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~ 1 ~

PROPOSED REGULATOR CUM ROAD BRIDGE AT CH 19.115KM OF

DABU KHAL IN PS CANNING

DESIGN CACULATION SHEET OF DRAW SHUTTER, FLAP SHUTTER

& ROPE DRUM TYPE HOIST SYSTEM.

Agency: GEE BEE ENTERPRISE

Page 1 to 20

~ 2 ~

REGULATOR CUM ROAD BRIDGE AT CH 19.115KM OF DABU KHAL IN PS CANNING

Canal data

1. Design discharge= 56.4cumec

2. Crest level of sluice= (-)1M

3. Full discharge level= 0.5M

4. High flood level= 2.395M

5. Bed level= (-)2.5M

6. Bed width= 19M

River data

1. Tidal lockage period= 8hr

2. Low tide level= (-)0.19M

Bridge data

1. Carriage way width= 3.5M

2. Proposed road top level at centre= 3.905M

3. Minimum vertical clearance from HFL to the soffit of bridge slab= 0.9M

Design of draw shutter & flap shutter

Material: Structural steel components as per IS 2062

TS=410N/MM 2 , YS=250N/MM 2

Permissible stresses considering wet and inaccessible condition

Compression/Tension in bending = 0.4x250 = 100N/mm 2

Direct tension = 0.4 x 250 = 100N/mm 2

Shear stress = 0.3x250 = 75 N/mm 2

Combined stress = 0.5 x 250 = 125N/mm 2

Bearing stress = 0.45 x 250 = 112.5N/mm 2

Draw shutter Size = 2100 (H) x 1800 (W)

Let no’s of main horizontal girder = 4 and for equal loading of all horizontal beams their spacing are

A) Girder Position (for equal loading)

H=HFL=3.395M

H=gate height=2.1M n= 4

β =

(H – h) 2

H 2 - (H – h) 2

y 2

y

y

3

4

= (3.395 – 2.1) 2

(3.395) 2 - ((3.395 – 2.1) 2

=

5.18

9.849

= 0.5259

~ 3 ~

2 x 3.395

y 1

=

3 √ 4 + 0.5259

[

(1 + 0.5259) 1.5

-

= 1.0639 [ 1.8849 – 0.3814 ] = 1.5996

(1 – 1 + 0.5259) 1.5 ]

=

=

=

=

1.0639 [ (2.5259) 1.5 - 1.8849 ]

2.2656

1.0639 [ (3.5259) 1.5 - 4.0144 ]

2.7729

=

1.0639 [ (4.5259) 1.5 - 6.6207 ]

= 3.2

l

l

l

1

2

3

l 4

l 5

F

E

D

C

B

A

=

=

=

=

=

3.395 – 3.2 = 0.195 M

3.395 – 2.7729 – 0.195 = 0.4271M = 427 mm. =

3.395 – 2.2656 – 0.195 - 0.427

0.5074 M = 0.507 mm.

3.395 – 1.5996 – 0.195 - 0.4271 - 0.5074

= 0.6659 M = 666 mm.

305 mm.

l

l

l

5

4

3

l 2

l 1

Choose l 1 = 195 mm.

l

l

l

l

2

3

4

5

=

=

=

=

430 mm.

500 mm.

670 mm.

305 mm.

~ 4 ~

B) Design of main horizontal & vertical girder

Total hydrostatic load on the gate = ω Ah (for HFL)

= 1000 kg /m 3 x 9.81 m/s 2 x [2.1 m x 1.8 m] x [3.395 –( 2.1/2)]

= 86956.82 N

Load on each horizontal beam/girder =

86956.82

4

= 21739.2 N

N

F

q

B

L

= qB = water load on each girder.

= F/B , uniformly distributed load within span B

= 1800 mm = seal span

= wheel centre to centre distance / support distance

= 1800 + 75 + 20

= 1895 mm.

Maximum . bending moment occurs at centre of beam

M max

=

[F/2 x L/2] – ( B . q)/2 x B/4

= (FL/4) – (FB/8)

= 21739.2 N [ (1895/4) – (1800/8)] mm.

= 5407626 N.mm.

Bending Stress :

σ =

M / Z

F B L
F
B
L

Allowable bending stress for wet and inaccessible condition of structural steel

σ permissible

=

100 N/mm 2

Section modules of horizontal girder, Z = M/σ permissible = 5407626 N/mm 100 N/mm 2

= 54076.26 mm 3

Choose Horizontal Girder section MC150 having Zxx =105000 mm 3 >54076.26 mm 3 (hence OK)

C) Spacing of load Rollers:

No. of rollers = 4

Position of rollers for equal loading , considering HFL

( 2 nos. On each vertical size)

HFL =

H = 3.395 m.

h =

2.1 m.

,

n=2

~ 5 ~

β =

=

n (H - h) 2

-------------------

H 2 -

(H – h) 2

2(3.395 – 2.1) 2 ---------------------------------- -

(3.395) 2

(3.395 – 2.1) 2

3.3541

= --------------

9.849

=

0.3406

y k =

2 H

----------------- [ (k + p) 3/2 -

----------

3√ n + β

(k + β + - 1) 3/2 ]

2 x 3.395

y 1 = ----------------------------- [ (1 + 0.3406) 2.5

---------------------

3 2 + 0.3406

-

( 0.3406) 1.5 ]

=

1.4794 [

1.3534 ]

=

2 m.

y 2 =

1.4794 [

(2.3406) 1.5 - ( 1.3406) 1.5 ]

=

3 m.

l 1 =

l 2 =

l 3 =

3.395 – 3

=

0.395 mm.

3.395 – 2 – 0.395 = 1000 mm.

2100 – 1395 =

705 mm.

Let the final position of wheel considering horizontal girder position.

l 1 = 400 mm. l 2 = 1100 mm. l 3 = 600 mm.
l 1 =
400 mm.
l 2 = 1100 mm.
l 3 =
600 mm.
D)
Checking for end girder (vertical) :
P1
Choosing end girder section MC 125
R1
Z xx = 68100 mm 3
Load on vertical girder at four position each P 1
P1
= (load on each horizontal girder) ÷ 2
= 21739.2 N ÷ 2
P1
= 10869.6 N
R2
Reactiona at roller position
R 1 ≈
R 2 ≈ 21739.2 N
P1

Bending moments

M A = 10.869.6 N x (400 – 195) mm.

M B = 10.869.6 N x 430 + 21739.2 x (430 + 195 – 400) mm. = + 217.392 x 10 3 N mm.

M D = - 10.869.6 N x 295 mm.

=

- 2228.268 x 10 3 N mm.

=

- 3206.532 x 10 3 N mm.

σ max

=

M Max

--------------

Z

=

3206.532 x 10 3 N mm

---------------------------- 68100 mm 3

=

~ 6 ~

47.08 N/mm 2

E) Checking of web thickness of horizontal beam t =

F

= Load on each girder

h

= web depth

τ permissiblel = allowable shear Stress = 75 N/mm 2

t=

21739.2

N

2 x 125 x 75 N/mm 2

F) Skin Plate

=

1.15 mm. < 5.7 mm.

< 100 N/mm 2

F

2 h τ permissible

(hence OK)

(hence OK)

Bending stress in flat plate

K

p a 2

 

σ =

x

 

100

s 2

where

σ = bending stress in flat plate N/mm 2

k

= non-dimensional factor depending on values of a & b.

p

= water pr. Relative to the pllate centre,

N/mm 2

a, b = panel width in mm.

s = plate thickness, mm.

Let plate thickness = 8 mm, considering 1.5 mm corrosion allowance effective thickness =6.5 mm.

Panel B – C

σ 3y

σσ a=430 σ 4x
σσ
a=430
σ
4x

σ 4y

b=1800 ρ g = 1000 kg m x 9.8 m 3 s 2 = 9.8
b=1800
ρ g
=
1000 kg
m
x
9.8
m 3
s 2
= 9.8 x
10 -6
N/mm 2

Ratio of support length = b/a = 1800/430 = 4.18

and four edged rigidly fixed.

~ 7 ~

Pressure at the plate centre (p) = 3.395 – 0.195 – (0.43/2)

= 2.985 m. of H 2 0

= 9.8 x 10 -6 x 2985 N/mm 2

= 29.253 x 10 -3 N/mm 2

From table 2, page 13 of IS 4622/03

k 2x = 25,

k 2y =

7.5 ,

k 3x =

50,

k 4y = 34.3

σ 2x = (25/100) x 29.253 x 10 -3 (N/mm 2 ) x (430) 2 mm 2

σ 4x

σ

σ

2y

3x

σ 3y

σ 4y

=

(6.5) 2 mm 2

= 32005.2 x 10- 3 N/mm 2

=

=

=

=

(7.5/100) x 29.253 x 10 -3 (N/mm 2 ) x (430) 2 mm 2

9.6

(6.5) 2 mm 2 N/mm 2

(50/100) x 29.253 x 10 -3 (N/mm 2 ) x (430) 2 mm 2

=

64

(6.5) 2 mm 2 N/mm 2

(0.3 x 64)

= 19.2 N/mm 2

=

(34.3/100) x 29.253 x 10 -3 (N/mm 2 ) x (430) 2 mm 2

= 43.9

(6.5) 2 mm 2 N/mm 2

(0.3 x 43.9) = 39.51 N/mm 2

Combined Stress

σ =

2

√ σ x 2 + σy 2 - σ x σy + 3F xy 2

= [ 32 2 + 9.6 2

= 23.44 N/mm 2

- 32 x 9.6 ]

σ √ (64) 2 + (19.2) 2 + 64 x 19.2

3

=

= 56.38 N/mm 2

σ = √ (43.9) 2 + (39.51) 2 – 43.9 x 39.51

4

= 41.87 N/mm 2

< 100 N/mm 2

(hence OK)

~ 8 ~

Panel C – D

~ 8 ~ Panel C – D a=500 σ 3y   σ 4y σ 4x b=1800

a=500

σ 3y

 
 
σ 4y
σ 4y

σ

4y

σ

4x

b=1800 p = ρgh ; h = 2.77 - (0.507/2) = 2.5165 m.
b=1800
p
= ρgh ;
h
=
2.77 - (0.507/2) = 2.5165 m.

= 9.8 x 10 -6 N/mm 2 x 2516.5 mm.

= 24.66 x 10 -3 N/mm 2

b/a

= 1800/500 = 3.6

k 2x = 25,

k 2y =

7.5 ,

k 3x =

50,

k 4y = 34.3

σ 2x = (25/100) x 24.66 x 10 -3 (N/mm 2 ) x (500) 2 mm 2

= 36.479

(6.5) 2 mm 2

N/mm 2

σ 2y = (36.479 x 7.5/25)

= 20.94

N/mm 2

σ 3x = (36.479 x 50/25)

=

72.958

N/mm 2

σ 3y = (0.3 x 72.958)

= 21.88 N/mm 2

σ 4y = (36.479 x 34.3/25)

= 50.05

N/mm 2

σ 4x

=

(0.3 x 50.05) = 15 N/mm 2

Combined Stresses

σ √ 36.5 2 + 11 2 - 36.5 x 11

2

=

= 37.64 N/mm 2

σ = √ (72.95) 2 + (21.88) 2 – 72.95 x 21.88

3

< 100 N/mm 2

(hence OK)

~ 9 ~

σ 4

=

√ (50) 2 + (15) 2 – 15 x 50

=

44.44 N/mm 2

σ 2, σ 3, σ 4 (all) < 125 N/mm 2

(hence OK)

Panel D - E a=670
Panel D - E
a=670
b=1800
b=1800
(all) < 125 N/mm 2 (hence OK) Panel D - E a=670 b=1800 σ 3x σ
σ 3x
σ 3x

σ 3y

σ 4x
σ
4x

σ 4y

Pressure at the panel

centre

=

9.8 x 10 -6 N/mm 2 x 1934.6 mm.

h = 1.5996 + (0.67/2)

=

18.959 x 10 -3 N/mm 2

= 1.9346 m.

b/a = 1800/670 = 2.6866

k 2x = 25,

k 2y =

8 ,

k 3x = 50,

k 4y = 34.3

σ 2x

σ 2y

k 2x

= ------

=

=

=

100

k

k

2x

2x

25

x

x

pa 2 -------- s 2 18.959 10 -3 N/mm 2

x

(670 2

----------------------------------------------------------------------

100 x (6.5) 2

x 2.01

x

2.0

=

50

N/mm 2

=

k 2y

=

= 16

8

x

x

2

2.0

N/mm 2

σ 3x

σ 3y

σ 4y

σ 4x

x

= 100 N/mm 2

=

50

2

=

=

=

0.3 x 100

30 N/mm 2 34.3 x 2

= 68.6

=

0.3

N/mm 2

x

68.6 =

20.58

N/mm 2

< 100 N/mm 2

(

(hence OK)

all)

~ 10 ~

Combined Stresses

σ √ 50 2 + 16 2 - 50 x 16

= 44.22 N/mm 2

2

=

σ √ (100) 2 + (30) 2 – 100 x 30

3

=

=

88.88 N/mm 2

σ = √ (68.6 2 + (20.58) 2 – 68.6 x 20.58

4

= 60.37 N/mm 2

< 125 N/mm 2

(hence OK)

Panel A - B b=1800 σ 15x a=195 σ 13x σ 13y σ 14x σ
Panel
A - B
b=1800
σ 15x
a=195
σ 13x
σ
13y
σ 14x
σ 12x
σ 14y
σ 12y

Water pr at the panel centre = 3.2 + 0.195/2 = 3.2975 m. of

= 9.8 x 10 -6 N/mm 2 x 3.297. 5 mm.

= 32.315 x 10 -3 N/mm 2

H 2 O

b/a = 1800/185 = 9.25 =

k 11x

= 22,

k 11y

75 ,

k 12x

k 14x = 205,

k 14y = 62 ,

k 15x

=

90,

k 12y = 300 ,

=

2,

k 15y = 0 ,

σ 11x = k 11x

= 32.315 x 10 -3 x (195) 2

100 x (6.5) 2

k 13x = 91, k 13y = 28

= k 11x x 0.2908 = 22 x 0.2908 = 6.39 N/mm 2

σ 75 x 0.2908 = 21.81 N/mm 2

11y =

σ 90 x 0.2908 = 26.17 N/mm 2

12x =

σ 300 x 0.2908 = 87.24 N/mm 2

12y =

σ 91 x 0.2908

13x =

=

26.46 N/mm 2

σ 26 x 0.2908 = 8.14 N/mm 2

13y =

σ 20591 x 0.2908 = 59.61 N/mm 2

14x =

σ 62 x 0.2908 = 18 N/mm 2

14y =

σ 15x

=

2 x 0.2908 =

0.58 N/mm 2

~ 11 ~

< 100 N/mm 2

(hence OK)

So we provide 10mm thick MS skin plate for more strength.

G) Roller Dimension :

Material : Cast steel grade 280-520 of IS 1030/1998 with bush bearing

Roller dia. = 179mm, width = 60mm Crown rad. = 850 mm

Bush ID =50mm, thickness=6mm, width= 60mm

Bush shall be force fit in the wheel

Wheel pin shall be running fit in the bushing.

Wheel load (normal condition) = 21739.2 N

when one wheel is not connecting (worst condition)

 

86956.82

Max. Wheel load =

-------------

= 28985.6 N

3

I) Wheel Pin ( cantilever type) :

Material AISI 304

Permissible Stresses,

YS = 245 N/mm 2

,

TS = 590 N/mm 2

bending stress = 0.40 x 245 = 98 N/mm 2

sheared stress = 0.3 x 245

= 73.5 N/mm 2

bearing stress = 0.45 x 245

= 110 N/mm 2

l = wheel centre to end girder distance = 304+5 = 35 mm.

F = hyd. Load + wheel wt. = 28985.6 + 104.81 = 29090.42 N

M = Fl

=

29090,42 x 35

=

1018164.69 N.mm.

32 M σ all = ----------- π d 3

dmin =

32 x1018164.69 ------------------- 3.14 x 98

~ 12 ~

3/2

= 47.3 mm.

So take wheel pin dia. = 50mm

J) Bronze Bushing

Bearing presume

P = load on bushing = wheel load = 29090.42 N (Max)

l = length of bushing = 60 mm.

d = inner dia of bushing = 50 mm.

σ

= P/ld

Crushing stress

29090.42 N ------------- 60 x 50

σ =

=

9.69 N/mm 2

< 15 MP a

Thickness of bronze brushing = 6 mm.

(hence OK)

H) Flap shutter specifications are same as draw shutter.

I) Determination of CG for lifting hook:

y =

1/(504+150) [ 237 x 129 + 17 x 62.5 + 149 x 62.5 + 43 x 895 + 14.5 x

+ 10.8 x 134 + 18.36 x 145 + 13.1 x 32.5 ]

= 92.1 say 92 mm. (approx)

+ 150

Design components of draw shutter & flap shutter

1. Skin plate thickness = 10mm

2. Horizontal girder MC150 , 04 nos

3. End vertical girder MC125 , 02 nos

4. Stiffner plate 10mm thick x 70 (W) at top & bottom of skin plate and at middle in

vertical direction.

5. Four nos rollers (C.I.) cantilever type. Roller OD= 179mm, ID 50mm

Roller Pin dia. = 50mm, L= 300mm

6. Rubber seal J (music node) type on both side and top. Dimensions Bulb OD 44mm, ID

24mm, L=100mm, Thickness= 12mm.

7. Flat rubber seal on bottom. Size: 60mm(W) x 12mm (Thick)

~ 13 ~

Proposed regulator cum road bridge at ch 19.115km of Dabu Khal in PS Canning

Design of hoisting system components of draw shutter

1. Two point lifting rope drum drum type hoist system

2. End gear box/reduction unit consist of single stage spur gear with spur pinion

3. Central worm gear reduction unit

4. End reduction unit and worm gear connected by floating shaft and flange coupling at

both end.

5. Mannually operated handle to be fix on worm shaft for operation.

6. Single fall wire rope on each side rope drum.

For calculation of wt. of gate structure (approx.)

Steel

ρ = 7.85 kg/cm 3

Bronze

ρ = 8.80 kg/cm 3

Natural rubber

Synthetic rubber ρ = 1.23 kg/cm 3

ρ = 0.93 kg/cm 3

Hoist Load Calculation :

1. wt. of gate (W a )

8 mm. plate

(0.67 x 2 + 0.43 x 2 ) x 0.125 x 62.8

:

1.8 x 2.1 x 62.8 = 237.384 kg.

= 17.27 kg.

MC

125 x 65

:

2.1 x 2 x 13.1 kg./m.

= 55.02 kg.

MC

150 x 75

:

1.8 x 4 x 16.8 kg./m. = 120.96 kg.

Wheel : 3.14x ((0.17) 2 /4) x 0.06 x 7850 x 4 = 42.74 kg.

Wheel pin: 3.11x((.05) 2 /4)x0.235x 7850x4 = 14.48 kg

Rubber seal (side & top): (2.1x2+1.8)[ (3.14/4) {(0.044) 2 - (0.024) 2 } + 0.056 x 0.012 ] x 930

(bottom) :

= 6 x 0.0017 x 930

= 9.7 kg.

0.055 x 0.012 x 930 x 1.8

= 1.1 kg.

Total : (237.38 + 17.27 + 55.02+ 120.96 + 42.74 + 14.78 + 9.7 + 1.1) kg.

= 498.64 kg.

Flat bar for seal :

( 50 x 6)

Bar (100 x 8)

Total wt. = 498

:

0

(2.1 x 2 + 1.8 x 2) x 0.05 x 0.006 x 7850 =

(2.1 x 0.1 x 0.008 x 7850) = 13.188 kg.

+ 18.369 + 13.88

= 530.88 kg.

= 5308.8 N

18.369 kg.

~ 14 ~

2. Wheel Frictional Force (Fm )

(calculation for HFL)

F

= P/R (f a . r +

f r )

= total wheel friction in N

P

= total hydrostatic load N = 86956.82 N ( for HFL)

R

= wheel radius in mm = 89.5 mm.

f a = coefficient of axle friction (sliding)

= for bronze bushing of bearing

0.2 (starting)

0.15 (running)

r = effective radius of bearing in mm. = 25 mm.

f r = coefficient of rolling friction in mm. = 1.0

F m =

86956.82

----------------- [ 0.2 x 25 + 1.0 ]

89.5

= 5829.5 N (starting)

86956.82

= ----------------- [ 0.15 x 25 + 1 ]

89.5

= 4615 N (running)

3. Seal friction force : (Fs )

Frictional coefficient between rubber seal On stainless steel

f = 1.5 (starting)

= 1.2 (moving)

Taking moment about O, F R . C = F 1 .a/2 + F 2 .c/2

Side Seal :

F R

= ( a/c) . (F 1 /2) +

+

(F 2 /2)

= (a/2c) . (acp) + (CLp/2)

= Lp/2 [ a 2 /c

c ]

L=length of seal P = av. pressure at seal centre.

a = 32 , c= 28, L = 2100mm, p = 2.345 M of H 2 O

F R =

Lp/2 [ a 2 /c

+

c ]

p = 2.345 x 1000 x 9.81 N/mm 2

= 23 x 10 -3 N/mm 2

F R =

(2.1 x 2)/2 x 23 x 10 -3 [{ (32) 2 /28 }

+ 28 ]

=

3.11 N

~ 15 ~

F s1 = f R R

= 1.5 x 3.11 = 4.678 N (starting)

=

1.2 x 3.11 = 3.732 N (moving)

Top Seal

9.81

p =

(3.395 – 2.1) x 1000 x --------- N/mm 2

10 -6

= 12.7 x 10- 3 N/mm 2

F R =

F

s2

(1.8)/2 x 12.7 x 10 -3 [{ (32) 2 /28 }

+ 28 ] N

=

1.5 x 0.738 = 1.1 N (starting)

=

1.2 x 0.738

= 0.885 N (moving)

= 0.738 N

4. Buoyant force during submerged condition :

F B

= (530.88/7850) x 1000 x 9.81 = 663.43 N

During lowering total upward force (Frictional forces)

= 4615 + 3.73 + 0.885 + 663.43 = 5283 N

Net downward force for closing the gate shall be at least 20% higher than

The frictional and other forces opposing the downward motion.

F

– 5283 = (20/100) x (5283)

F

= 6339.6 N

Gate wt = 5308.8 N

For self closing wt. of ballast = 6339.6 – 5308.8

= 1030.8 N

=

103 kg. Say, = 110 kg. (taken)

Hoist load =

W g + F w + F s1 + F s2 + Ballast wt.

=

5308.8 + 5829.5 + 4.678 + 1.1 + 1100

=

12243.77 N

= 1224.37 kg.

Adding 20% for reserved hoist capacity

Hoist load = 1224.37 x 1.2 = 1469.25 kg. Say, 1500 kg. = 1.5 ton.

~ 16 ~

Design Hoist load = 1.5 Ton

A) ROPE SELECTION :

Single fall rope

Load on wire rope (each side) = 1500/2 kg. = 750 kg.

Factor of safety for normal operating condition = 6

Design load

= 750 x 6

=

4500 kg.

=

45 KN

We select round steel core wire rope of 6 x 37 construction 12 mm. dia.

rope of 1960 grade.

Breaking force of 12 mm did rope (IS 2266/02, Table No.3) = 90 KN > 45 K N (hence OK)

B) ROPE DRUM

Pitch dia of drum = 20 x 12 = 240 mm.

Lift of gate = 2.5 m.

No. of turns required = 2500/π x 240 = 3.31 = 4 (say)

Provide (4 + 2 + 1) = 7 nos turns.

2 nos. Idle turns for rope fixing.

,

Groove radius = 0.53 x 12 = 6.36

say 7 mm.

Groove depth = 0.35 x 12 = 4.2

say 4 mm.

Length of drum = 7 x 14 + 20 x 2 (flange width) + 30 x 2 (denance)

= 198 mm. say 200 mm.

Checked for crushing and bending stress

Material = Cast iron FG 200 (IS 210)

TS = 200 N/mm 2

Permissible compressive stress = 0.2 x 200 = 40 N/mm 2

C t = kT/pt

1 x 7500 N t = kT/pC t = --------------------------- = 13.39 mm. 14 mm x 40 N/mm 2

t = thickness of drum at bottom of groove.

Select

t = 20 mm. > 13.39mm

(hence OK)

Total load at Centre of Drum

W = wt. of drum + rope tension.

wt. of drum = π/4 [ (240) 2 – (188) 2 ] x 0.2 x 7850

W = 300 + 7500

section module Z = π/32 [ (D) 3 – (d) 4 /D ]

=

7800 N

= π/32 [ (240) 3 – (188) 4 /240 ]

= 27.42 kg. Say, 30 kg.

= 845740 mm 3

c/c distance of drum shaft bearing = 200 + 100 = 300 mm.

Bending moment at the centre of drum M b = WL/4 = (7800 N x 300 mm.)/4 = 58.5 x 10 4 N.mm.

Bending Stress

M b

~ 17 ~

58.5 x 10 4

σ b = ----------- = ------------------

Z 845740

= 0.6917 N/mm 2 < 21 N/mm 2 (hence OK)

Twisting moment on Drum

= 7500 x 240/2 x 1/0.95 = 947368.42 N.mm.

= Moment on drum gear

Moment on Pinion = 947368.42 x (16/48) x (1/0.95) = 332409.97 N.mm

Nos of teeth on pinion P1= 16 & gear G1 = 48

Torque on floating shaft = 332409.97 N.mm

Torque on worm wheel shaft = 332409.97 N.mm x 2 = 664819.94 N.mm.

C) Gear & Pinion design

Pinion material: FS C45, class 4, IS 2004

TS= 620MPa, YS= 320MPa

σ permissible = 620/5 = 124 MPa, FS=5

Gear material: CS, Gr 340-570, IS 1030

TS = 570 MPa, YS = 340 MPa

σ permissible = 570/5 = 114 MPa

All gear & pinion are 20 0 full depth involute tooth profile

Spur gear ratio = 3

Z P1 = 16 & Z G1 = 48

Let module m = 7

Face width b = 8m = 8x7 = 56mm

Lewis bending eqn. =

F = tooth load

q= constant

For Z = 16, q = 3.75 (IS6938, table 4)

For Z = 48, q = 2.8+(2.9-2.8)x2 /10 = 2.82

PCD of G1 =48x7 = 336 mm

PCD of P1 = 16x7 = 112 mm

Tooth load of gear G1, F = 947368.42/168 = 5639 N

Tooth load of Pinion p1, F = 5639 N

Tooth bending stress

For gear , =

.

= 40.56MPa <114 MPa (Hence OK)

For pinion , =

.

= 53.94MPa <124 MPa (Hence OK)

~ 18 ~

D) Torque Shaft/floating Shaft :

Length = 500mm

Material FS C45, class 4, (IS 2004), hot rolled & normalised

TS= 620MPa, YS= 320MPa

Permissible shear stress, τ permissible = 320 x (30/100) = 96 MPa,

,

Twisting moment M t = 332409.97 N.mm

Minimum shaft dia., d min

= (16 M t / π F permissible ) 1/3

=

/ π F p e r m i s s i b l e ) 1

16 x 332409.97

--------------------- 3.14 x 96

So take shaft dia. = 40 mm

1/3

=

26 mm.

(hence OK)

E) Drum shaft :

Length = 386 mm

Material FS C45, class 4, (IS 2004), hot rolled & normalised

TS= 620MPa, YS= 320MPa

Permissible bending stress, σ permissible = 620/5 = 124 MPa,

Load on drum shaft are

Wt. Of drum = 40kg

Wt of gear G1 = 39 kg

Load on gear tooth = 5639 N

Tension on rope = 7500 N

P1 P2 93 128 165 R1
P1
P2
93
128
165
R1

R2

P1=390+5639= 6029 N P2 = 7500+ 400 = 7900 N Reactions, R1 = 7954 N , R2 = 5975 N

Moment at P1 = 7654 x 93 =739722 Nmm Moment at P2 = 5975 x 165 = 985875 N mm

Bending stress

σ

=

32 M ----------- π d 3

~ 19 ~

Take shaft dia. d = 50 mm

σ b

=

32 x 985875 -------------------- = 80.37 MPa < 124 MPa π x 50 3

F) Worn Gear Selection:

Output torque > 664.8 N.m.

Ratio = 60 : 1

Size = 4

Efficiency = 73%

With both end output power.

Allroyd or reputed make

G) Manual operation with handle.

(hence OK)

Torque on worm wheel shaft = 664819.94 N.mm.

Torque on worm shaft =

664819.94 / (60 x 0.73) = 15178.53 N mm

Operating handle crank length = 350 mm

Force required on handle = 15178.53 / 350 = 43 N = 4.3 kg < 10kg (hence OK)

Manual operation crank rpm = 20 (approx)

Manua lifting speed = 20 x (1/60) x (16/48) x 3.14 x 240 = 83.73 mm / min

H) Key of flange coupling (Steel key)

Torque on floating shaft = 332409.97 N.mm

Sq key size = 10x10 x 50 (L)

332409.97

Sheer stress = -------------------- 50/2 x 50 x 10

=

26.59 N/mm 2

< 120 N/mm 2

(hence OK)

947368.42

Crushing Stress = ---------------------- 50/2 x 50 x 5

= 53.18 N/mm 2 < 150 N/mm 2 (hence OK)

~ 20 ~

Design Hoist capacity = 1.5Ton Manual lifting speed = 83mm/min

DESIGN COMPONENTS OF HOIST MECHANISM

1. Worm gear unit: ratio 60:1, size 4, output torque > 665 Nm, with both end output power.

2. Rope drum: Material FG 200(IS210) PCD=240mm, ID=186, Thicknes at bottom of groove=20mm, No of turns=7, groove rad.=7mm, groove depth=4mm, pitch=14, length=200

3. End reduction unit: Spur Gear & Pinion, both 20 0 full depth involute.

GEAR(G1)

PINION(P1)

Material:

CS, GR 340-570, IS1030

FS, C45, IS 2004

Teeth:

48

16

Module:

7

7

PCD:

336

112

Width:

56

56

Addendum:

7

7

Dedendum:

8.75

8.75

Hub dia:

100

integral with shaft

Hub length:

56

4. Drum shaft: Material: C45, IS2004, hot rolled & normalised, dia.=50mm, L=386mm

5. Floating shaft: Material: C45, IS2004, hot rolled & normalised, dia.=40mm, L=500mm

6. Wire rope: Round steel core type, 6x37 construction, Ф12mm, 1960grade, IS2266(table:3)

7. Flange coupling: Cast steel, flange OD160, Thickness 20, Hub OD 90, Length 82, 04 nos M16 bolt at Ф 125, as per drawing & IS 6196.

8. Manual drive handle: MS, crank length=350mm