~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/MM2 , YS=250N/MM2
Permissible stresses considering wet and inaccessible condition
Compression/Tension in bending = 0.4x250 = 100N/mm2
Direct tension = 0.4 x 250 = 100N/mm2
Shear stress = 0.3x250 = 75 N/mm2
Combined stress = 0.5 x 250 = 125N/mm2
Bearing stress = 0.45 x 250 = 112.5N/mm2
Draw shutter Size = 2100 (H) x 1800 (W)
Let nos 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
(H h)2
= ___________
H2 - (H h)2

~3~
=

(3.395 2.1)2
_______________________
(3.395)2 - ((3.395 2.1)2
5.18

= 0.5259

________________
9.849
2 x 3.395

y1 =

________________________

[ (1 + 0.5259)

1.5

- (1 1 + 0.5259)1.5 ]

_________________

3 4 + 0.5259
= 1.0639 [ 1.8849 0.3814 ]
= 1.5996
y2

1.0639 [ (2.5259)1.5 - 1.8849 ]

=
y3 =
=
y4 =
=

2.2656
1.0639 [ (3.5259)1.5 - 4.0144 ]
2.7729
1.0639 [ (4.5259)1.5 - 6.6207 ]
3.2
l1 = 3.395 3.2 = 0.195 M
l2 = 3.395 2.7729 0.195 = 0.4271M = 427 mm.
l3 = 3.395 2.2656 0.195 - 0.427 =

0.5074 M = 0.507 mm.

l4 = 3.395 1.5996 0.195 - 0.4271 - 0.5074 = 0.6659 M = 666 mm.

l5 = 305 mm.
F

l5

l2 = 430 mm.
l4

l3 = 500 mm.
l4 = 670 mm.

l3
C
l2
B
l1
A

Choose l1 = 195 mm.

l5 = 305 mm.

~4~

B) Design of main horizontal & vertical girder

Total hydrostatic load on the gate =

Ah (for HFL)

= 1000 kg /m3 x 9.81 m/s2 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 N
4
= 21739.2 N
F = qB = water load on each girder.
q = F/B , uniformly distributed load within span B
B = 1800 mm = seal span
L = 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 :

= M/Z

Allowable bending stress for wet and inaccessible condition of structural steel
permissible = 100 N/mm2
Section modules of horizontal girder, Z = M/permissible = 5407626 N/mm
100 N/mm2
= 54076.26 mm3

Choose Horizontal Girder section MC150

having Zxx =105000 mm3>54076.26 mm3 (hence OK)

C) Spacing of load Rollers:

No. of rollers = 4 ( 2 nos. On each vertical size)
Position of rollers for equal loading , considering HFL
HFL = H = 3.395 m.
h = 2.1 m. ,
n=2

~5~

=
=

n (H - h) 2
------------------H2 - (H h)2
2(3.395 2.1) 2
---------------------------------(3.395) 2 - (3.395 2.1) 2

3.3541
= -------------9.849
y

= 0.3406

2H
= ----------------- [ (k + p)3/2 - (k + + - 1)
---------3 n +

3/2

2 x 3.395
y1

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

[ (1 + 0.3406)2.5 - ( 0.3406)1.5 ]

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

2 + 0.3406

= 1.4794 [ 1.3534 ]

= 2 m.

y2 = 1.4794 [ (2.3406)1.5 - ( 1.3406)1.5 ] = 3 m.

l1 = 3.395 3 = 0.395 mm.
l2 = 3.395 2 0.395 = 1000 mm.
l3 = 2100 1395 = 705 mm.
Let the final position of wheel considering horizontal girder position.
l1 = 400 mm.
l2= 1100 mm.
l3 = 600 mm.

D) Checking for end girder (vertical) :

P1
Choosing end girder section MC 125
Z

xx

R1

= 68100 mm3

Load on vertical girder at four position each P1

= (load on each horizontal girder)
= 21739.2 N

P1

P1

= 10869.6 N
Reactiona at roller position

R2
R1

R2 21739.2 N

P1

Bending moments
MA = 10.869.6 N x (400 195) mm. = - 2228.268 x 103 N mm.
MB

10.869.6 N x 430 + 21739.2 x (430 + 195 400) mm. = + 217.392 x 103 N mm.

MD

= -

10.869.6 N x 295 mm. = - 3206.532 x 103 N mm.

MC

= -

10.869.6 N x 670 + 21739.2 x 375 mm. = 869.568 x 103 N mm.

~6~

M Max

max =

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

3206.532 x 10 N mm
---------------------------- =
3
68100 mm

< 100 N/mm2 (hence OK)

47.08 N/mm2

E) Checking of web thickness of horizontal beam t =

__F________
2 h permissible

F = Load on each girder

h = web depth

permissiblel = allowable shear Stress = 75 N/mm2

t=

21739.2
2 x 125 x 75

= 1.15 mm. < 5.7 mm.

(hence OK)

N/mm2

F) Skin Plate
Bending stress in flat plate

K
________ x

p a2
____________

100

where

s2

= bending stress in flat plate N/mm2

k = non-dimensional factor depending on values of a & b.
p = water pr. Relative to the pllate centre, N/mm2
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
3y

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

and four edged rigidly fixed.

4y

a=430

4x
b=1800
g =

1000 kg
_________
m3

m
x 9.8 ____
s2

= 9.8 x 10-6 N/mm2

~7~
Pressure at the plate centre (p) = 3.395 0.195 (0.43/2)
= 2.985 m. of H20
= 9.8 x 10-6 x 2985 N/mm2
= 29.253 x 10-3 N/mm2
From table 2, page 13 of IS 4622/03
k2x = 25, k2y = 7.5 , k3x = 50, k4y = 34.3

2x = (25/100) x 29.253 x 10-3 (N/mm2 ) x (430)2 mm2

(6.5)2 mm2
= 32005.2 x 10-3 N/mm2

2y =

(7.5/100) x 29.253 x 10-3 (N/mm2 ) x (430)2 mm2

(6.5)2 mm2

= 9.6

3x =

N/mm2

(50/100) x 29.253 x 10-3 (N/mm2 ) x (430)2 mm2

(6.5)2 mm2

< 100 N/mm2

= 64 N/mm2
(hence OK)

3y =

(0.3 x 64)

4y =

(34.3/100) x 29.253 x 10-3 (N/mm2 ) x (430)2 mm2

= 19.2 N/mm2

(6.5)2 mm2
= 43.9 N/mm2

4x =

(0.3 x 43.9) = 39.51 N/mm2

Combined Stress

________________________
= x 2 + y 2 - x y + 3Fxy 2

__________________________
=

[ 32 2 + 9.6 2 - 32 x 9.6 ]

= 23.44 N/mm2

_________________________
= (64) 2 + (19.2) 2 + 64 x 19.2

= 56.38 N/mm2

________________________________
= (43.9) 2 + (39.51) 2 43.9 x 39.51

= 41.87 N/mm2

2,

3,

4 (all) < 125 N/mm2

(hence OK)

~8~
Panel C D
3y

4y

a=500

4x

b=1800
p

gh ;

h = 2.77 - (0.507/2) = 2.5165 m.

9.8 x 10-6 N/mm2 x 2516.5 mm.

24.66 x 10

-3

N/mm2

b/a = 1800/500 = 3.6

k2x = 25, k2y = 7.5 , k3x = 50, k4y = 34.3

2x = (25/100) x 24.66 x 10-3 (N/mm2 ) x (500)2 mm2

(6.5)2 mm2
= 36.479 N/mm2

2y = (36.479 x 7.5/25)
= 20.94

N/mm2

3x = (36.479 x 50/25)
= 72.958

N/mm2

< 100 N/mm2

3y = (0.3 x 72.958)
= 21.88 N/mm2

4y = (36.479 x 34.3/25)
= 50.05

N/mm2

4x = (0.3 x 50.05) = 15 N/mm2

Combined Stresses

________________________
= 36.5 2 + 11 2 - 36.5 x 11
=

37.64 N/mm2
___________________________________
= (72.95) 2 + (21.88) 2 72.95 x 21.88
= 64.84 N/mm2

(hence OK)

~9~

________________________
= (50) 2 + (15) 2 15 x 50

= 44.44 N/mm2

2,

4 (all) < 125 N/mm2

3,

(hence OK)

Panel D - E
b=1800

a=670

4y
4x
3y
3x
Pressure at the panel
centre = 9.8 x 10

-6

N/mm2 x 1934.6 mm.

= 18.959 x 10

-3

h = 1.5996 + (0.67/2)

N/mm2

= 1.9346 m.

b/a = 1800/670 = 2.6866

k2x = 25, k2y = 8 , k3x = 50, k4y = 34.3

2x

k2x
= ------ x
100

pa2
-------s2
18.959 10

k2x x

k2x x 2.01

25 x 2.0

50 N/mm2

2y =

-3

N/mm2

x (670

---------------------------------------------------------------------100 x (6.5)2

k2y x 2.0

8 x 2

16 N/mm2

< 100 N/mm2 (

(hence OK)

3x

50 x 2

3y

=
=

100 N/mm2
0.3 x 100

4y

=
=

30 N/mm2
34.3 x 2

4x

= 68.6 N/mm2
= 0.3 x 68.6 =

20.58 N/mm2

all)

~ 10 ~

Combined Stresses

____________________
= 50 2 + 16 2 - 50 x 16
=

44.22 N/mm2
_________________________
= (100) 2 + (30) 2 100 x 30

< 125 N/mm2 (hence OK)

= 88.88 N/mm2
_______________________________

=
=

(68.6 2 + (20.58) 2 68.6 x 20.58

60.37 N/mm2

Panel A - B

b=1800

15x
a=195

13x
13y
14x

12x

14y

12y

Water pr at the panel centre

= 3.2 + 0.195/2 = 3.2975 m. of H2 O
= 9.8 x 10-6 N/mm2 x 3.297. 5 mm.
= 32.315 x 10-3 N/mm2
b/a = 1800/185 = 9.25
k11x = 22, k11y = 75 , k
k14x = 205, k14y = 62 , k

11x

12x
15x

= 90, k12y = 300 , k13x = 91, k13y = 28

= 2, k15y = 0 ,

= k11x = 32.315 x 10-3 x (195)2

100 x (6.5)2
= k11x x 0.2908 = 22 x 0.2908 = 6.39 N/mm2

~ 11 ~

11y

= 75 x 0.2908 = 21.81 N/mm2

12x

= 90 x 0.2908 = 26.17 N/mm2

12y

= 300 x 0.2908 = 87.24 N/mm2

13x

= 91 x 0.2908 = 26.46 N/mm2

13y

= 26 x 0.2908 = 8.14 N/mm2

14x

= 20591 x 0.2908 = 59.61 N/mm2

14y

= 62 x 0.2908 = 18 N/mm2

15x

< 100 N/mm2

(hence OK)

= 2 x 0.2908 = 0.58 N/mm2

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 = ------------3

= 28985.6 N

I) Wheel Pin ( cantilever type) :

Material AISI 304
Permissible Stresses,

YS = 245 N/mm2

TS = 590 N/mm2

bending stress = 0.40 x 245 = 98 N/mm2

sheared stress = 0.3 x 245

= 73.5 N/mm2

bearing stress = 0.45 x 245

= 110 N/mm2

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
all = ---------- d3

~ 12 ~
3/2

dmin =

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

= 47.3 mm.

So take wheel pin dia. = 50mm

J) Bronze Bushing
Bearing presume

= P/ld

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

l = length of bushing = 60 mm.
d = inner dia of bushing = 50 mm.
Crushing stress

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

= 9.69 N/mm2

< 15 MPa

(hence OK)

Thickness of bronze brushing = 6 mm.

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 ] + 150
= 92.1 say 92 mm. (approx)

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 ...

= 7.85 kg/cm3

Bronze ...

= 8.80 kg/cm3

Natural rubber

= 0.93 kg/cm3

Synthetic rubber = 1.23 kg/cm3

Hoist Load Calculation :
1.

wt. of gate (Wa )

8 mm. plate

1.8 x 2.1 x 62.8 = 237.384 kg.

(0.67 x 2 + 0.43 x 2 ) x 0.125 x 62.8 = 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
= 6 x 0.0017 x 930
= 9.7 kg.
(bottom) :

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)

(2.1 x 2 + 1.8 x 2) x 0.05 x 0.006 x 7850 = 18.369 kg.

Bar (100 x 8) :

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

Total wt. = 498..0 + 18.369 + 13.88

= 530.88 kg.
= 5308.8 N

~ 14 ~

Wheel Frictional Force (Fm ) (calculation for HFL)

2.

F = P/R (f

. 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

= 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.

fr = coefficient of rolling friction in mm. = 1.0

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, FR . C = F1.a/2 + F2 .c/2
FR

= ( a/c) . (F1/2) + (F2 /2)

= (a/2c) . (acp) + (CLp/2)
= Lp/2 [ a2/c + c ]

L=length of seal
P = av. pressure at seal centre.
Side Seal :
a = 32 , c= 28, L = 2100mm, p = 2.345 M of H2O
FR = Lp/2 [ a2/c + c ]

p = 2.345 x 1000 x 9.81 N/mm2

= 23 x 10

-3

N/mm2

FR = (2.1 x 2)/2 x 23 x 10-3 [{ (32)2 /28 } + 28 ]

3.11 N

~ 15 ~
Fs1 = f R

= 1.5 x 3.11 = 4.678 N (starting)

= 1.2 x 3.11 = 3.732 N (moving)

Top Seal
9.81
(3.395 2.1) x 1000 x --------- N/mm2
10-6
= 12.7 x 10-3 N/mm2

p=

FR = (1.8)/2 x 12.7 x 10-3 [{ (32)2 /28 } + 28 ] N

= 0.738 N

Fs2 = 1.5 x 0.738 = 1.1 N (starting)

= 1.2 x 0.738 = 0.885 N (moving)

4.

Buoyant force during submerged condition :

FB = (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 = Wg + Fw + Fs1 + Fs2 + 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/ 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/mm2
Permissible compressive stress = 0.2 x 200 = 40 N/mm2
Ct = kT/pt
t = kT/pCt

1 x 7500 N
= --------------------------14 mm x 40 N/mm2

= 13.39 mm.

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 = /4 [ (240)2 (188)2 ] x 0.2 x 7850 = 27.42 kg. Say, 30 kg.
W = 300 + 7500 = 7800 N
section module Z = /32 [ (D)3 (d)4 /D ]
= /32 [ (240)3 (188)4/240 ]

= 845740 mm3

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

Bending moment at the centre of drum Mb = WL/4 = (7800 N x 300 mm.)/4 = 58.5 x 104 N.mm.

~ 17 ~
b =

Bending Stress

Mb
58.5 x 104
----------- = ------------------ = 0.6917 N/mm2
Z
845740

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

permissible = 620/5 = 124 MPa, FS=5

Gear material: CS, Gr 340-570, IS 1030
TS = 570 MPa, YS = 340 MPa

permissible = 570/5 = 114 MPa

All gear & pinion are 200 full depth involute tooth profile
Spur gear ratio = 3
ZP1 = 16 & ZG1 = 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 ,
For pinion ,

=
=

.

.

40.56MPa

<114 MPa (Hence OK)

53.94MPa

<124 MPa (Hence OK)

< 21 N/mm2
(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,

permissible = 320 x (30/100) = 96 MPa,

,
Twisting moment Mt = 332409.97 N.mm
Minimum shaft dia., d

min

= (16 Mt /

Fpermissible )1/3

1/3

16 x 332409.97
--------------------3.14 x 96

So take shaft dia. = 40 mm

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,

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
93

P2
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

32 M
---------- d3

~ 19 ~
Take shaft dia. d = 50 mm

b =

32 x 985875
-------------------- = 80.37 MPa < 124 MPa (hence OK)
x 503

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.

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/mm2

947368.42
Crushing Stress = ---------------------50/2 x 50 x 5

< 120 N/mm2 (hence OK)

= 53.18 N/mm2

< 150 N/mm2 (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 200 full depth involute.

Material:

GEAR(G1)

PINION(P1)

CS, GR 340-570, IS1030

FS, C45, IS 2004

Teeth:

48

16

Module:

PCD:

336

112

Width:

56

56

Addendum:

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, 12mm, 1960grade, IS2266(table:3)
7. Flange coupling: Cast steel, flange OD160, Thickness 20, Hub OD 90, Length 82, 04 nos
M16 bolt at 125, as per drawing & IS 6196.
8. Manual drive handle: MS, crank length=350mm