Module 2

Design of Hoisting Mechanism

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 1
Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 2
 Snatch Block

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 3
Multiple Pulley Systems:

a) 2 fall system, b) 4 fall system with 3 bends, c) 4 fall system with 4 bends

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 4
 •Efficiency of Pulley system:

T1 T2 T3 T4 T5 T6

Let Q is a load to be lifted with efforts Z and T1, T2, T3, T4, T5, T6 are the tensions in the rope shown.
Now, T1 + T2 + T3 + T4 + T5 + T6 = Q

If ε be the transmission ratio, then , T5 = T6 X ε, Similarly,

T4= T5 X ε = T6 X ε2

T3 = T6 X ε3

T2 = T6 X ε4 T1 = T6 X ε5

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 5
 T6 [ ε5 + ε4 + ε3 + ε2 + ε + 1 ] = Q,

Now Ideal effort:

Efficiency of the pulley:

general equation for the efficiency of n number of pulleys,

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 6
Recommended fall system corresponding to different loads and efficiency of pulley system

Load to be Lifted No. of Fall System Efficiency of Pulley

Upto 40 KN 2 0.97

50-200 4 0.95

200-250 6 0.92

250-750 8 0.90

750-1000 10 0.85

1000-1200 12 0.8

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 7
• Bend

• Compensating Pulley

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 8
• Wire Rope

 Advantage of wire rope over chain

 Lighter weight.
 Less susceptibility to damage from jerk.
 Silent operation even at high working speed.
 Greater reliability in operation.

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 9
• Construction of wire rope

Wire Rope and its strands

6×7 > rope is made up of heavy wires and provides maximum resistance to wear and vibration.
6×19 > good compromise between flexibility and wear. It is most popular and widely used.
6×37 > Extra flexible are used where abrasion and wear are not very severe. Relatively sharp bends can be tolerated.

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 10
 (a) parallel, (b) cross, (c) Composite Lays of wire Rope

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 11
 The relation between the diameter of rope and diameter of wire is given by

• SIZE OF ROPE BASED ON DIRECT AND BENDING STRESSES

maximum tension per fall

Considering direct and Bending stresses

Where, A = cross sectional area ( Metal content) =

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 12
E’ =Modified Young modulus = 0.8 X106 kgf/cm2 ( Considering twisting which causes reduction in bending stress)
dw = wire diameter,
Dmin = minimum diameter of sheave,

n = stress factor = n’ x duty factor , n’ = factor of safety

Rearranging the above equation,

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 13
 For 6 x 37 wire designation,
=

For 6 x 19 designation, A =

Breaking strength of the wire rope is given by,

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 14
  Check for life:

Value of Z are mentioned corresponding to values of m,

Life in No. of months , N =
m- a constant relating to life of rope
( Multiplication factor for m is 0.01 and for Z is 1000)

where, Z = no. of cycles, a = No. of working cycles per month,  = Endurance factor, Z2 = No. of bends

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 15
 • Crosspiece

 Crosspiece design procedure

1. Material of crosspiece is selected. Then design stresses are

determined.
2. Length of crosspiece is determined based on axle
dimensions.
3. Trunion diameter is calculated based on shear stress
criteria.
4. Trunion is then checked for bending and bearing failure.
5. Then width of crosspiece is calculated and sectional
modulus is found out.
6. After that crosspiece is checked under bending condition.

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 16
• Shackle Plate

 Shackle plate design

1. The crosspiece is secured in the side plates which are strengthened
with shackles or straps. As a rule, only shackles are checked for
strength neglecting the plates in view of their relatively small
thickness.
2. Material for shackle plate is determined.
3. Then width of shackle plate is calculated
4. Shackle plate is checked under three conditions i.e. tensile, double
shear and crushing failure.

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 17
 • Hook
Material used for hook is mild steel and high tensile steel.

 Design procedure of hook

1. Material for hook is selected and stresses for shank and threaded part are
determined.
2. Value of throat diameter C is decided based on the load to be lifted and the
material of hook.
3. Then using data from PSG 9.11 and PSG 6.3 hook dimensions are calculated.
4. The design load acting on hook is determined.
5. The hook shank is checked for tensile stresses in the threaded portion.
6. The stresses (bending and shear stresses) at different sections are checked using
different design theories
7. The most critical section at inner and outer fibre is checked for direct tensile and
bending stresses.
8. If stresses are beyond safe limit then either change the material of the hook or
redesign it.
Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 18
  Important sections of hook

• Section 1-1 is threaded part and it is checked for tensile failure.

• Section 2-2 is critical section and checked for combined tensile and bending failure at
inner and outer fiber. Inner fiber is most critical as magnitude of total stress induced at
inner fiber is maximum there.

• Section 3-3 is critical stress region, subjected to tensile, shear and bending hence,
Maximum Principal Stress theory (MPST) and Maximum shear stress theory (MSST) are
applied at this section to calculate induced stresses.

• Section 4-4 is subjected to direct shear stress, hence checked for shear failure

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 19
 Thrust bearing selection

1. Bearing series is selected based on hook thread diameter.

2. The required dynamic capacity is calculated based on radial and axial load
acting on hook.
3. A standard bearing is selected from the catalogue which has dynamic capacity
more than required dynamic capacity and inner diameter equal to hook thread
diameter .

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 20
• Rope drum

Rope drum cross section

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 21
QUIZ:

Prof. Sanjay W. Rukhande, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai 22