- Theory of winches

The force requirement of winches and windlasses are defined by classification

societies. Depending on the grade of the chain cable and anchor depth, windlasses
must be capable of exerting the following nominall pull Z at a mean speed of at least
0.15 m/s (9 m/min)

Z = d2 x (f+0.218x(h-100)) [N]

d = Chain diameter [mm]

h = Anchor depth [m]
f = nominal pull factor [-]

Grade K1 K2 K3
f 37.5 42.5 47.5

Zmax = 1.5 x Z [N] at reduced speed at least 2 minutes.

The calculation of nominal pull shall be based on a minimum anchor depth of 100 m.
The pull of stern windlasses with an anchor rope can be determined by reference to
the anchor weight and the diameter of the corresponding chain cable.

The tables at rule books show the weight of anchor and necessary chain length.

Break holding load of windlasses are defined by existing of chain stoppers. In case
chain stoppers are fitted in front of windlasses, than break holding load is either 45%
or 20% of chain breaking strength depending of classification societies.

Connection of windlasses to ship’s hull to be supplied by counter foundations. Those

foundations and connection elements should be strong enough and strength is
calculated according to brake holding forces and if deck is exposed, green sea forces
which is mainly act at forward quarter of ship.

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Brake holding load for windlasses

Cable lifter accommodates the chain with at least five snugs. The calculation
diameter is 13 times the chain diameter d.

The torque coming from holding load of brake is :

M = 2.925 x d x BPL [kNm]

d = Chain diameter [mm]

BPL = Breaking Pull Load of Chain [kN]

BPL = 9.807 x Kc x d2 x (44-0.08xd) x10-3 [kN]

Grade K1 K2 K3
Kc 1 1.4 2

Brake Leg Holding Load (BHL) = M / L [kN]

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Brake holding load for mooring winches

The working side of drums is drum side which is under load exertion. In split drums,
there are two side; Working and Stowage. Stowage side is used to accommodate
the remnant length of rope used at working side. Generally first layer of drums are
layer for nominal pull force. Drums always have rope end fastening fittings.
Generally three rows of rope left at drum at least at breaking stage.

Drum diameter D and the rope diameter d define the torque and breaking load on
drum. Rope Holding Load are defined by owner. If the vessel is tanker than OCIMF
rules to be used as guidance.

The torque coming from test holding load is :

M = 5 x (D + d) x HL x 10-4 [kNm]

D = Drum diameter [mm]

d = Rope diameter [mm]
HL = Defined Holding Load of rope [kN]

Brake Leg Holding Load (BHL) = M / L [kN]

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Drive Calculations

Windlasses

When nominal pull Z is known at windlasses or any winch system using chain and
cable lifter, the drive is calculated 1.5 times of nominal which is Zmax as given
above.

The output torque of driving shaft Mms :

Mms = 6.5 x Zmax x d x 10-6 [kNm]

d = chain diameter [mm]

The output power of winch P:

P = Mms x n /(9.55xd) [kW]

d = Efficiency of gear box/motor, if unknown 0.81

n = Revolution of drive shaft [rpm]

n = V/ (0.041 x d)

V = Speed of windlass/Cable Lifter [m/min]

In case there is a drive motor, either hydraulic or electric or air driven and capable to
give the power P at above at n rpm than windlass can directly fitted with motor to
drive the winch. If this is not possible than a gear box can be used to reduce the
torque to available motor and conditions.

I : The sum of gear ratio of gear box

Input Torque Mis :

Mis = Mms/ (i x d) [kNm]

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Input motor shaft revolution ni :

ni = i x n [rpm]

Input motor power Pi :

Pi = Mis x ni / (9.55 x d) [kW]

n1 = Revolution of first stage pinion [rpm]

z1 = Number of teeth of first stage pinion

n2 = Revolution of second stage wheel [rpm]

z2 = Number of teeth of second stage wheel
…
…
n1xz1 = n2xz2
i= z2/z1=n1/n2=na/ne

na = Starting revolution [rpm]

ne = Ending revoltion [rpm]

i=i1 x i2 x i3 …
i also called as reduction ratio of gear box.

m = modul
p = pitch
z = number of teeth
d = pitch circle
m = p/ p = d/z
ha + hb = 2 x m + c, ha=m
ha = Addendum height, hb = dedendum height, c = clearence
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Mooring Winches

When nominal pull F is known at mooring winches or any winch system using rope
and drum, the drive is calculated at least 1.3 times of nominal force. Mooring winch
pull load and line holding load calculations includes the wind forces as well. Mr.
Beaufort classified The wind forces and now this classification named as Beaufort
scale. The classification society rules

The output torque of driving shaft Mms :

Mms = 0.5 x F x (D+d) x 10-6 [kNm]

F = Nominal pull load of winch [N]

D = Drum diameter [mm]

d = Rope diameter [mm]

The output power of winch P:

P = Mms x n / (9.55 x d) [kW]

d = Efficiency of gear box/motor, if unknown 0.81

n = Revolution of drive shaft [rpm]

n = V / ((D+d) x p) x 10 3

V = Speed of Winch [m/min]

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In case there is a drive motor, either hydraulic or electric or air driven and capable to
give the power P at above at n rpm than winch can directly fitted with motor to drive
the winch. If this is not possible than a gear box can be used to reduce the torque to
available motor and conditions.

i : The sum of gear ratio of gear box

Input Torque Mis :

Mis = Mms/ (i x d) [kNm]

Input motor shaft revolution ni :

ni = i x n [rpm]

Input motor power Pi :

Pi = Mis x ni / (9.55 x d) [kW]

Slipping Cluthes

Slipping cluthes are installed to motor shaft or one of other stage of gear box shaft in
order to protect gear box from over load conditions.

Most common slipping clutches are in design of friction disc lamels under pressure of
springs. The level of torque transmission is adjustable by these springs.

Load Sensors

Load sensors at revolutionary shafts are used to have a feed back information of
applied load and result a command through electronic boards to motor to give auto
tensioning facility to winch. Load sensors are generally made of strain gauges.

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