overload Sheave
Max. Load on the Rod = 746 kg
Proposed Rod of Dia.: 30 mm, Length : ## mm
Nos. Required : 1 , Material of Rod : IS2062 E250 (Fe410W)
Area of Rod = (3.14X3^2)/4
= 7.065 cm
2
Tensile Stress on the Rod = 745.66/7.065

= 105.54 kg/cm2 < 1401.63 kg/cm2 SAFE
Nut for Rod
Max. Load on the Nut = 745.66 kg
Pitch of the nut = 3 mm
Number of thread = 10
Size of the Nut = M28 48
Shear Stress of the Nut = 745.66/(3.14X10X4.8X0.3)
= 16.49 kg/cm2 < #REF! kg/cm2 #REF!
Design of Spring
Max. Load on the Spring = 745.66 kg
Spring Index(C ) = D/d
Where, D : Mean Coil Diameter
d : Wire Diameter
Assume Spring Index(C) = 6
Wahl's Factor(K) =  4C  1  0.615

 
 4C  4  C
Where, C : Spring Index
= (4X6-1)/(4X6-4)+0.615/6
K = 1.25
1
 8 PK 
 
2
Diameter of coil of spring(d) =
 t 
Where, P: Load on
K: Wahl's Factor
t : Allowable Shear Stress of Spring(kg/cm2)
d = ((8X745.66X1.25)/(3.14X4810))^0.5
d = 0.7 cm
= 7 mm
Proposed Rod Diameter of the Spring: 12 mm, Mean Coil Diameter: 72 mm

Outside Coil Diameter : 84 mm, Inside Coil Dia.: 60 mm, Stiffness: 69.44 kg/cm
Number of Effictive Coil: 8 Total Nos. of Coil: 10 Free Length of Spring: 240 mm
Pitch of the Spring: 24 mm, Helix Angle of the Spring: 6 0 , Solid Length of Spring: 120
mm, Modulus of Rigidity: 800000 kg/cm 2 , Material: 65Si7
F1 (F 2  F 1)

h1 h
F1 = 745.66-675.28
= 70.38 kg
h1 = 10.0 mm
G  d 4
 h1
Number of Working Coils on the Spring(n) =
8  D  F1
3
= (800000X1.2^4X1)/(8X7.2^3X70.38)
= 7.89
@ 8
Type of End = Square End
=2
Total number of Coils = 8+2
= 10
G  d 4
Actual Stiffness(k) =
8  D 3
 N
= (800000X1.2^4)/(8X7.2^3X8)
= 69.44 kg/cm
Deflection under Normal Load = 675.28/69.44
= 9.72 cm
= 97.2 mm
Deflection under Over Load = 745.66/69.44
= 10.7 cm
= 107 mm
Deflection of spring from normal load to over load = 10.13346 mm
Deflection under Rope Slackening = 165.2/69.44
= 2.379 cm
= 23.79 mm
Deflection of spring from normal load to Rope Slackening = 73.46 mm
Solid Length of the Spring = 10X12
= 120 mm
Minimum clearance between Coils = 120X0.15
= 18 mm
@ 16 mm
Free Length of the Spring = 107.38+120+16
= 243.38 mm
@ 240 mm
Length of the Spring Rope Slackening Condition = 216.21 mm
Length of the Spring Normal Load Condition = 142.75 mm
Length of the Spring Overload Condition = 132.62 mm
Pitch of the Spring(p) = (240-120)/10+12

= 24 mm
Helix Angle = tan (24/(3.14X72))
-1
= 0.11
= 6.06 0
Proposed Limit Switch of Type: LLA , Make : Industriaes Syndicate, BCH
Nos. Required : 2

GTS, PTS & Technical Data Sheet of Pakaldul H.E.project

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GTS, PTS & Technical Data Sheet of Pakaldul H.E.project

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DESIGN CALCULATION OF 7.5MT ROPE DRUM HOIST FOR HEAD PAGE : 1 of 42..............

REGULATOR VERTICAL LIFT GATE SIZE 3500MM X 2900MM

c. IS: 800 – Code of Practice for General Construction in Steel.

a. Capacity of Hoist - 7.5 MT

b. Type - Electrically Operated Rope Drum Hoist

c. Lifting speed - 0.5  5% m / min.

d. Lift - 5.0 Mts.

e. No. of Hoists required -2

f. Number of Rope Drum - 2 Nos.

g. Number of fall on each Drum - 2 Nos.

1. Structure Structural Steel IS2062 E250 (Fe410W)

2. Rope drum Structural Steel IS:1030 Gr.340-570W

3. Sheaves & Pulleys Cast Steel IS:1030 Gr. 280-520W

4. Shafts Forged Steel IS: 2004 Class 5, 55C8/En9

7. Gear Wheel Cast Steel IS:1030 Gr.340-570W

8. Pinions Forged Steel IS: 2004 Class 5, 55C8/En9

9. Threaded Fasteners Mild Steel IS: 1363 / IS: 1367

SL.No. Material & Strength

Y.P. = 240 N/mm for thickness > 20mm and <40mm

Y.P. = 230 N/mm for thickness > 40mm

U.T.S = 410 N/mm

U.T.S = 520 N/mm

b. Break down condition:-

b). Brake Down Condition –

b). Brake Down Condition:-

B.Type-1 & 2 Gears : IS:1030 Gr.340-570W

C. Pinion : IS:2004, Class5

E. Pin for Sheave : IS:2004, Class5

b. Shear Stress under Normal Condition = 3567.79x0.3 = 1070.34 kg/cm

c. Bending Stress under BDT condition= 3567.79x0.8 = 2854.23 kg/cm

d. Shear Stress under BDT condition = 3567.79x0.8 = 2854.23 kg/cm

F. Key for Shafts : IS:2004 Class 4

b. Crushing Stress : 6320.08x0.3 = 1896.02 kg/cm

b. Shear Stress under BDT Condition : 6320.08x0.8 = 5056.07 kg/cm

b. Crushing Stress under BDT Condition : 6320.08x0.8 = 5056.07 kg/cm

Plate < 20 mm < 40 mm = 0.55x2446.48 = 1345.57 kg/cm

Plate < 40 mm = 0.55x2344.55 = 1289.5 kg/cm

Break down condition:-

Plate < 20 mm < 40 mm = 0.73x2446.48 = 1785.93 kg/cm

Plate < 40 mm = 0.73x2344.55 = 1711.52 kg/cm

ii). Shear Stress

Plate < 20 mm < 40 mm = 0.4x2446.48 = 978.59 kg/cm

Plate < 40 mm = 0.4x2344.55 = 937.82 kg/cm

Break down condition = 1.33 X Allowable stress

Plate < 20 mm < 40 mm = 1.33x978.59 = 1301.52 kg/cm

Plate < 40 mm = 1.33x937.82 = 1247.3 kg/cm

iii). Bearing Stress

B D T condition= 1.33 X Allowable stress = 1.33x1671.76 = 2223.44 kg/cm

iv). Combined Stress

Plate < 20 mm < 40 mm = 0.75x2446.48 = 1834.86 kg/cm

Plate < 40 mm = 0.75x2344.55 = 1758.41 kg/cm

B D T condition= 1.33 X Allowable stress = 1.33x1274.21 = 1694.7 kg/cm

Bending stress with keys = 0.75x1264.02 = 948.02 kg/cm

Torsional stress without keys = 0.3x3261.98 = 978.59 kg/cm

Torsional stress with keys = 0.75x978.59 = 733.94 kg/cm

Combined stress without keys = 0.24x6320.08 = 1516.82 kg/cm

Combined stress with keys = 0.75x1516.82 = 1137.62 kg/cm

Equivalent bending stress without keys = 1.2x1264.02 = 1516.82 kg/cm

Equivalent bending stress with keys = 1.2x948.02 = 1137.62 kg/cm

Equivalent Torsional stress without keys = 1.2x978.59 = 1174.31 kg/cm

Equivalent Torsional stress with keys = 1.2x733.94 = 880.73 kg/cm

b. Break Down Condition

Bending stress with keys = 0.75x2609.58 = 1957.19 kg/cm