DESIGN OF AN ELEVATOR FOR THE ALMACEN NACIONAL’S WAREHOUSE PLACED IN TRUJILLO, VALLE

PROJECT PROPOSAL FOR THE MECHANICAL DESIGN COURSE

CAMILO CACERES CARDONA

SCHOOL OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSIDAD DEL VALLE
SANTIAGO DE CALI, VALLE DEL CAUCA
 I. INTRODUCTION

Fig. 1. Example of a dangerous maneuver by a worker.

L. Ruiz, ''Manipulación manual de cargar, guía técnica del INSHT'', Instituto Nacional de Seguridad
e Higiene en el Trabajo, 2011.
 METHODOLOGY

To achieve the purpose of the project, the following steps are considered:

• Measure the operating conditions that the elevator would have in the warehouse of the market in
order to determine the daily work cycles and the different loads to which it would be subject.

• Design the structure of the elevator along with the cabin.

• Design the mobile work table on which the elevator and motor would be supported.

• Select the elevator motor according to torque and power requirements.

• Design the reducer system and its parts (gears, pinions, shafts and suspension cable reel).

• Evaluate the cost/benefit of the project and compare it with alternatives available in the market.
 OPERATING CONDITIONS:

The normal storing operations in the warehouse during a standard day between week (Monday to
Friday) are about 10 charges per hour, those days the normal time work is of 10 hours a day. On
Saturdays the storing operations are about 15 chargers per hour with a normal time work of 12 hours
a day. The warehouse is closed on Sundays. Which means a total of around 680 chargers a week, 35360
a year as shown in Equation 1.

10 𝑐𝑦𝑐𝑙𝑒𝑠 10 ℎ𝑜𝑢𝑟𝑠 5 𝑑𝑎𝑦𝑠 15 𝑐𝑦𝑐𝑙𝑒𝑠 12 ℎ𝑜𝑢𝑟𝑠 1 𝑑𝑎𝑦

𝑊𝑜𝑟𝑘 𝑐𝑦𝑐𝑙𝑒𝑠 = ( ∙ )∙ +( ∙ )∙
ℎ𝑜𝑢𝑟 𝑑𝑎𝑦 𝑤𝑒𝑒𝑘 ℎ𝑜𝑢𝑟 𝑑𝑎𝑦 𝑤𝑒𝑒𝑘
680 𝑐𝑦𝑐𝑙𝑒𝑠 52 𝑤𝑒𝑒𝑘𝑠 35360 𝑐𝑦𝑐𝑙𝑒𝑠
= ∙ ≈
𝑤𝑒𝑒𝑘 𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
 ESTRUCTURE

Fig. 2. Selection of the commercial L-shaped profile

Fig. 3. Isometric of the initial structure of the elevator made with the profiles selected.
 CABIN

Fig. 4. Isometric of the structure of the cabin.

 Fig. 5. FBD of the cabin with constant velocity or static.

Assuming that the elevator could be overloaded with 70 kg of charge, plus a 5 kg additional load because of the cabin
wheels and rollers, based on the parameters of linear density for the profiles in Figure 2 and their dimensions for the
cabin, the total weight can be computed as shown in Equation (2).

9.81 𝑚 2.88 𝑘𝑔𝑓 9.81 𝑁

𝑊𝑚𝑎𝑥 = 𝑚𝑔 + 𝜌𝑙 𝑙 = 75 𝑘𝑔 ∙ + ∙ ∙ (4 ∙ 0.808 𝑚 + 8 ∙ 0.712𝑚) ≈ 988 𝑁
𝑠2 𝑚 1𝑘𝑔𝑓
 0.4 𝑚
𝑃𝑟 = 988 𝑁 ∙ = 395.2 𝑊 ≈ 0.53 𝐻𝑃
𝑠

𝑃𝑟 0.53 HP
𝑃𝑚 = 2 = = 0.639 𝐻𝑃
𝜂𝑐 ∙ 𝜂𝑏 2 0.922 ∙ 0.992
 Fig. 6. Siemens brand three-phase motor catalog available in the local market.

A 0.75 HP three-phase motor must be selected to supply the power necessities. This value
leaves a 15% extra power with respect of the power required computed, that will help to
overcome the initial inertia of the cabin and load, and also the friction loses in pulleys and
rollers.
 SPEED REDUCER

Fig. 7. Speed reducer scheme.

 𝐷𝑅 100 𝑟𝑒𝑣 1 𝑚𝑖𝑛 ∙ 2𝜋 𝑟𝑎𝑑 76 𝑚𝑚
𝑉𝐶 = 𝜔𝑜𝑢𝑡 ∙ = ∙ ∙ = 398 𝑚𝑚/𝑠 = 0.398 𝑚/𝑠
2 𝑚𝑖𝑛 60 𝑠 ∙ 1 𝑟𝑒𝑣 2

Which is very closed to the expected speed of 0.4 m/s.

 TRANSMISION RATIO

𝑖 𝑇 = 𝑖1−2 ∙ 𝑖3−4 , 𝑖1−2 = 𝑖3−4 → 𝑖 𝑇 = 𝑖1−2 2 → 𝑖1−2 = 𝑖2−3 = √𝑖 𝑇 = √9 = 3

𝜔1 𝜔1 900 𝑟𝑝𝑚
𝑖1−2 = → 𝜔2 = = = 300 𝑟𝑝𝑚
𝜔2 𝑖1−2 3

Since the gears 2 and 3 are connected by the same shaft, in this way all the angular speeds
are defined. It is 𝜔1 =900 rpm, 𝜔2 =𝜔3 =300 rpm and 𝜔4 =100 rpm.
 GEAR 1 (PINION) – GEAR 2 (GEAR)

For the first gear stage, the following parameters are given or proposed:

𝑚=2
8𝑚 ≤ 𝐹 ≤ 16𝑚 → 𝐹 = 14𝑚 = 28𝑚𝑚
𝑄𝑉 = 6
𝑃 = 0.75 𝐻𝑃 = 559.2 𝑊
𝜔1 = 900 𝑟𝑝𝑚 = 94.25 𝑟𝑎𝑑/𝑠
𝜔2 = 300 𝑟𝑝𝑚 = 31.42 𝑟𝑎𝑑/𝑠
𝑁1 = 32
𝑁2 = 96
𝐻𝐵1 = 240 𝐻𝐵
𝐻𝐵2 = 200 𝐻𝐵
𝑑 = 𝑚 ∙ 𝑁 → 𝑑1 = 64 𝑚𝑚, 𝑑2 = 192 𝑚𝑚
 CHECK OF VELOCITY

𝑑
𝑉= ∙ 𝜔 → 𝑉1 = 3.02 𝑚/𝑠, 𝑉2 = 3.02 𝑚/𝑠
2

Fig. 8. AGMA Dynamic Factors [5].

𝑇1 = 5.93 𝑁𝑚, 𝑊𝑡1 = 185.4 𝑁

𝑇2 = 17.8 𝑁𝑚, 𝑊𝑡2 = 185.4 𝑁

 Fig. 9. Spur gear geometric factor

According to Figure 10 the geometric factor for the first gear stage J = 0.39.
 K FACTORS

Based on [5],[6] service factor Ka is 1 for a uniform application, such an electric

motor at constant speed. Load distribution Km for face width F < 50 mm is 1.6.
According to [5] the AGMA recommends a size factor Ks set to 1 unless particular
situations, such as very large teeth, which is not the case. And Kv must be
calculated as follows.

𝐴 𝐵 12−𝑄𝑣 2
𝐾𝑣 = ( ) ,𝐵=( )3 , 𝐴 = 50 + 56(1 − 𝐵)
𝐴+√200𝑉𝑡 4

𝐵 = 0.8255 → 𝐴 = 59.77 → 𝐾𝑣 = 0.753

 C FACTORS

The 𝐶𝑝 , 𝐶𝑓 , and 𝐼 parameters are needed. According to [6], the elastic coefficient
𝐶𝑝 for steel gears is 191 MPa and 𝐶𝑓 assuming a good surface finish is 1. The
surface geometry factor can be computed as:

𝑐𝑜𝑠𝜙𝑠𝑖𝑛𝜙
𝐼= = 0.12
1 1
𝑑(𝑟 + 𝑟 )
𝑝 𝑔
Finally, CH depends of the hardness ratio which in this case is set to 1.2 which indicates a CH value of
1.005 according to Figure 11.

Fig. 10. Hardness-ratio factor (for hardened steel).

 SECURITY FACTORS

For the pinion

𝑺𝑭 = 𝟕. 𝟖𝟎 and 𝑺𝑯 = 𝟏. 𝟓𝟗
For the gear

𝑺𝑭 = 𝟕. 𝟎𝟑 and 𝑺𝑯 = 𝟏. 𝟒𝟏
 GEAR 3 (PINION) – GEAR 4 (GEAR)

For the second gear stage, the following parameters are given or proposed:

𝑚=3
8𝑚 ≤ 𝐹 ≤ 16𝑚 → 𝐹 = 12𝑚 = 36𝑚𝑚
𝑄𝑉 = 6
𝜔3 = 300 𝑟𝑝𝑚 = 31.42 𝑟𝑎𝑑/𝑠
𝜔4 = 100 𝑟𝑝𝑚 = 10.47 𝑟𝑎𝑑/𝑠
𝑁1 = 30
𝑁2 = 90
𝐻𝐵1 = 240 𝐻𝐵
𝐻𝐵2 = 200 𝐻𝐵

The power of the second stage is the power of the first minus the transmission losses at the
moment, thus:

𝑃3−4 = 𝜂𝑏 𝜂𝑐 𝑃1−2 = 0.92 ∙ 0.99 ∙ 559.2 𝑊 = 509.4 𝑊

 SECURITY FACTORS

For the pinion

𝑺𝑭 = 𝟖. 𝟐𝟔 and 𝑺𝑯 = 𝟏. 𝟔𝟎
For the gear

𝑺𝑭 = 𝟕. 𝟒𝟓 and 𝑺𝑯 = 𝟏. 𝟒𝟕
 ELEVATOR SYSTEM

Fig. 11. Final elevator system design.

DESIGN PLANS
 6 5 4 3 2 1

D D

C C

00
0 0,
40

0
0 ,0
75

6,35

B B

6,35

Date Date
A Designed by Checked by Approved by
A
CACERES C. CACERES C. CASANOVA G.12/04/2019 04/04/2019

ALL DIMENSIONS IN MM L-SHAPED PROFILES

SCALE 1:10 perfilL
Edition Sheet
1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D D
1600,00
62,00

60,00 60,00

2,00

C C

766,00 750,00

1600,00
B B

5
6,3
766,00

12,00
100,00

Date Date
A Designed by Checked by Approved by
A
CACERES C. CACERES C. CASANOVA G.12/04/2019 06/04/2019

ALL DIMENSIONS IN MM SUPPORT TABLE

50,00 60,00
24,00 SCALE 1:10 Edition Sheet
1/1
6 5 4 3 2 1
 6 5 4 3 2 1

28,00
0
2,0
D 1 9 D

R40
,00

259,96
127,85

C C

,00
R15

4 ,00
6

B B

195,94

Date Date
A Designed by Checked by Approved by
A
CACERES C. CACERES C. CASANOVA G.12/04/2019 11/04/2019

GEARS STAGE 1
ALL DIMENSIONS IN MM Edition Sheet
1-2-1 1/1
6 5 4 3 2 1
 6 5 4 3 2 1
90 36,00
,0
0
0
R20,0
D D

27
0,0
179,98

0 0

365,97
R50,

C C

B B

275,99

Date Date
A Designed by Checked by Approved by
A
CACERES C. CACERES C. CASANOVA G.12/04/2019 06/04/2019

ALL DIMENSIONS IN MM GEARS STAGE 2

SCALE 1:4 Edition Sheet
1/1
6 5 4 3 2 1
 6 5 4 3 2 1

D D
40,30

,00 50

182,96
3 0 ,0
0
142,66

142,66
50
,0
0

213,00
C 453,00 C

159,34

206,20 246,80
118,37 30,00

30,00

B B
223,00

213,00

14,00

100,00 14,00
40,00

80,00
Date Date
A Designed by Checked by Approved by
A
CACERES C. CACERES C. CASANOVA G.12/04/2019 06/04/2019

2 STAGES GEAR REDUCER

ALL DIMENSIONS IN MM Edition Sheet
SCALE 1:4 1 1/1
6 5 4 3 2 1