GREY HOUND ENGINEERS

Design of 50t Rope drum Hoist

for operation of Tail Race gates

1. Technical details : As per Technical Specification

No. of hoists : 3Nos
Capacity of hoist : 50t
Speed : 0.50M / min 10%
Type : Rope drum Hoist
Lift : 20M
Designed : As per IS 6938 2005

2. Materials : As per Technical specification

a) Hoist bridge, Hoist supporting Structural Steel IS 2062

Structures, treastles etc.,
b) Rope drum Gear wheels and Cast Steel IS1030
c) Pinions Forged Steel IS2004
d) Shafts Forged Steel 45C8 IS 2004
e) Bush bearings Al Bronze IS 305

3. Permissible stress : As per IS : 6938 2005 and technical specification

A. Normal Working Condition :
a) Rope drum : IS 1030 Grade 340 570W
compressive stress = 570x10.2x0.2 = 1160 kg/cm2
b) Gear wheels : IS 1030 Grade 340 570W
Root stress = 570x10.2x0.2 = 1160kg/cm2
c) Pinions : IS 2004 Forged steel 55C8 Yp = 350MPa UTS = 710MPa
Root stress = 710 X 10.2 X 0.2 = 1448kg/cm2.

d) Shafts : Forged steel

45C8 IS2004/ En8
YP : 3264kg/cm2
UTS: 6324kg/cm2
Bending stress without key way= 0.2UTS 1265kg/cm2

Bending stress with key way = 0.75 X 836 949kg/cm2

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Shear stress without keyway = 0.3 X Y.P 979kg/cm2

Shear stress with keyway = 0.75 X 702 734kg/cm2

Eqt. Bending stress with keyway= 1.2 X 627 1138kg/cm2

Eqt. twisting stress with keyway = 1.2 X 526 881kg/cm2

Combined stress for bending and torsion

0.60Yp or 0.24 UTS which ever is less 1518kg/cm2
d) Bush bearings :
1. Al Bronze IS 305 Grade AB1 UTS = 500MPa
Permissible stress = 0.04 UTS
Permissible stress = 204kg/cm2
f) Structural Steel : Yp : 2550 kg/cm2 UTS : 4180 kg/cm2 impact factor = 1.1
i) Direct tension, trunnion Compression (0.66 X 2550) / 1.1 = 1530kg/cm2
ii) Average Shear stress = (0.40 / 1.1) X 2550 = 927kg/cm2

B. Under Breakdown torque condition :

i) Rope drum : Crushing stress 0.8Y.P = 0.8 X 3468 = 2774kg/cm2.

ii) Gear wheels : Root stress 0.8Y.P = 0.8 X 3468 = 2774kg/cm2.

iii) Pinions : Root stress 0.8Y.P = 0.8 X 3570 = 2856kg/cm2.

iv) Shafts : Forged steel

45C8 IS2004 / En8
YP :3264 kg/cm2
Bending stress without 2610 kg/cm2
keyway 0.8Y.P
Bending stress with 1958 kg/cm2
Keyway 0.75 X 1872
Shear stress without 2610 kg/cm2
Keyway 0.8YP
Shear stress with 1958 kg/cm2
Keyway 0.75 X 1872

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Eqt. Bending / Torsional 1958 kg/cm2 stress with
keyway

4.0 Design of the Hoist Mechanism :

Hoist capacity : 50t
Lifting Speed : 0.50M/min
No. of drums 2 and No. of falls on each drum : 4
Total lift : 20M

4.1 Design of Wire Rope :

Max. Rope tension = P1= w/2 (1- / 1-n)
P1 = (50000 / 2) (1 0.95 / 1 0.954) = 6738kg
P2 = 6738 X 0.95 = 6402kg
P3 = 6402 X 0.95 = 6082kg
P4 = 6082 X 0.95 = 5778kg
Proposed 32 wire rope, 6 / 37 construction, Right hand lay, galvanised, main fiber
core, UTS 180kg/mm2, having breaking load capacity of 54434kg conforming to IS
2266 - 1989.
Factor of safety = 54434/ 6738 = 8.07 > 6.0
4.2 Motor :
H.P required = MV / 4.5E
Where M = 50t
V = 0.50M/min
E = Efficiency :
Starting Running
Rope drum : 0.93 0.95
Open gears : 0.932 0.952
Pulleys : 0.933 0.953
Worm reducer : 0.44 0.78 .
0.285 0.573
H.P = (50 X 0.50) / (4.5 X 0.573) = 9.6H.P
Proposed 11 KW (15 H.P) 935rpm Squirrel cage, S3 duty 150 starts per hour TEFC,
Class F insulation Foot mounted working on 400 / 440V A.C 3 phase 50 Cycles / sec.
Output shaft extension on either sides confirming to IS 325. Frame size : 160L 1No.

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Make : Bharat Bijlee or EQT
% of POT / FLT = 320% % of STG.T / FLT = 230%

4.3 Brake :
Braking torque required = [{(71620 X 15) / 935} X 1.5] = 1723kgcm.
Proposed 250 A.C Electromagnetic solenoid operated single phase brake
100% coil rating class F insulation working on 400/440 V A.C having braking
capacity 19.3kg.m 1 No. Make : Sterling / EMC
4.4 Rope Drum :
Wire rope : 32mm
Proposed 2 drums with each 4 falls
Material : Cast steel IS 1030 Grade 280 520 W
Min. drum : 20 X 32 = 640mm
Proposed 1000mm PCD. Circumference = 3.1416M
Lift : 20M
No.of grooves required / drum =(20 X 4 / 3.1416)+3 = 28.464grooves 29 grooves
z Pitch of the grooves = 32 + 3 = 35mm
Depth of grooves = 0.35d = 0.35 X 32 = 11.0mm
Radius of the groove = 0.53d = 0.53 X 32 = 16.96 17mm
Length of the drum = 170 + (29 X 35) + 50 = 1235mm
Groove Details :

30 50 29X35 = 1015
32

R 17

5
28 11
1150

1
1080 PCD

912

Design of Shell :
Proposed shell thickness = 28mm
Compressive stress = C = (K X P) / (p X t)
Where K = Coefficient for single layer wind = 1
P = Max. Rope tension =6739 kg
p = pitch = 3.5cm
t = Thickness of shell = 2.8cm
C= (1 X 6739) / (3.5 X 2.8) = 688kg/cm2 < 1060kg/cm2

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1255
1235
50 29x35 = 1015 70 100
100

66

1000
1150
1080
990

912
40 20
30

120
90
Check for bending :

Self weight of drum = 1225kg

6739kg
1225kg
Wire rope tension Max. P1 = 6739kg
A B
123.5
RA = RB = 3987kg
Bending moment = 227131kgcm
ZXX = / 32D (D4 d4) = ( / 32 X 96.8) (96.84 91.24) = 18886cm3
Bending stress = 227131 / 18886 = 12kg/cm2 < 1160 kg/cm2
Combined stress = 6882 + 122 = 688kg/cm2 < 1160 kg/cm2

4.5 Design of Gear Wheel W1 and Drum connection bolts :

Proposed 16mm - 6Nos. of fit bolts to IS 3640 having Shank 17mm.
Max. Load on each bolt = 6739 + (1225 / 2) = 7352kg
Load on each bolts = (7352 X 100) / 108 X 6 = 1135kg
Shank Area of bolts = ( / 4) X 1.72 = 2.27cm2
1080 PCD

Shear stress = 1135 / 2.27 = 500kg/cm2 < 960kg/cm2

1000 PCD

Material of bolts : class 4.8 of IS 1367

Yp = 320Mpa UTS = 420Mpa

4.6 Design of Reduction Unit :

The reduction unit consists of 2 end gear boxes of open gear with 2 train each
and on central drive unit consists of worm reducer, brake and motor.

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Hoist speed 0.50M/min Drum 1000 PCD circumference = 3.1416

Drum speed : (0.5 X 4) / 3.1416 = 0.6366rpm.
Motor speed = 935rpm.
Total Reduction ratio required = 935 / 0.6366 = 1469
Proposed worm reducer ratio 70 : 1
Open reduction required = 1469 / 70 = 20.9
Proposed the following open gears
10M 6M
(133 / 24) X (84 / 22) = 21.159
Actual hoisting speed : (935 X X 1.00) / (70 X 21.159 X 4) = 0.4958M/min
Total load on W 1 P1 = (6739 X 1) / (1.596 X 0.95) = 4444.6kg
Total load on W 2 P2 = (4444.6 X 0.288) / (0.672 X 0.95) = 2005kg
Load Face Permissible
No. of Module PCD root=Pq/fm
Design P width q stress Material
Teeth PA cm kg/cm2
kg cm kg/cm2
C.S IS
12 / 1030
W1 133 159.6 4445 12 2.5 772 1160
20 Gr340-
570W
Forged
P1 24 12 / 20 28.8 4445 12 3.2 988 1448 steel
55C8
C.S IS 030
W2 84 8 / 20 67.2 2005 9 2.56 713 1160 Gr340-
570W
Forged
P2 22 8 / 20 17.6 2005 9 3.33 927 1448 steel
55C8

Torque transmitted by P2 shaft = (2 X 2005 X 8.8) = 35288kg cm

Torque required by worm reducer output shaft = 35288 / 0.95 = 37145kg cm
Torque developed by the motor shaft = 37145 / (70 X 0.78) = 680kg cm
H.P of motor required = (680 X 935) / 71620 = 8.87H.P
Proposed 12.5HP is in order

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Worm reducer:
Proposed worm reducer 70 : 1 Type U, size 10 input H.P 16.3 input speed
1000 rpm output torque 620kgm, output shaft extended on either side with self
locking gear box 1 No. Make : Shanti / Elecon / Premium.

4.7 Checking up of Wire Rope, drum and Gears for Motor Break down torque
condition of motor i.e. 320 % of Motor Torque :
Motor provided = 15 HP 935rpm POT / FLT = 2.75
275 % of motor torque = ((71620 X 15) / 935) X 2.75 = 3159 kg cm
Starting efficiency of system up to drum = 0.933 X 0.44 = 0.354
Torque on each drum = X 3159 X 0.354 X 70 X 21.159 = 828163 kgcm
Rope tension = 828163 / 50 = 16563 kgs
Rope tension in BDT : ( 0.93)
P1 = 16563kg P2 = 15484g P3 = 14325kg P4 = 13322kg

4.7.1 Wire rope

F.O.S = 54434 / 16563 = 3.29 > 3.0

4.7.2 Rope drum

c = (1 X 16563) / (3.5 X 2.8) = 1690 kg/cm2 < 2774kg/cm2

Note : No check is required for bending stress since the crushing stress is on
very much on lower side than permissible

4.7.3 Checking the Gear wheels and Pinion under BDT condition :
Tooth load on W 1P1 = (16563 X 100) / (159.6 X 0.93) = 11159 kg
Tooth load on W 2P2 = (11159 X 28.8) / (67.2 X 0.93) = 5142kg

Desc No of teeth Module / PA P kg q f root = pq / fm Allowable stress

W1 133 12 / 20 11159 2.5 12 1937 2776
P1 24 12 / 20 11159 3.2 12 2479 2856
W2 94 8 / 20 5142 2.56 9 1828 2776
P2 22 8 / 20 5142 3.33 9 2378 2856

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5.0 Design of Shafts : Gear Box Assembly

626

5
72
452

14
72

942
1326

310
90

123
W1
874

300

548
W2 P2

112
130 130
8

30 120
95
825

10 3
320 260
380 320

525
400

400
380
50

100 810 893 424 173 100

1317
2500

17.5 HOLES FOR M16X100 LG HEX

BOLT,NUT&SPRING WASHER

13.5 HOLES FOR 1755

FIXING COVER
120 100 1435 100
20

20 345 310
100
200
180
425

1255
910
810
300

1600
300
300

590
2500

690
100
303
1135

1000
424

90
173
100

120 100 320 100 100

20

720

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5.1 Tooth load on Gear Wheel W1 and P1 :

942 PtHW1
W1
Pt
P1

PtVW1

PtW
1
Pr

PrVW1
W
P1 1
300 PrHP1

PrVP1
PrP1 PrHW1
PrW1
PrP
1

PtVP1
Pt
P1
Rt

Pt
W 1

PtHP1

Rope load horizontal = 0

Rope load Vertical = Normal = 6739kg
BDT =16563kg
= sin-1 (300 / 942) = 17.6651862
Ptw1 = (-) 4445 PtP1 = (+) 4445
Prw1= 4445 X tan 20 = (+) 1618 PrP1 = (-) 1618
PtHw1 = 4445 sin 17.6651862 = (-) 1349kg
PtHP1 = 4445 sin 17.6651862 = (+) 1349kg
PtVw1 = 4445 cos 17.6651862 = (-) 4235kg
PtVP1 = 4445 cos 17.6651862 = (+) 4235kg
PrHw1 = 1618 cos 17.6651862 = (+) 1542kg
PrHP1 = 1618 cos 17.6651862 = (-) 1542kg
PrVw1 = 1618 sin 17.6651862 = (-) 491kg
PrVP1 = 1618 sin 17.6651862 = (+) 491kg

Normal condition :
Fw1 (V) = - 4235 491 = - 4726kg Fw1 (H) = + 1542 1349 = + 193kg
FP1 (V) = + 4235 + 491 = +4726kg FP1 (H) = - 1542 + 1349 = - 193kg
BDT Condition :
Fw1 (V) = - 11865kg Fw1 (H) = + 484kg
FP1 (V) = +11865kg FP1 (H) = - 484kg

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5.2 Tooth load of Gear Wheel W2 and P2 :

Normal condition :
PtP2 (V) = - 2005kg w2 PtP2
PrP2 (H) = - 730kg
PtW 2 (V) = + 2005kg
PrW 2 (H) = + 730kg P2

BDT Condition :
PrP2
PtP2 (V) = - 5142kg PrP2 (H) = - 1872kg
Prw2
PtW 2 (V) = + 5142kg PrW 2 (H) = + 1872kg

5.3 Design of Drum shaft:

Ptw2
Case i. : When gate is just lifted
Material of shaft Forged steel 45 C 8 IS 2004 En 8
A. Normal loads:
a) Vertical load in kgs: At a At b(W 1)
Rope tension 6739 -----
Weight of drum 613 613
Tooth load of W 1 ---- -4445
Weight of gear wheel ---- 610
7352 - 3222
b) Horizontal load in kgs:
Tooth load of W1 --- 193
Vertical reaction : (Taking moment about B)
RVA = + 6738kg
RVB = - 2707kg
Horizontal reaction : 7352 - 3222kg
RHA = 11kg RHB = 182 193kg
a b
RA = (6738)2 + 112 = 6738kg A B
6.5 151.5 8
RB = (-2707)2 + 1822 = 2713kg 166
Max. BM at a = 6738 X 6.5 = 44617kgcm
Max. BM at b = 2713 X 8 = 21704kgcm
Proposed : 90mm shaft ZXX = 72cm3 Area = 64cm2
Bending stress = 44617 / 72 = 608kg/cm2 < 1265kg/cm2
Shear stress = 6738 / 64 = 105kg/cm2 < 979kg/cm2

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Bearing :
Gear wheel W1 side:
Proposed bush bearing Al. bronze IS 305 Grade AB1
Permissible stress : 0.04 X 500 X 10.2 = 204kg/cm2
Size ID : 90 OD : 120 150 long
Bearing Stress = 3222 / 9 X 15 = 24kg/cm2 < 204kg/cm2
Non gear wheel side (Drum Hub side) :
Proposed bush bearing Al. bronze IS 305 Grade AB1
Size ID : 90 OD : 120 90 long
Bearing stress = 7352 / 9 X 9 = 109kg/cm2 < 204kg/cm2

B. Checking for BDT condition:

a) Vertical load in kgs: At a At b(W 1)
Rope tension 16563 -----
Weight of drum 613 613
Tooth load of W 1 --- - 11865
Weight of gear wheel --- 610
+17176 - 10642
b) Horizontal load in kgs:
Tooth load of W 1 --- 484
Vertical reaction :
RVA = 17016kg
RVB = - 10801kg
Horizontal reaction : 17176 -10642kg
484kg

RHA = 23kg RHB = 461kg a b

A 6.5 151.5 8 B
RA = (17016)2 + 232 = 17016kg 166

RB = (-10801)2 + 4612 = 10810kg

BM @ a = 17016 X 6.5 = 110604kgcm
BM @ b = 10810 X 8 = 86480kgcm
Proposed : 90 shaft ZXX = 72cm3 Area = 64cm2
Bending stress = 110604 / 72 = 1536kg/cm2 < 2610kg/cm2
Shear stress = 17016 / 64 = 266 kg/cm2 < 2610kg/cm2

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Case ii. : When gate is fully lifted

Material of shaft Forged steel 45 C 8 IS 2004 En 8
A. Normal loads:
a) Vertical load in kgs: At a At b(W 1)
Rope tension ---- 6739
Weight of drum 613 613
Tooth load of W 1 ---- -4445
Weight of gear wheel ---- 610
613 3517
b) Horizontal load in kgs:
Tooth load of W 1 --- 193
Vertical reaction : (Taking moment about B)
RVA1 = + 784kg
RVB1 = - 3346kg
613 3517kg
Horizontal reaction : 193kg
a b
RHA1= 11kg RHB1 = 182 A1 B1
6.5 151.5 8
RA1 = (784)2 + 112 = 784kg 166

RB1 = (-3346)2 + 1822 = 3351kg

Max. BM = 3351 X 8 = 26808kgcm
Bending stress = 26808 / 72 = 372kg/cm2 < 1265kg/cm2
Shear stress = 3351 / 64 = 52kg/cm2 < 979kg/cm2
Note : Bearing stresses are safe.

B. Checking for BDT condition:

a) Vertical load in kgs: At a At b(W 1)
Rope tension --- 16563
Weight of drum 613 613
Tooth load of W 1 --- - 11865
Weight of gear wheel --- 610
+613 5921

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b) Horizontal load in kgs:

Tooth load of W 1 --- 484
Vertical reaction :
RVA1 = 874kg
RVB1 = - 5659kg
Horizontal reaction :
RHA1 = 23kg RHB1 = 461kg 613 5921 kg
484kg
RA1 = (874)2 + 232 = 874kg a b
A1 B1
RB1 = (-5659)2 + 4612 = 5678kg 6.5 151.5
166
8

Max. BM = 5678 X 8 = 45422kgcm

Bending stress = 311024 / 72 = 544kg/cm2 < 2610kg/cm2
Shear stress = 5678 / 64 = 89 kg/cm2 < 2610kg/cm2

5.4 Design of shaft P1W2: Material Forged steel 45 C8 IS: 2004

A. Normal Condition:
a) Vertical load in kgs:
At c(W 2) At d(P1)
Tooth load of P1 ---- 4726
Tooth load of W 2 2005 ---
Self weight of P1 ---- 78
Self weight of W 2 110 -------
+ 2115 + 4804
b) Horizontal load in kgs:
Tooth load of P1 ------- - 193kg
Tooth load of W 2 + 730 ------
Vertical reaction :
RVC = + 3096kg
RVD = + 3823kg
Horizontal reaction : 2115kg 4804kg
730 kg - 193kg
RHC = + 483kg P1
c W2 d
RHD = 112kg
C D
RC = (3096)2 + 4832 = 3133kg 15 15 16
46

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RD = 38232 + 1122 = 3825kg

BM @d = 3825 X 16 = 61200kgcm
BM @c = 3133 X 15 = 46995kgcm
Torque transmitted = 4445 X 14.4 = 64008kgcm
Proposed : 11cm shaft at key way & 9cm at bearing.
ZXX = 131cm3 ZPP = 262cm3
Bending stress = 61200 / 131 = 467kg/cm2 < 949kg/cm2
Twisting stress = 64008 / 262 = 244kg/cm2 < 734kg/cm2
Combined stress = 4672 + 3(244)2 = 630kg/cm2 < 1518kg/cm2
Eqt. Twisting moment = 612002 + 640082 = 88558kgcm
Eqt bending = (88558 + 61200) = 74879kgcm
Eqt. Bending stress = 74879 / 131 = 571kg/cm2 < 1044kg/cm2
Eqt. Twisting stress = 88558 / 262 = 338kg/cm2 < 880kg/cm2
Bearing : Proposed plummer block SNA 520TC cast steel to suit 90 shaft
at bearing with 22220EK bearing and H 320 sleeve, having Static
capacity 490KN & Dynamic capacity 425KN

B. Check for BDT Condition:

a) Vertical load in kgs:
At c(W 2) At d(P1)
Tooth load of P1 ---- 11865
Tooth load of W 2 5142 ---
Self weight of P1 ---- 78
Self weight of W 2 110 -------
+5252 +11943
b) Horizontal load in kgs:
Tooth load of P1 ------- - 484
Tooth load of W 2 + 1872 ------
Vertical reaction :
RVC = +7693kg RVD = + 9501kg

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Horizontal reaction :
RHC = + 1093kg
RHD = + 295kg 5252kg 11943kg
1872kg P1 -484kg
RC = (7693)2 + 10932 = 7770kg c W2 d
C D
RD = 95012 + 2952 = 9505kg 15 15
46
16

BM = 9505 X 16 = 152080kgcm
Torque transmitted = 11865 X 14.4 = 170856kgcm
Eqt. Twisting moment = 1520802 + 1708562 = 234506kgcm
Eqt bending = (234506 + 152080) = 190408kgcm
Proposed : 11 shaft ZXX = 131cm3 ZPP = 262cm3
Bending stress = 152080 / 131 = 1161kg/cm2 < 1958kg/cm2
Twisting stress = 170856 / 262 = 652kg/cm2 < 1958kg/cm2
Combined stress = 11612 + 3(652)2 = kg/cm2 < 1958kg/cm2
Eqt. Bending stress = 190408 / 131 = 1620kg/cm2 < 1958kg/cm2
Eqt. Twisting stress = 234506 / 262 = 873kg/cm2 < 1958kg/cm2

5.5 Design of P2 Shaft :

A. Normal Condition : Material Forged steel 45 C 8 IS 2004 or En 8
Vertical load in kgs:
Tooth load of P2 - 2005
Weight of P2 + 22
- 1983
Horizontal load in kgs:
Tooth load of P2 - 730kg
Vertical reaction : - 1983kg
- 730kg
RE = - 1391kg
E F
15 31
RF = - 647kg 46

Horizontal reaction :
RE = - 492kg RF = - 238kg
Resultant reaction :
RE = - 13912 + 4922 = -1424kg
RF = - 6472 + 2382 = - 689kg
Max. BM = 1424 X 15 = 21360kgcm

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Torque transmitted = 2005 X 8.8 = 17644kgcm
Proposed : shaft 8cm at key way and 7.5cm at bearing
ZXX = 50cm3 ZPP = 100cm3
Bending stress = 21360 / 50 = 427kg/cm2 < 949kg/cm2
Twisting stress = 17644 / 100 = 176kg/cm2 < 734kg/cm2
Combined stress = 4272 + 3(176)2 = 525kg/cm2 < 1518kg/cm2
Eqt. Torque = 213602 + 176442 = 27705kgcm
Eqt. Bending = (27705 + 17644) = 22674kgcm
Eqt. Bending stress = 22674 / 50 = 453kg/cm2 < 1138kg/cm2
Eqt. Twisting stress = 27705 / 100 = 277kg/cm2 < 881kg/cm2
Bearing :
Proposed Plummer block SNA 517 TC to suit 75 shaft with 22217EK
bearing and H317 adopter sleeve having dynamic capacity 285KN, static
capacity 325KN.
B. BDT Condition :
Vertical load in kgs: Material Forged steel 45 C 8 IS 2004 or En 8
Tooth load of P2 - 5142
Weight of P2 + 22
- 5120
Horizontal load in kgs:
Tooth load of P2 - 1872
Vertical reaction :
RE = - 3450kg
RF = - 1670kg
Horizontal reaction : - 5120 kg
- 1872 kg
RE = - 1262kg
RF = - 610kg E
15 31
F

Resultant reaction : 46

RE = - 34502 + 12622 = - 3674kg

RF = - 16702 + 6102 = - 1778kg
Max. BM = 3674 X 15 = 55110kgcm
Torque transmitted = 5142 X 8.8 =45250kgcm
Proposed : shaft 8cm at key way and 7.5cm at bearing
ZXX = 50cm3 ZPP = 100cm3

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Bending stress = 55110 / 50 = 1102kg/cm2 < 1958kg/cm2
Twisting stress =45250 / 100 = 453kg/cm2 < 1958kg/cm2
Combined stress = 11022 + 3(453)2 = 1353kg/cm2 < 1958kg/cm2
Eqt. Torque = 551102 +452502 = 71307kgcm
Eqt. Bending = (71307 + 55110) = 63209kgcm
Eqt. Bending stress = 63209 / 50 = 1264kg/cm2 < 1958kg/cm2
Eqt. Twisting stress = 71307 / 100 = 713kg/cm2 < 1958kg/cm2
C. Checking of Plummer Block Vertical load for fixing bolts :
Max. Vertcal load in tension : -1391kg
Proposed bolt M20 Material quality Cl. 4.6 of IS 1367 Yp : 240 MPa UTS : 400MPa
Permissible stress : 0.2 X 400 X 10.2 = 816kg/cm2
Area of each bolt : 2.45cm 2 ( Appendix A of IS 1367 Part 114)
Tensile stress : 1391 / (2 X 2.45) = 273kg/cm2 < 960kg/cm2

5.7 Design of Manual operation:

H.P of the motor provided in the hoist = 15 H.P 935rpm
Torque of the motor = (71620 X 15) / 935 = 1149 kgcm
SP1

Clutch

SP2
Motor

Sprocket No. of teeth Pitch PCD cm

SP1 20 (3/4) 115.75cm
SP2 20 (3/4) 115.75cm

Torque at hand operation shaft = 1149 X 1 = 1149kgcm

Crank radius 40cm
Effort required = 1149 / 40 = 29kg
Proposed 4 people for operation of manual operation.
Effort required by each person = 29 / 4 = 7.25kg < 10kg
Actual Hoisting speed for manual operation
= (24 X X 1) / (70 X 21.159 X 4) = 0.0127M/min = 1.27cm/Min

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6.0 Dial & Dial Assembly Calculations :

Dial Calculations :
Total lift : 20M
110
No. of revolutions made by drum for 20M lift

= (4 X 20) / ( X 1) = 25.4647 revolutions

61 41

8
SP2
No. of revolutions made by P1w2 shaft
100

50
25 60

150
= 25.4647 X (133 / 24) = 141.11 revolutions
185

Proposed 12 = 1.0 50

Dial rotation = (20 X 12) / 360 = 0.666 revolutions.

Open reduction required

95 130

= 141.11 / 0.666 = 211.874

Proposed worm gear box size1 (5/8)

24 40
type U Ratio 70 : 1 with output shaft P 1 W2 SHAFT

75 25 40
extended 180mm on either side.
125

SP1
Utilised ratio of worm gear box

= (70 X 306) / 360 = 59.5

25
50
Sprocket ratio required = 211.874 / 59.5

= 3,560

A provided = 57 / 16 = 3.563

Sprocket No. of Teeth Pitch PCD

SP1 16 (1 / 2) 65.10mm

SP2 57 (1 / 2) 230.54mm

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7.0 Design of Hoist Bridge :

The arrangement of members and position of Gear boxes and central drive unit,
fixed pulleys are shown in the sketch.

4925
1120 3200 605

98

1080

1080
1923 1277

? OF GUIDE ? OF DRUM
1081 842 810 467

1215

1543
328

527
1627

135

2127
20 20
280 12.01
1600

320
500

9250
9500
500

1600

2127
1627

527
328

1543
1215

1283 590 1328

830

830

3200

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7.0.1 Technical Details :

Type of Hoist Rope Drum
Capacity 50t
Nos required 3 nos

7.0.2 Material :
Structural Steel IS 2062 2006 Grade E 250 quality B

7.0.3 Permissible Stress :

The permissible stresses for normal load condition is de-rated considering
impact factor of 1.1

A. Normal Condition :
Bending stress in tension or compression
= 0.66 Yp = 0.66 X 2448 = 1615 / 1.1 = 1468kg/cm2
Average shear stress = 0.4 X 2448 = 979 / 1.1 = 890kg/cm2
Bearing stress = 0.75 Yp = 0.75 X 2448 = 1836 / 1.1 = 1669kg/cm2

B. BDT Condition :
Permissible stress under BDT condition 0.8 Yp
= 0.8 X 2448 = 1958kg/cm2

C. The loads of various points are as follows :

Point Normal Loads BDT loads

in kg In kg
A +784 +874
B +3351 +4898
C +3133 +7770
D +3825 +7933
E -1424 -3674
F -689 -1778

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7.1 Design of Cross Member : C1

Normal Condition :
The load at pulley 1 = Rope tensions of P2 + P3 + Self wt. of pulley, pin etc
= 6402 + 6082 + 150 = 12634kg
The load at pulley 2 = Rope tensions of P4 + Self wt. of pulley
= 5778 + 150 = 5928kg
The load at a = load at pulley 1 + pulley2
= 12634 + 5928 = 18562
Self weight = 200 kg
18562kg 200kg
RA1 = 14058kg
a
RB1 = 4495kg A1 B1
52.7 160

212.7

Max. BM = 739810 kgcm

Proposed 750mm X 16mm plate 2nos.
ZXX = 2 X 1.6 X (752 / 6) = 3000cm3
Bending stress = 739810 / 3000 = 247kg/cm2 < 1468kg/cm2
Shear stress = 14058 / (2 X 40 X 1.6)= 110kg/cm2 < 890kg/cm2
Check for Deflection :
Permissible deflection = 0.22cm
Actual Deflection = 0.061cm < 0.22cm

Design of Weld : 25

The length of weld provided

= 35 X 4 = 140cm length.
350
Weld strength required

= 14058 / 140 = 101kg/cm length.

25

Proposed 6mm fillet weld having strength of 0.7 X 0.6 X 890 = 373kg/cm length.

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BDT Condition :
The load at pulley 1 = Rope tensions of P2 + P3 + Self wt. of pulley, pin etc
= 15484 + 14325 + 150 = 29959 kg
The load at pulley 2 = Rope tensions of P4 + Self wt. of pulley
= 13322 + 150 = 13472kg
The load at a = load at pulley 1 + pulley2 = 29959 + 13472 = 43431 kg

RA1 = 32770kg 43431 200kg

kg
RB1 = 10861kg
a
A1 B1
52.7 160
Max. BM = 1725684kgcm
Proposed 750mm X 16mm plate 2nos. 212.7
ZXX = 2 X 1.6 X (752 / 6) = 3000cm3
Bending stress = 1725684 / 3000 = 575kg/cm2 < 1468kg/cm2
Shear stress = 32770 / (2 X 40 X1.6)= 256kg/cm2 < 927kg/cm2

7.2 Cross channel C2 :

Normal Load :
The load at a : Reaction of shaft P1W 2 = RC = 3133kg
The load at b :Reaction of shaft P2 = RE = -1424kg
UDL : Self weight = 30kg
3133kg 1424kg
30kg
RB2 = 1851kg a b
B2 A2
RA2 = - 137kg 25.3 42.4 60.6

128.3
Max. BM at a = 46802.6kgcm

Proposed ISMC 200mm X 75mm plate 1.14

Area = 28.5cm2
0.62
IXX = 1830cm4
20 17.72
ZXX = 181cm3

f bending = 46802 / 181 = 258 kg/cm2 < 1530kg/cm2

f shear = 1851 / (20 X 0.62) = 149kg/cm2 < 927kg/cm2
7.50

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Check for Deflection :
Permissible deflection = 0.160cm
Actual Deflection = 0.009cm < 0.16cm

BDT Condition : 7770kg - 3674kg

30kg
a b
RA2 = - 391kg B2 A2
25.3 42.4 60.6
RB2 = 4517kg
128.3

Max. BM at b = 114225 kgcm

fbending = 114225 /181 = 631kg/cm2 < 1958kg/cm2
fshear = 4517/ (20 X 0.62) = 364 kg/cm2 < 1958kg/cm2

7.3 Cross channel C3 :

Normal Load : 1851kg 48kg
The load at a = RB2 of C2 = 1851 kg a
B3 A3
UDL : Self weight of member = 48 kg
RB3 = 1852kg 121.5
RA3 = 1.28kg

Max. BM = 39 kgcm
Proposed ISMC 200mm X 75mm channel
1.14

Area = 28.5cm2
0.62

20 17.72
IXX = 1830cm4

ZXX = 181cm3

7.50

fshear = 1852 / (20 X 0.62) = 149 kg/cm2 < 927kg/cm2

Check for Deflection :

Permissible deflection = 0.22cm
Actual Deflection = 0.029cm < 0.22cm

BDT Condition :
No need in checking as stresses coming in normal conditions are very less.

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7.4 Cross Girder C4 :

Normal Load :
The load at a = RA of Drum reaction = 784kg
The load at b = RA1 of C1 = 14058kg
The load at c = RB3 of C3 = 1852 kg
The load at d = RD of shaft P1 W 2 = 3825kg
The load at e = RF of shaft P2 = - 689kg

784kg 1852kg - 689kg

14058kg 3825kg
279kg
a b c d e
B4 A4
RB4 = 10323kg
132.8 60.6
RA4 = 9787kg 7.8 51.2 25.2 42.4

Max. BM = 1436587 kgcm 320

1.72
18
Proposed ISMB 500 X 180 girder

Area = 111cm2
1.02
IXX = 45200cm4

46.56
50
ZXX = 1810cm3

fbending = 1436587/ 1810 = 793 kg/cm2 < 1530kg/cm2

fshear = 10323 / (50 X 1.02) = 203 kg/cm2 < 890kg/cm2
1.72

BDT Condition : 876kg 2385kg 1488kg

7933kg
279kg
32770kg
a b c d e
B4 A4
RB4 = 22251kg 132.8 7.8 51.2 25.2 42.4 60.5

RA4 = 20505kg 320

Max. BM = 3113115kgcm

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fbending = 3113115 / 1810 = 1719kg/cm2 < 1958kg/cm2
fshear = 22251 / (50 X 1.02) = 437 kg/cm2 < 1958kg/cm2

7.5 Design of Cross Girder C5 :

Normal Load :
Load at a = RB1 of C1 = 4495 X 2 = 8990 kg
UDL = self weight = 200 kg
UDL at A5 side = drive unit weight + Live load
= 800 + 0.96 X 1.282 X 500 = 1415.36 1420kg
8990kg
1420kg
RB5 = 5461 kg 279kg
a
RA5 = 5216 kg
B5 A5
140.6 51.2 128.2
Max. BM = 757319 kgcm
320

Section Proposed is as follows : Proposed ISMB 500 X 180

1.72
18

Area = 111cm2
1.02
IXX = 45200cm4 46.56
50
ZXX = 1810cm3 and web thick is 1.02cm

fbending = 757319/ 1810 = 419 kg/cm2 < 1530kg/cm2

fshear = 5416 / (50 X 1.02) = 106 kg/cm2 < 927kg/cm2
1.72

Check for Deflection :

Permissible deflection as per IS 6938 2005 = span / 800 = 320 / 800 = 0.4cm
10861kg
Actual deflection = 0.143 < 0.4cm 1420kg
279kg
a
BDT Condition
B5 A5
140.6 51.2 128.2

320
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3100kg

B9 A9
RB5 = 6516kg
950
RA5 = 6039 kg
Max. BM = 906800 kgcm
f bending = 906800 / 1810 = 500 kg/cm2 < 1958kg/cm2
f shear = 6516 / (50 X 1.02) = 128 kg/cm2 < 1958kg/cm2

7.6 Design of Cross Channel C6 :

Normal Load :
UDL = self weight + Live load = 1170 + 0.75 X 9.5 X 500 = 4733 kg
RA4 = 9787 kg
RA2 = - 137 kg 137kg 137kg
9787kg 5216kg 9787kg 4733kg
RA5 = 5216 kg
A9 A2 A5 A2 A9
B6 A6
204.5 32.8 212.7 212.7 32.8 229.5
RB6 = 15236 kg 925
RA6 = 14559 kg

Max. BM = 4223181 kgcm

21
Proposed ISMB 600mm X 210mm girder

1.2
Area = 156cm2

60
IXX = 110200cm4

ZXX = 3060cm3

Web thickness = 1.2cm

2 cm

24

fbending = 4223181/ 3060 = 1380kg/cm2 < 1530kg/cm2

f shear = 15236 / (60 X 1.2) = 211 kg/cm2 < 927kg/cm2

BDT Condition ;
391kg 391kg
20505kg 6039kg 20505kg 4733kg
RB6 = 26924 kg A9 A2 A5 A2 A2
RA6 = 25634kg B6 A6
204.5 32.8 212.7 212.7 32.8 229.5
925

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Max. BM = 7141754 kgcm
fbending = 7141754 / 3060 = 2333 kg/cm2 < 1958kg/cm2 ( Additional Plate of 20 mm at centre will be

Provided)

fshear = 21297 / (60 X 1.2) = 295 kg/cm2 < 1958kg/cm2

7.7 Design of Cross Girder C7 :

UDL = self weight of girder + live load = 247 + 0.6 X 9.5 X 500 = 3100 kg

RB7 = RA7 = 1548 kg

Max. BM = 367731 kgcm

Proposed 225 X 80 channel having following properties :
Area = 33.3 cm2
IXX = 2710 cm4
ZXX = 241 cm3
web thickness = 0.65 cm
fbending = 367731 / 241 = 1525 kg/cm2 < 1530kg/cm2
fshear = 1548 / (22.5 X 0.65) = 105 kg/cm2 < 880kg/cm2

7.8 Design of End Girders AB / CD :

Normal Load :
UDL = 90kg/M
1548kg 15236kg 15236kg
RA = 17594 kg
B9 B6 378kg
RB = 14803 kg B8
A
114.5 320

BM = 182949 kgcm
Proposed ISMB 500 X 180 girder for rigidity :
Area = 111cm2
IXX = 45200cm4
IYY = 1810cm4
fbending = 183949 / 1810 = 101 kg/cm2 < 1530kg/cm2
fshear = 17594 / (50 X 1.2) = 293 kg/cm2 < 927kg/cm2

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8.0 Design of Column :

i. Max. vertical load due to reactions
Normal Load : 17594 x 2 = 35188 kgs, BDT : 26391 x 2 = 52782 kgs
ii. Self weight of column : 2000kgs ( Approx)
iii. Vertical load on column due to wind load on gate :
= (8.25 X 4.565) X 1.2 X 50 = 2260kgs
Wind load centroid at the height : 30 + (456.5 / 2) = 231.25 cms
Span of columns : 950 cms
Reaction = 2260 X (231.25 / 950) = 550 kgs
vertical load on column
For Normal Condition: 35188 + 2000 + 550 = 37738kgs 17594kg

For BDT : 52782 + 2000 + 904 = 55686kgs 1520kg

Wind Load :
700
224kg
a) Load due to wind on hoist & hoist girder
= Area X form factor X wind pressure 350

= 9.5 X 2 X 1.6 X 50 = 1520 kg

b) Wind load on column = 7.0 X 0.4 X 1.6 X 50 = 224kg
Moment on column = 1520 X 800 + 224 X 400 = 1305600kgcm

It is proposed 2 No. of columns ISMC 300 X 90 with 280 X 10mm as Box.

Area = 2 X 46.3 + 76 = 168.6cm2
IXX = 2 X 6420 + 2 X 38 X 15.52 = 31099cm4
IYY = 2 X 428 + 2 X 46.3 X 17.652 + 2 X 1 X 383 / 12 = 38848cm4
ZXX = 1944cm3
1.0

ZYY = 1942cm3
2.35 2.35
rXX = 13.58cm 17.65 17.65
38
30
30

rYY = 15.18cm
Proposed bracings on RXX direction
Effective length = 700 cm
38
Slenderness ratio = 700 / 13.58 = 51.5 40

Permissible compressive stress as per table 5.1 of IS 800 - 84 = 128Mpa

= 128 X 10.2 = 1306kg/cm 2

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Permissible bending stress = 1530kg/cm 2
Bending stress = 1305600 / 1942 = 672 kg/cm2 < 1530kg/cm2
Compressive stress = 37738 / 168.6 = 224 kg/cm2 < 1306kg/cm2
Check for unity = (672 / 1530) + (224 / 1306) = 0.61 < 1

Note : The column is safe for BDT Condition.

8.1 Design of Bracings :

The columns are provided with box sections and hence no bracings are required.
however the bracings are provided to arrest vibration.
8.2 Design of Base Plate :
Bearing plate area = 60 X 52 = 3120cm2
Bearing pressure on concrete P =37738 / 3120 = 12 kg/cm2 < 42kg/cm2

5 15 10 10 15 5 5
21
52

21
5

60

Thickness of plate required (as per clause 5.4.3 of IS 800 1984)

t = (3w / Fb) (A2 B2 / 4)
Where w = Bearing pressure on concrete = 12 kg/cm2
Fb = 185Mpa = 1887kg/cm2
A = Greater projection of plate beyond column in mm = 11
B = Lesser projection of plate beyond column in mm = 11
t = (3 X 12 / 1887) (112 112 / 4) = 1.72 cm
Proposed base plate as 32mm thick.

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8.3 Design of Anchor Bolts :

Bending moment in the column = 1305600kgcm

Proposed 8 Nos. of 40 anchor bolts each having area = 12.6 cm2

Load on the bolts = 1305600 / 21 = 62171kg

Load on each bolts = 62171 / 8 = 7771 kg

Shear stress = 7771 / 12.6 = 616 kg/cm2 < 960 kg/cm2

The quality of bolts are provided as Cl 4.6 of IS 1367.

******

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