INTRODUCTION

TELESCOPIC CHUTE
Telescopic chute for bulk material handling

Robust construction
Low maintenance
Easy cleaning
Social attention to safety

Figure 1
Telescopic chute

MAIN FEATURES
The telescopic chute is designed for loading bulk material on trucks, trains, ships,
inside storages. It is provided with inner tubes to contain the flow of material and
an outer flexible bellow to limit the propagation of dusts. It is operated by an
electric hoist with three lifting cables outside the material flow that raises and
lowers the bellows with cones without cable wear. Also available with double
bellow for non abrasive materials.
APPLICATIONS

Loading of products on trucks, tankers, trains, ships inside storages in:

Steel Plants
Cement Factories
Chemical Industries
Fertilizer Industries
Food Industries

OPTIONS

Suitable for low temperature and for high temperature

Construction for Hazardous Areas (ATEX)
Stainless steel construction
Built-in dust filter
ROPE DRUM:
Drums Grooved
Drums are the means by which power is transmitted to the rope and thence to the
object to be moved. For the wire rope to pick up this power efficiently and to
transmit it properly to the working end, installation must be carefully controlled.

If the drum is grooved, the winding conditions should be closely supervised to

assure adherence to the following recommended procedures:
1. The end of the rope must be secured to the drum by such means as will give
the end termination at least as much strength as is specified by the
equipment manufacturer.
2. Adequate tension must be maintained on the rope while it is being wound so
that the winding proceeds under continuous tension.
3. The rope must follow the groove.
4. It is preferable to have at least three dead wraps remaining on the drum
when the rope is unwound during normal operation. Three dead wraps are a
mandatory requirement in many codes and standards.
If the wire rope is carelessly wound and, as a result, jumps the grooves, it will be
crushed and cut where it crosses from one groove to the other. Another, almost
unavoidable problem is created at the drum flange; as the rope climbs to a second
layer there is further crushing and the wires receive excessive abrasion. Riser and
filler strips may help remedy this condition.
Another factor that must be given serious consideration is the pitch of the drum
grooves relative to the actual rope diameter. Wire rope is normally manufactured to
a plus tolerance. If this oversize tolerance in the rope is not taken into account, it
can mean severe damage.
Drums Plain (Smooth)

Installation of a wire rope on a plain (smooth) face drum requires a great deal of
care. The starting position should be at the correct drum flange so that each wrap of
the rope will wind tightly against the preceding wrap here too, close supervision
should be maintained during installation. This will help make certain that:
1. The rope is properly attached to the drum,
2. Appropriate tension on the rope is maintained as it is wound on the drum,
3. Each wrap is guided as close to the preceding wrap as possible, so that there
are no gaps between turns,
4. And that there are at least two dead wraps on the drum when the rope is fully
unwound during normal operating cycles.
Loose and uneven winding on a plain (smooth) faced drum can, and usually does,
create excessive wear, crushing and distortion of the rope. The results of such
abuse are lower operating performance and a reduction in the ropes effective
strength. Also, for an operation that is sensitive in terms of moving and spotting a
load, the operator will encounter control difficulties as the rope will pile up, pull
into the pile and fall from the pile to the drum surface. The ensuing shock can
break or otherwise damage the rope.

Figure 1. By holding the right or left hand with index finger extended, palm up or
palm down, the proper procedure for applying left- and right-lay rope on a smooth
drum can be easily determined.

Figure 2
The proper direction of winding the first layer on a smooth drum can be
determined by standing behind the drum and looking along the path the rope
5

travels, and then following one of the procedures illustrated in Figure 1. The
diagrams show: the correct relationship that should be maintained between the
direction of lay of the rope (right or left), the direction of rotation of the drum
(overwind or under wind), winding from left to right or right to left.
WIRE ROPE:
Wire rope, or cable, is a type of rope which consists of several strands of
metal wire laid (or 'twisted') into a helix. Initially wrought iron wires were used,
but today steel is the main material used for wire ropes.
Historically wire rope evolved from steel chains which had a record of mechanical
failure. While flaws in chain links or solid steel bars can lead to catastrophic
failure, flaws in the wires making up a steel cable are less critical as the other wires
easily take up the load. Friction between the individual wires and strands, as a
consequence of their twist, further compensates for any flaws.
Construction:
Wires
Steel wires for wire ropes are normally made of non-alloy carbon steel with a
carbon content of 0.4 to 0.95%. The tensile forces and to run over sheaves with
relatively small diameters.
Strands
In the so-called cross lay strands, the wires of the different layers cross each other.
In the mostly used parallel lay strands, the lay length of all the wire layers is equal
and the wires of any two superimposed layers are parallel, resulting in linear
contact. The wire of the outer layer is supported by two wires of the inner layer.
These wires are neighbours along the whole length of the strand. Parallel lay
6

strands are made in one operation. The endurance of wire ropes with this kind of
strand is always much greater than of those (seldom used) with cross lay strands.
Parallel lay strands with two wire layers have the construction Filler, Seale or
Warrington.

Spiral ropes
In principle, spiral ropes are round strands as they have an assembly of layers of
wires laid helically over a centre with at least one layer of wires being laid in the
opposite direction to that of the outer layer. Spiral ropes can be dimensioned in
such a way that they are non-rotating which means that under tension the rope
torque is nearly zero. The open spiral rope consists only of round wires. The halflocked coil rope and the full-locked coil rope always have a centre made of round
wires. The locked coil ropes have one or more outer layers of profile wires. They
have the advantage that their construction prevents the penetration of dirt and
water to a greater extent and it also protects them from loss of lubricant. In
addition, they have one further very important advantage as the ends of a broken
outer wire cannot leave the rope if it has the proper dimensions.
Stranded ropes:

Figure 3
Left-hand ordinary lay (LHOL) wire rope (close-up). Right-hand lay strands are
laid into a left-hand lay rope.

Figure 4
Right-hand Lang's lay (RHLL) wire rope (close-up). Right-hand lay strands are
laid into a right-hand lay rope.

Stranded ropes are an assembly of several strands laid helically in one or

more layers around a core. This core can be one of three types. The first is a fiber
core, made up of synthetic material. Fiber cores are the most flexible and elastic,
but have the downside of getting crushed easily. The second type, wire strand core,
is made up of one additional strand of wire, and is typically used for suspension.
The third type is independent wire rope core, which is the most durable in all types
of environments. Most types of stranded ropes only have one strand layer over the
core (fiber core or steel core). The lay direction of the strands in the rope can be
right (symbol Z) or left (symbol S) and the lay direction of the wires can be right
(symbol z) or left (symbol s). This kind of rope is called ordinary lay rope if the lay
8

direction of the wires in the outer strands is in the opposite direction to the lay of
the outer strands themselves. If both the wires in the outer strands and the outer
strands themselves have the same lay direction, the rope is called a lang lay rope
(formerly Alberts lay or Langs lay). Multi-strand ropes are all more or less
resistant to rotation and have at least two layers of strands lay helically around a
Centre. The direction of the outer strands is opposite to that of the underlying
strand layers. Ropes with three strand layers can be nearly non-rotating. Ropes
with two strand layers are mostly only low-rotating.

Classification of ropes according to usage:

Depending on where they are used, wire ropes have to fulfill different
requirements. The main uses are:

Running ropes (stranded ropes) are bent over sheaves and drums. They are
therefore stressed mainly by bending and secondly by tension.

Stationary ropes stay ropes (spiral ropes, mostly full-locked) have to carry
tensile forces and are therefore mainly loaded by static and fluctuating tensile
stresses. Ropes used for suspension are often called cables.

Track ropes (full locked ropes) have to act as rails for the rollers of cabins or
other loads in aerial ropeways and cable cranes. In contrast to running ropes,
track ropes do not take on the curvature of the rollers. Under the roller force, a
so-called free bending radius of the rope occurs. This radius increases (and the
bending stresses decrease) with the tensile force and decreases with the roller
force.

Wire rope slings (stranded ropes) are used to harness various kinds of goods.
These slings are stressed by the tensile forces but first of all by bending stresses
when bent over the more or less sharp edges of the goods.

Rope drive:
There are technical regulations for the rope drives of cranes, elevators, rope
ways and mining installations not exceeding a given tensile force and not falling
short of a given diameter ratio D/d of sheave and rope diameters. A general
dimensioning method of rope drives (and used besides the technical regulations)
calculate the five limits [

Working cycles up to rope discarding or breakage (mean or 10% limit) Requirement of the user

Rope safety factor = minimum breaking force F min / nominal rope tensile
force S. (ability to resist extreme impact forces) F min/S 2,5 for simple
lifting appliance

Discarding number of wire breaks (detection to need rope replacement)

Minimum number of wire breaks on a reference rope length of 30d should be
BA30 8 for lifting appliance

Optimal rope diameter with the max. rope endurance for a given sheave
diameter D and tensile rope force S - For economic reasons the rope diameter
should be near to but smaller than the optimal rope diameter d dopt.

The calculation of the rope drive limits depends on:

Data of the used wire rope

10

Rope tensile force S

Diameter D of sheave and/or drum

Simple bending per working cycle

Reverse bending per working cycle

Combined fluctuating tension and bending per working cycle

Rope bending length l

PLUMMER BLOCK
A pillow block, also known as plummer block or bearing housing, is a
pedestal used to provide support for rotating shaft with the help of compatible
bearings and various accessories. Housing material for a pillow block is typically
made of cast iron or cast steel.

11

Figure 5
Pillow blocks are usually referred to the housings which have a bearing
fitted into them and thus the user need not purchase the bearings separately. Pillow
blocks are usually mounted in cleaner environments and generally are meant for
lesser loads of general industry. These differ from Plummer blocks which are
bearing housings supplied without any bearings and are usually meant for higher
load ratings and corrosive industrial environments. However the terms pillowblock and Plummer block are used interchangeably in certain parts of the world.
The fundamental application of both types is the same which is to primarily
mount bearings safely enabling their outer ring to be stationary while allowing
rotation of the inner ring. The housing is bolted to a foundation through the holes
in the base. Bearings housings are either split type or un split type. Split type
housings are usually two piece housings where the cap and base can be detached,
while certain series are one single piece housings. Various seals are provided to
prevent dust and other contaminants from entering the housing. Thus the housing
12

provides a clean environment for the expensive bearings to freely rotate, hence
increasing their performance and duty cycle.
Bering housings are usually made of grey cast iron. However various grades
of metal can be used to manufacture the same.
ISO 113 specifies internationally accepted dimensions for Plummer blocks.
FASTENERS
A fastener is a hardware that mechanically joins or affixes two or more
objects together. Fasteners can also be used to close a container such as a bag, a
box, or an envelope; or they may involve keeping together the sides of an opening
of flexible material, attaching a lid to a container, etc.

There are also special-purpose closing devices, e.g. a bread clip. Fasteners
used in these manners are often temporary, in that they may be fastened and
unfastened repeatedly.
Some types of woodworking joints make use of separate internal reinforcements,
such as dowels or biscuits, which in sense can be considered fasteners within the

13

scope of the joint system, although on their own they are not general purpose

Figure 6

Furniture supplied in flat-pack from often uses cam dowels locked by cam
locks, also known as conformant fasteners.
Items like rope, string, wire (e.g. metal wire, possibly coated with plastic, or
multiple parallel wires kept together by a plastic strip coating), cable, chain, or
plastic may be used to mechanically join objects; but are not generally categorized
as fasteners because they have additional common uses. Likewise, hinges and
springs may join objects together, but are ordinarily not considered fasteners
because their primary purpose is to allow articulation rather than rigid affirming.

14

Other alternative methods of joining materials include: crimping, welding,

soldering, brazing, taping, gluing, cementing, or the use of other adhesives. The
use of force may also be used, such as with magnets, vacuum (like suction cups),
or even friction.
ROPE DRUM SHAFT
An axle is a central shaft for rotating wheel or gear. On wheeled vehicles,
the axle may be fixed to the wheels, rotating with them, or fixed to its
surroundings, with the wheels rotating around the axle. In the former case, bearings
or bushings are provided at the mounting points where the axle is supported. In the
latter case, a bearing or bushing sits inside the hole in the wheel to allow the wheel
or gear to rotate around the axle. Sometimes, especially on bicycles, the latter type
is referred to as a spindle.

On cars and trucks, several senses of the word Tandem axle co-occur in
casual usage, referring to the shaft itself, its housing, or simply any transverse pair
of wheels. The shaft itself rotates with the wheel, being either bolted or splined in
fixed relation to it, and is called an axle or axle shaft. However, it is equally
true that the surrounding housing (typically casting) is also called an axle (or
axle housing). An even broader (somewhat figurative) sense of the word refers to
the every transverse pair of the wheels, whether they are connected to each other or
not. Thus even transverse pairs of wheels in an independent suspension are usually
called an axle.

15

A straight axle is a single rigid shaft connecting a wheel on the left side of
the vehicle to a wheel on the right side. The axis of rotation fixed by the axle is
common to both wheels. Such a design can keep the wheel positions steady under
heavy stress, and can keep wheel positions steady under heavy stress, and can
therefore support heavy loads. Straight axles are used on trains, for the rear axles
of commercial trucks, and on heavy duty off-road vehicles. The axle can be
protected and further reinforced by enclosing the length of the axle in housing.

In split-axle designs, the wheel on each side is attached to separate shaft.

Modern passenger cars have split drive axles. In some designs, this allows
independent suspensions of the left and right wheels, and therefore a smoother
ride. Even when the suspension is not independent, split axles permit the use of a
differential, allowing the left and right drive wheels to be driven at different speeds
as the automobile turns, improving traction and extending tire life.

A tandem axle is a group of two or more axles situated close together. Truck
designs will use such a configuration to provide a greater weight capacity than a
single axle. Semi-trailers usually have a tandem axle at the rear.

16

SPECIFICATION

S.NO

DESCRIPTION

QUANTITY

Chute assembly

Rope drum assembly

6x19 galvanized fiber core 6mm wire rope

P205 pillow block

L angle

3.5 meters

25 mm square pipe

7.5 meters

Fasteners

12

U clamp for rope

M10 Grub screw

10

Sheave roller

10 meters
2

Table 2

17

CALCULATIONS

Wire rope selection

Weight to carry upward distance (H) = 0.7 m
Total weight of the chute
Velocity

(W) = 300 N
(v)

= 4m / min

Time taken for achieve the height (t) = 42 sec

Design load: assume

FOS = 4

300 x 4

= 1200 N

Taking 6 x 19 diameter 6mm rope

Tensile strength of wire

= 1100 to 1250 kgf/mm2

Breaking strength

= 15000 N

Area of cross section

A

= 0.4d2
= 0.4(6)2x (/4)
= 11.31 mm2

Wire diameter

dw

d
1.5 i

0.375 mm
18

Weight of the rope

= 0.105 kg
= 1.05 N

Calculation of various loads:

Direct load

Wd

= w + wr
= 1200+1.72
= 1202 N

Bending load

Wb

= E r d w A/ D
=

84000 X 0.375 X 11.3

160

= 2226.65 N
Acceleration load

Wa

direct load
g

Xa

= (3502/9.81) X 1.59 x10-3

= 0.569 N
Starting load

W st

= 2W d
= 2 (1200)
=2004 N

EFFECTIVE LOAD ON THE ROPE:

During normal working load W normal = Wd + Wb
19

= 1200 + 2226.65
= 3426.65 N

During acceleration

= Wd + Wb + Wa
= 3426.65 + 0.569
= 3427.219 N

During starting

= Wb + Wst
= 2226.65+ 2004
= 4628.65 N

Working F.O.S

Breaking load
accelarationload
15000

= 3427.219
= 4.67
For cranes and hoists in general hoist blocks factor of safety 4.5
Working factor of safety 4.67 is greater than the 4.5 , hence the design was safe.

Rope drum:

Drum dia for 6 x 19 (class II)

D
d

= 23

(Ref PSG pg. no. 9.1)

20

= 23 x 6
= 138 mm

Drum diameter 138 mm, drum diameter was 159mm so the design was safe.

Length of the drum :

L

2 Hi

= ( D

+ 12)s + L

(Ref PSG pg. no. 9.2)

= 217 mm

Where,
Pitch

=7.5 mm

Length L

=100mm

Minimum groove diameter

= d+0.8

(Ref PSG pg. no. 9.3)

= 6+0.8
=6.8 mm

Depth of the groove

= 0.1d

(Ref PSG pg. no. 9.3)

=0.1x 6
=0.6 mm
Shaft calculation

21

Total weight of the chute was 35kg (350 N approximately),If we use the motor
0.25 HP power is required to drive the rope drum.
0.25 HP

= 0.25 x 0.745

Power (P)

= 0.18625 kw
P

(1 HP = 0.745 kw)

= 2NT/60

The speed of the rope drum was 20 rpm

T

= 60 x 0.18625/ (2 x x 20 )

= 0.08893 N-m

= 88.93 N-mm

The support reactions at point A & B

RA and RB

= 350 N

RA

= 175 N

RB

= 175 Nm

Maximum bending moment action on center of the shaft

Max. B.M

= 175x200
= 35000 N-mm

We know that equivalent twisting moment,

Te

(M2 + T2)

= (35000)2 + (88.93)2

= 16 d3
Shaft diameter

(assume =42 Mpa)

= 16.19 mm

22

Te

32

32

b d3

(assume b

=63Mpa)
d
Shaft diameter d

x 63 x d3

= 17.82

Our rope drum shaft diameter was 30 mm , it was greater than the 17.82 mm . so
the design of the shaft was safe.

DRAWINGS
23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

FABRICATION PROCESS

1. CHUTE SUB ASSEMBLY:

STEP 1: Machining the seamless pipe as per the required dimensions
STEP 2: 8 mm thickness plate was cutting by using the gas cut and the flange
was prepared as per the drawings.
STEP 3: The flanges was welded with the pipes as per the sub assembly
drawing SA1

2. ROPE DRUMSUB ASSEMBLY

STEP 1: Machining the 159mm seamless pipe for the required length
STEP 2: Drum grooved was formed by the 3.4 mm radius forming tool.
STEP 3: Flange was welded with the rope drum.
STEP 4: Drum shaft was machined as per the design.

3. BASE FRAME SUB ASSEMBLY

STEP 1: L angles are cutting as per the part drawings, and it was welded as per
the sub assembly drawing.
STEP 2: 25 mm square pipe was use for the base leg , it was welded with the
base frame.
STEP 3: locking plate was cutting and the locking holes were done by using the
radial drilling machine.
STEP 4: Locking plate was welded with the base frame as per the drawing SA3

74

4. HANDWHEEL SUB ASSEMBLY

STEP1: 4 mm thickness round plate was drilled by using the radial drilling
machine.
STEP 2 : The hub was machined and 8 mm hole was drilled by the drilling
machine on the side wall of the hub, M10 thread was formed by using the tap
sets.
STEP 3: The round plate and the hub was matched in the center axis, both are
welded.
STEP 4: The handle was welded with hand wheel for grip to rotate the hand
wheel.

SHEAVES SUB ASSEMBLY:

STEP 1: The roller was welded with the small size angle and the sheave set up
was prepared.
STEP 2: the sheaves are welded in the base frame as per the assembly drawing.

75

PHOTOGRAPH

Figure 7
76

COST ESTIMATION
S.NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
22

DESCRIPTION
Flange 1
Flange 2
Flange 3
Flange 4
Flange 5
Flange 6
Drum flanges ( 4 nos)
Pipe material
Pipe 1 (machining + labour)
Pipe 2 (machining + labour)
Pipe 3 (machining + labour)
Shaft(material + labour)
Hubs (3 nos) (material + labour)
Welding charge
Rope drum machining
Grub screw
Wire rope
Frame material
Rope grip
Sheaves
Fasteners
Pillow block (2 nos)
Painting cost
TOTAL

AMOUNT
500
160
200
275
325
400
900
4000
100
125
125
400
225
1200
100
50
450
1700
150
400
65
700
800
13350

Table 2

CONCLUSION:
77

Telescopic chute was fabricated as per the designed parameters and

dimensions. The up/down movement of the chute was done manually
using a hand wheel. Locking provision has been made to stop the chute
at any desired height.
Drive unit and safety limit switches were not added and this could
be taken up as part of a mini project work in future.

REFERANCES

78

1. v.jayakumar DESIGN OF TRANSMISSION SYSTEM

Lakshmi publication (third edition) edition 2011

2. PSG design data book, revised edition1978

3. Stephen Herman, Industrial Motor Control Cengage Learning, 2009

chapter 11 "Limit Switches" ISBN 1435442393,

79