Design of Hoisting Mechanism For Crane R1

DESIGN OF HOISTING
MECHANISM FOR CRANE

By Prof: B.J.DESAI
CLASSIFICATION OF MATERIAL
HANDLING EQUIPMENTS-1
• TRANSPORT EQUIPMENT
• a) Conveyors
• b) Cranes
• c) Industrial Trucks
• POSITIONING EQUIPMENT
CLASSIFICATION OF MATERIAL
HANDLING EQUIPMENTS-2
• UNIT LOAD FORMATION EQUIPMENT
• STORAGE EQUIPMENT
• IDENTIFICATION AND COMMUNICATION

EQUIPMENT
INTRODUCTION
• The crane is one of the most important equipment
for handling of material in any industries with fast
speed, reliability, safety, economy.
• EOT(Electric Overhead Travel) crane is a
mechanical lifting device used for lifting or
lowering the material and also used for moving the
loads horizontally or vertically. It is useful when
lifting or moving the loads (beyond the capacity
of human.)
Different Types of Cranes
• https://www.youtube.com/watch?v=Osq_KlD
ty30
Assembly of EOT CRANE
STRUCTURE OF EOT CRANE
coupling
motor Bearings
Grooved rope Drum
Hoist rope
Pulley
Gear box
Bottom block
Thrust bearing
Load
SCHEMATIC VIEW OF THE HOISTING DEVICE

ASSEMBLY
8|Page
Exploded view of Crane Hoist
Different Types of Hoisting
mechanisms
•
COMPONENTS OF HOISTING
MECHANISM
• Hoisting is the process of lifting/lowering
some load or person with the help of some
device or mechanism.(Hoisting Mechanism)
• List of components used in Hoisting
Mechanism of EOT Crane Design-
1. Crane Hook 2. Thrust ball bearing
3 Pulley 4.Wire rope
5 Drum 6. Gear box
7 Electric motor 8. Brake
ASSEMBLY OF HOISTING
MECHANISM
• The gear box is coupled to the rope drum
• The rope is wounded on the rope drum The

pulleys are arranged with 8 rope falls
• At the bottom of the pulley the hook is

attached with the help of a thrust bearing
DESIGN OF CRANE HOOK-1
• The hooks are tested to more than double the
working load.
Analysis of the stresses in the hook, which is
a curved bar subjected to combined bending

and tensile stresses
Theoretically we can have

following cross sections for
crane hook
i)Circular
ii)Rectangular
iii)Triangular
iv)Trapezoidal
FEA analysis of above
sections proved that
Trapezoidal section is the
optimum.
• Design Calculations
• Hook bed diameter is given by the formula, C=µ√p
(Emperical Relation)
• Where P is the load applied in tonne & µ is a
• constant varying from 3.75 to 7.5
• For economy of material, the value of µ should
• be kept as low as possible, the lower limit
• beingfixed by the size of slings, ring etc. to be

• accommodated. In shank hooks using metal
• fittings, µ has been fixed at 3.75.
• For 5 Tonne Hook, C = 3.75√5
• = 8.385 cm
• This relation between C and d for the recommended
standard section is
• d= 3.125 √P +0.1 C = 3.125 √5 + 0.1×8.385
• =7.8275 cm =7.8 cm
• The working tensile stress in the shank may be
assumed at 400 kgf/cm².as recommended by
Standards.Materialforhook:ForgedsteelAISI4140
• Let d¹=Dia. Of shank at bottom of the threads.
Then, 0.785 (d¹)²×400= 5000

• (d¹)²= 16, d¹= 4 cm
• The hook load will be carried by ball thrust
• bearing through a round nut screwed on to the
• end of the shank.
• Full dia. Of the shank = 40/0.84 = 48 mm say
• 50 mm
• The other dimensions of Trapezoidal section
of the body of the hook are as follows
• Breadth at intrados (Inner surface)
• =0.65 × 78 =50.8 say 51mm
• Radius of intrados curve = 0.75×78= 58 mm
Bed dia. = 84 mm
• Corner radius = 78/8 =10 mm
CRANE HOOK ASSEMBLY
SELECTION OF THRUST BALL
BEARING
• Function of bearing to prevent the spinning
action of the load relative to the wire ropes.
• For this reason, the speed factor need
not be taken into consideration
• Single thrust ball bearing type 51210 (50 mm
• bore) will be suitable
• The dimensions and load carrying capacity
• are asfollows:-
• Bore - 50 mm and 50.2 mm Outside diameter
• – 78 mm Thickness – 22 mm
• Static carrying capacity – 9000 kg Factor of
• Safety = 9000/5000 =1.8
DESIGN OF ROPE PULLEYS
• For 6/37 construction of the wire ropes the
• minimum dia. Of rope pulley at the bottom of
thev-groove as recommended by IS-2266-1963,
should be 6 times the circumference of the rope

• P.C. dia. Of rope pulley should be 6×4.4
• =26.4, say 27 cm or 270 mm at
• the bottom of the groove say 285 mm rope crs
• (min.) adopt 290 mm dia.

CROSS SECTION OF ROPE PULLEY
• CALCULATIONS ARE GIVEN IN NEXT SLIDE
DESIGN OF ROPE PULLEY
• Symbol Value in value
• terms of d
• d 29
• t 0.4d 11.6
• h 1.6d 46.4
• b1 2.7d 70.3
• b2 2 .1d 60.9
• l 0.75d 19.7
• R0 1.1d 31.9
•
DESIGN OF ROPE DRUM
• The rope drum material seamless pipe
machined & grooved accurately, to -ensure
proper seating of wire rope .
• The drum should be fitted with two heavy
duty Ball / Roller bearings smooth operation
& longer life.
CROSS SECTION OF ROPE DRUM
DESIGN OF ROPE DRUM
symbol Value in d Value
Drum groove radius(r) 0.5d+1.5mm 16mm
Pitch(p) 2r+3mm 35mm
H1 0.25d 7.25
h 1.1d 31.9mm
23d to 30d
Drum dia [d0] 667mm
Take 23d
Drum length 4197mm
Drum length =pitch x ground height x no of ropefall/drum dia =35x10000x8/667

=4197mm
[let ground height be 10m]
Average drum thickness = h+h/2 = 31.9+7.1/2 =35

Typical cross sections of a wire
Rope
CONSTRUCTION OF WIRE ROPE
• Core
• Core
Outer strands with triangular
wire
Core
ADVANTAGES OF WIRE ROPES
• High strength to weight ratio
• Silent operation even at high velocities.
• Greater reliability
DESIGN OF WIRE ROPES
• A hoisting device use chain, fiber or wire rope as
its lifting medium
• Wire rope consists of several strands laid (or
‘twisted’) together like a helix.
• Each strand is likewise made of metal wires laid
together like a helix.Abrasion resistance
increases with fewer,larger outside wires/per
strand. And fatigue resistance increase with more
outside smaller wires per strand
PROPERTIES OF WIRE ROPES
• Wire rope 6*37 is selected as it is more
flexible.
SELECTION OF WIRE ROPE
Design Considerations
• Factor of safety minimum 8 for Electric
Overhead Travelling cranes.
• Load per fall (8 Nos) + 5 % load due to Hook
Block= 5000/8*1.05= 1313 Kg.
• Breaking load of the wire rope should be
1313×8 = 10500 kg (approx.).

SELECTION OF ELECTRIC MOTOR
• Hoist & crane duty hour rated squirrel cage
induction motors, confirming to IS 325 with
comparatively higher H.P. and higher starting
torque to reduce handling time. It is flange
mounted to suit the design and provided with
suitable insulation
• Lifting speed varies from =10 to 26 f or 50.79
• To 132.08 mm/sec.
SELECTION OF ELECTRIC MOTOR
• Power in kw= 2*3.14*N* T/60*1000
= 158.4 kw
DESIGN OF GEAR BOX
• Parameters for selecting Gear Box
• Totally enclosed splash lubricated with dust
free enclosures
• Gear material: Low alloy steel
• Gear manufactred by Hobbing case hardened
mounted on shafts supported on Ball
bearings.Gear Ratio= drum rotating angular
speed/motor angular speed=342
SELECTION OF BRAKES
• Following factors are considered for selecting
Brake.
➢brake torque
➢stopping time
➢deceleration rates
➢brake mounting.
SELECTION OF BRAKES
• Brake location
• Thermal rating
• Environment
• Brake style
SELECTION OF BRAKES
• T (brake)= 5250 × HP × S. F/RPM

• where: 5250 = constant
• HP = motor horsepower = power inWatt/ 746
RPM = speed of motor shaft
• S.F. = application service factor( assumed to
be 1.25) Tbrake = static brake torque
SELECTION OF BRAKE
=5250x158400/746 x1.25/600 =232.23 Nm
Tbrake
Factors for deciding Crane Hoist braking torque.
• 1.5 times T-brake when only one brake is

used
• 1.75 times T-brake when hot metal is hoisted
Engineering drawing of Crane Hoist
CONCLUSION
• 5 Tonne EOT crane provide more reliability,
safety & speed comparison to other available
crane because different components used to
perform function. Generally, there is one rope
drum, motor and gearbox used in hoisting
mechanism.
• Safety is prime consideration in designing
Crane components.Standards given in reference
should be followed.
REFERENCES
1 V.B.Bhandari“Design of Machine Elements”

FourthEdition 2017.
2 Indian standard Design, erection and testing
(structural portion) of cranes and hoists code

of practice (second revision), IS 807:2006.
3 Indian standard code of practice for EOT
and gantry cranes other than steel work cranes
(second revision). IS 3177:1999
REFERENCES
4 Dhaval H. Kanjariya “A Review on Design
and analysis of Hoisting Machinery in EOT

Crane” review paper, 2015
5 Dr. Frank jauch, “care, use & Maintenance of
Wire Ropes on Cranes”, Crane Industry
Council of Australia (CICA) 2012.
REFERENCES
6 Pradyumnakesharimaharana, “Computer
• Aided Analysis and Design of hoisting
mechanism of an EOT crane”, Mechanical
Engineering Thesis 2012.
7.PSG Design Data Book edition 2007

• THANK YOU

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What are the main components of a wire rope?

What are the main components of a wire rope?

What are some advantages of using wire ropes?

What are some advantages of using wire ropes?

DESIGN OF HOISTING

MECHANISM FOR CRANE

• IDENTIFICATION AND COMMUNICATION

SCHEMATIC VIEW OF THE HOISTING DEVICE

• The rope is wounded on the rope drum The

• At the bottom of the pulley the hook is

a curved bar subjected to combined bending

Theoretically we can have

• be kept as low as possible, the lower limit

• beingfixed by the size of slings, ring etc. to be

• d= 3.125 √P +0.1 C = 3.125 √5 + 0.1×8.385

Then, 0.785 (d¹)²×400= 5000

• minimum dia. Of rope pulley at the bottom of

thev-groove as recommended by IS-2266-1963,

should be 6 times the circumference of the rope

• the bottom of the groove say 285 mm rope crs

• (min.) adopt 290 mm dia.

Pitch(p) 2r+3mm 35mm

Drum length 4197mm

Drum length =pitch x ground height x no of ropefall/drum dia =35x10000x8/667

Average drum thickness = h+h/2 = 31.9+7.1/2 =35

1313×8 = 10500 kg (approx.).

• T (brake)= 5250 × HP × S. F/RPM

Factors for deciding Crane Hoist braking torque.

• 1.5 times T-brake when only one brake is

1 V.B.Bhandari“Design of Machine Elements”

(structural portion) of cranes and hoists code

4 Dhaval H. Kanjariya “A Review on Design

and analysis of Hoisting Machinery in EOT

7.PSG Design Data Book edition 2007

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