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Technical Data

Gate
Width (clear span) = B ≔ 12.25

Elevation of Sill Level = Elsl ≔ 2345

Water Lever = FSL ≔ 2366.68

Height of Gate = Hg ≔ 4191.0 = 13.75

Width of Gate = Wg ≔ 3833.8 = 12.58

Nos. of Gates. = 04 Nos.

Weight of Gate = Weightgate ≔ 5451.6

Weight of Counter Weight = WeightCW ≔ 5451.6

Gatetravel ≔ Hg = 4191
Water and Water Head
Design Head = Hw ≔ FSL − Elsl = 21.68

Head at Bottom = Hb ≔ Hw

Head at Top = Htop ≔ Hb − Hg = 7.93

Head of Water at Specific Location of gate = Variable

Horizontal / Vertical seismic factor a/g = ag ≔ .15

Specific weight of water = ω ≔ 62.4 ――


3

Beam, Chanel and Skin Plate


Thickness of skin plate = tsk ≔ 12

BEAM IPN 360 x 61.0 kg / m

Section Properties

Height of beam = Hbm ≔ 360


2
Area of beam = Abm ≔ 78.35
4 4
Moment of inertia of beam = Ixx ≔ 15130 = 363.5

Page 3 of 42
Wheel , Wheel Pin and Lifting pin
Diameter of the Wheel Dwheel ≔ 355

Length of Bronze bush Lbush ≔ 96

Dia of Bronze bush dbush ≔ 100

Dpin ≔ 100

ACp ≔ 408

BCp ≔ 351

ABp ≔ 57

Lifting Eye pin dia =

Pin dia = depin ≔ 45

Hoisting Machine
Module of first pinion and gear m1 ≔ 4 mm Module of second pinion and gear m2 ≔ 5 mm

Teeth of first pinion Tp ≔ 17 Teeth of second pinion TP2 ≔ 20

Teeth of first Gear TG ≔ 65 Teeth of second Gear TG2 ≔ 52

N = Rpm of Motor/First pinion Np ≔ 120 rpm

Sill Beam
Thickness of Sill Plate t1 ≔ 10

Width of Sill Plate w1 ≔ 150

Thickness of Sill Bearing Plate t2 ≔ 20

Width of Sill Bearing Plate w2 ≔ 125

Thickness of Web Plate t3 ≔ 12

Width of Web Plate w3 ≔ 150

Thickness of Base Plate t4 ≔ 12

Width of Base Plate w4 ≔ 150

Page 4 of 42
Second Stage Embedded Parts
Slide track
Thickness of track bar t5 ≔ 40

Width of track bar w5 ≔ 75

Thickness of guide bar angle t6 ≔ 12


(Long side)
Width of guide bar angle (Long side) w6 ≔ 200

Thickness of guide bar angle t7 ≔ 12


(Short Side)
Width of guide bar angle (Short side) w7 ≔ 100

Thickness of Web Plate t8 ≔ 12

Width of Web Plate w8 ≔ 150

Rope Drum
Pitch dia of Rope Drum = PCDRD ≔ 20 = 508

Inside radius of drum = Rin ≔ 9 = 228.6

Dia of Axle of rope drum = DAxle ≔ 80 = 3.15


Width of keyway of Axle = bkw1 ≔ 22 = 0.866

Thicknes of keyway of Exle = tkw1 ≔ 14 = 0.551

Unsupported length of Exle = LAxle ≔ 22 = 558.8

Dia of Cross Shaft = Dcs ≔ 80 = 3.15

Width of keyway of Cross Shaft = bkw2 ≔ 22 = 0.866

Thickness of keyway of Cross Shaft = tkw2 ≔ 14 = 0.551


3
Section modulus of Rope Drum Sxx ≔ 280.0
Support Chanel =

We are using Girder 8" x 20 lbs / ft.

Maximum Length of Support = Lsup ≔ 1000

Weight of Rope Drum (from drawing) = WeightRD ≔ 306

Page 5 of 42
Allowable Stresses for the design of Gate Equipment

Fy = Yield Stress Bending Stress = fb ≔ 21600

Fu = Ultimate Stress fu ≔ 65000

Fa = Allowable Stress Fy ≔ 36000

E = Modulus of Elasticity E ≔ 30000000

Sr. Type of stress Load case


No.
a) - For Structural members Normal Exceptional Extreme

1 Bending Stress 0.60 Fy 0.80 Fy 0.95 Fy


2 Shear Stress 0.40 Fy 0.50 Fy 0.60 Fy
3 Tension Stress 0.45 Fy 0.50 Fy 0.60 Fy
4 Bearing Stress 0.80 Fy 0.85 Fy 0.90 Fy
5 Combined Stresses 0.75 Fy 0.95 Fy No
b) ii - For all mechanical and 0.33 Fy or 0.67 Fy or 0.90 Fy or
Electrical Components 0.20 Fu 0.4 Fu or 0.55 Fu
Which ever Which ever
is minimum is less

MATERIALS USED.
Materials Specifications
1- Structural Steel.

a- For Skin plate, Beams & Stiffeners of Stop log. ASTM-A36 "Specification for structural steel"
b- For Embedded parts ASTM-A36 "Specification for structural steel"
( except Seal & track plates & Side guides)

2- Corrosion- Resisting (or Corrosion Resistant) Steel. ASTM-A-276, "Specification for stainless & heat
( Bars, Bolts, Nuts & Washer etc.) resisting steel bars & shapes.

3- Corrosion- Resisting (or Corrosion Resistant) Steel.


ASTM-A-276, "Specification for stainless & heat
(Pins & Rods) resisting steel bars & shapes.

4- Stainless Steel( plates, sheet & strips) ASTM-A-240, " Specification for heat resisting
chromium & chromium - nickel stainless steel plates,
sheet & strip.

5- Steel Shafting. ASTM - A29 ,For Steel Bars Carbon and


Alloy, Hot Rolled, Cold Finished.

ASTM - A307, For Low Carbon Steel Externally


6- Steel Bolts and Nuts. and Internally Threaded Standard Fasteners.
ASTM - A325, For High Strength Bolts for
Structural Steel Joints Including Suitable Nuts and Plain
Hardened Washers.

Page 6 of 42
Loading
Hg = 4191

B = 3733.8

Hw = 21.68

Hb = 21.68

Htop = 7.93

Specific weight of water ω = 62.4 ――


3

Horizontal/Vertical seismic factor a/g ag = 0.15

1- Hydro static Pressure on gate Ps ≔ ω ⋅ Hb = 1352.832

Ps = 1352.832
7 .5
2- Hydrodynamic Pressure Pd ≔ ―⋅ ⎛⎝Hw ⋅ Hb⎞⎠ ⋅ ω ⋅ ag
8
Pd = 177.559

3- Total hydraulic force on gate (including earthquake factor) =


Hb
Wtotal ≔ ⎛⎝Ps + Pd⎞⎠ ⋅ ―― ⋅ Wg = 208663.38
2
Hw
4- Hydrostatic Load on gate) = WHS ≔ Ps ⋅ Wg ⋅ ―― = 184453.81
2
5- Pressure Intensity at the top of Gate: Ptop ≔ ω ⋅ Htop = 3.436 ―― as H = 0
2

6- Pressure Intensity at the bottom of Gate Pbottom ≔ Ps + Pd = 10.63

Page 7 of 42
Beam Spacing

d1 ≔ 811 d2 ≔ 720 d3 ≔ 650 d4 ≔ 580

d5 ≔ 540 d6 ≔ 510 d7 ≔ 220

d1 + d2 + d3 + d4 + d5 + d6 + d7 = 4031
d1
AB ≔ ― = 405.5
2

d1 d2
BC ≔ ―+ ―= 765.5
2 2

d2 d3
CD ≔ ― + ―= 685
2 2

d3 d4
DE ≔ ― + ―= 615
2 2

d4 d5
EF ≔ ―+ ―= 560
2 2

d5 d6
FG ≔ ― + ―= 525
2 2

d6
GH ≔ d7 + ― = 475
2

Page 8 of 42
Hb = 6608.06

H1 ≔ Hb − GH = 6133.06

H2 ≔ H1 − FG = 5608.06

H3 ≔ H2 − EF = 5048.06

H4 ≔ H3 − DE = 4433.06

H5 ≔ H4 − CD = 3748.06

H6 ≔ H5 − BC = 2982.56

Hydraulic Forces
ω = 62.4 ―― Hb = 21.68 ag = 0.15
3

Hydrostatic Pressure , Ps Ps ≔ ω ⋅ Hb = 1352.832 Hn ≔ H1 H2 ....... H5

7 .5
Hydrodynamic Pressure , Pd = ―⋅ ω ⋅ ag ⋅ ⎛⎝Hbottom ⋅ Hn⎞⎠
8

v) Load on Girder No.7 = Average Pressure Intensity x Area


⎛ 7 .5⎞
LoadG7 ≔ ⎜ω ⋅ Hb + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ Hb⎞⎠ ⎟ ⋅ Wg ⋅ GH = 29998.228
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8

LoadG7 ⋅ B
Mu7 ≔ ―――― = 551217.434 ⋅
8

v) Load on Girder No.6 = Average Pressure Intensity x Area


⎛ 7 .5⎞
LoadG6 ≔ ⎜ω ⋅ H1 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H1⎞⎠ ⎟ ⋅ Wg ⋅ FG = 30908.305
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8

LoadG6 ⋅ B
Mu6 ≔ ―――― = 567940.113 ⋅
8

Page 9 of 42
v) Load on Girder No.5 = Average Pressure Intensity x Area
⎛ 7 .5⎞
LoadG5 ≔ ⎜ω ⋅ H2 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H2⎞⎠ ⎟ ⋅ Wg ⋅ EF = 30312.082
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8
LoadG5 ⋅ B
Mu5 ≔ ―――― = 556984.5 ⋅
8
(v) Load on Girder No.4 = Average Pressure Intensity x Area
⎛ 7 .5⎞
LoadG4 ≔ ⎜ω ⋅ H3 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H3⎞⎠ ⎟ ⋅ Wg ⋅ DE = 30166.85
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8
LoadG4 ⋅ B
Mu4 ≔ ―――― = 554315.865 ⋅
8
(vi) Load on Girder No.3 = Average Pressure Intensity x Area
⎛ 7 .5⎞
LoadG3 ≔ ⎜ω ⋅ H4 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H4⎞⎠ ⎟ ⋅ Wg ⋅ CD = 29765.517
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8
LoadG3 ⋅ B
Mu3 ≔ ―――― = 546941.369 ⋅
8
(vii) Load on Girder No.2 = Average Pressure Intensity x Area
⎛ 7 .5⎞
LoadG2 ≔ ⎜ω ⋅ H5 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H5⎞⎠ ⎟ ⋅ Wg ⋅ BC = 28463.667
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8

LoadG2 ⋅ B
Mu2 ≔ ―――― = 523019.872 ⋅
8
(viii) Load on Girder No.1 = Average Pressure Intensity x Area
⎛ 7 .5⎞
LoadG1 ≔ ⎜ω ⋅ H6 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H6⎞⎠ ⎟ ⋅ Wg ⋅ AB = 12213.762
⎝ 8 ⎠
Considering gate as a beam with uniformly distributed resting on free supports.
WL
Maximum bending Moment = ――
8

LoadG1 ⋅ B
Mu1 ≔ ―――― = 224427.885 ⋅
8

Page 10 of 42
HORIZONTAL BEAM
From Page No; 9 it is found that Maximum Bending Moment is at Girder No. 6

Therefore section Modulus for girder sizing is calculated based on Maximum Bending Moment at
Girder No.6 Mu6 = 567940.113 ⋅
Mu6 3
Section Modulus Z ≔ ―― = 26.29
fb
GATE GIRDERS
Section Modulus of Girder IPN 360 including 24 x t of skin plate.

Thickness of plate tsk = 12

width of plate bplate ≔ 24 tsk = 288


2
Area of plate Aplate ≔ bplate ⋅ tsk = 3456

Height of Beam Hbm = 360


2
Area of Beam Abm = 7835
3
bplate ⋅ tsk 4 4
Moment inertia of Plate Ixp ≔ ―――― = ⎝⎛4.147 ⋅ 10 ⎞⎠
12
8 4
Moment inertia of Beam I = ⎛⎝1.51 ⋅ 10 ⎞⎠
xx

2
Total Area Atotal ≔ Aplate + Abm = 11291
tsk
Arm of plate Yplate ≔ ― = 6
2
Hbm
Arm of beam Ybeam ≔ ―― + tsk = 192
2
3
Moment of Plate AYplate ≔ Aplate ⋅ Yplate = 20736
−3 3
Moment of Beam AYbeam ≔ Abm ⋅ Ybeam = ⎛⎝1.5 ⋅ 10 ⎞⎠
3
Total Moment AYtotal ≔ AYplate + AYbeam = 1525056
AYtotal
Y ≔ ――― = 135.07
Atotal
Y' ≔ Ybeam − Y = 56.93
tsk
dy ≔ Y − ― = 129.07
2
dy' ≔ Hbm − Y + tsk = 236.93
2 8 4
IxBeam ≔ Ixx + Abm ⋅ Y' = ⎛⎝1.77 ⋅ 10 ⎞⎠
2 7 4
IxPlate ≔ Ixp + Aplate ⋅ dy = ⎛⎝5.76 ⋅ 10 ⎞⎠
4
Ix ≔ IxBeam + IxPlate = 23430.86

Page 11 of 42
Ix 3
Zc ≔ ― = 1734.74
Y
Ix 3
Zt ≔ ―― = 988.93
dy'

Let us see how the stresses are acting on the selected size of Girders.
Maximum bending moment is at Girder No.6

Maximum Bending Moment : Mu6 = 567940.113 ⋅


Mu6 Mu6
fc ≔ ―― = 5364.988 ft ≔ ―― = 9411.061
Zc Zt
Which are less than allowable bending stress i.e 21600 psi

Check For Flexure.

Mu ≔ Mu6 = 567940.113 ⋅

Mn ≔ 0.9 ⋅ Fy ⋅ Zc = 3429878.705 ⋅

Mn > Mu

Hence our design is safe

Check For Deflection.

L ≔ Wg = 12.578 W ≔ LoadG6 = 30908.305

E = 30000000
4
Ixx = 363.5

3
5⋅W⋅L
f ≔ ―――― = 3.223
384 E ⋅ Ixx

Allowable Deflection.
L
fa ≔ ―― = 5.112
750
fa > f

Hence our design is safe

Page 12 of 42
Skin Plate
The bending stresses from water pressure are calculated with the theory of plates based on
the theory of elasticity, through the formula
2
k P⋅a
fb = ―― ⋅ ―― Ref : Page 115 Eq. 5.3
100 T 2
sk
Hence ‾‾‾‾‾‾‾‾‾2
k P⋅a
Tsk= ――――⋅
100 fb
Allowable bending stress = fb = 21600

horizontal/vertical seismic factor a/g = ag = 0.15

k = Non dimensional factor = 50 ( for 4 Edge fixed ) k ≔ 50

a = support length= d2,d3,d4,d5,d6and d7 reference to Girder 1,2,3,4,5 and 6

Tsk = plate thickness d1 = 811 d2 = 720

P = water pressure including siesmic factor at Girder d3 = 650 d4 = 580

d6 = 510 d5 = 540

P1,P2,P3, P4,P5,P6, and P7 refer to the Girder No, 1, 2, 3, 4,5,6,7 d7 = 220

corrosion allowance = Ca ≔ 0.05906


So .5⎞
⎛ 7
Pn = ⎜ω ⋅ Hn + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hbottom ⋅ Hn⎞⎠ ⎟
⎝ 8 ⎠

⎛ 7 .5⎞
P1 ≔ ⎜ω ⋅ H5 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H5⎞⎠ ⎟ = 6.257
⎝ 8 ⎠
‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k P ⋅d 2 ⎞
1 1
Tsk1 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 11.261 < 12mm
⎝ 100 fb ⎠

⎛ 7 .5⎞
P2 ≔ ⎜ω ⋅ H4 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H4⎞⎠ ⎟ = 7.312
⎝ 8 ⎠

‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k P ⋅d 2 ⎞
2 2
Tsk2 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 10.868 < 12mm
⎝ 100 fb ⎠

⎛ 7 .5⎞
P3 ≔ ⎜ω ⋅ H3 + ―⋅ ω ⋅ ag ⋅ ⎛⎝H3 ⋅ H4⎞⎠ ⎟ = 8.06
⎝ 8 ⎠

‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k P ⋅d 2 ⎞
3 3
Tsk3 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 10.378 < 12mm
⎝ 100 fb ⎠

Page 13 of 42
⎛ 7 .5⎞
P4 ≔ ⎜ω ⋅ H2 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H2⎞⎠ ⎟ = 9.109
⎝ 8 ⎠

‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k P ⋅d 2 ⎞
4 4
Tsk4 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 9.922 < 12mm
⎝ 100 fb ⎠

⎛ 7 .5⎞
P5 ≔ ⎜ω ⋅ H1 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H1⎞⎠ ⎟ = 9.907
⎝ 8 ⎠
‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k P ⋅d 2 ⎞
5 5
Tsk5 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 9.678 < 0.12 in
⎝ 100 f b ⎠

⎛ 7 .5⎞
P6 ≔ ⎜ω ⋅ H1 + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ H1⎞⎠ ⎟ = 9.907
⎝ 8 ⎠
‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k P ⋅d 2 ⎞
4 6
Tsk6 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 8.906 < 0.12mm
⎝ 100 fb ⎠
k1 = Non dimensional factor = 75
.5⎞
( for 3 Edge fixed )
⎛ 7
P7 ≔ ⎜ω ⋅ Hb + ―⋅ ω ⋅ ag ⋅ ⎛⎝Hb ⋅ Hb⎞⎠ ⎟ = 10.628 k1 ≔ 75
⎝ 8 ⎠
‾‾‾‾‾‾‾‾‾‾‾‾
⎛ k 2
P7 ⋅ d7 ⎞
1
Tsk7 ≔ Ca + ⎜―― ⋅ ――― ⎟ = 5.726 < 0.12
⎝ 100 fb ⎠

From above it is found theoretically that the thickness of the


skin plate required is less than 0.394 in. 10.0mm. The Extra thickness is
provided as a corrosion allowance for longer life.

Page 14 of 42
Center of Gravity
WEIGHT OF GATE AND CENTRE OF GRAVITY (Ref. Shop Dwgs.)
Sr. Item Qty. Size U. T. Arm. Moment
No (mm) Weight Weight
. No. Length Height Thick kgs kgs mm mm- kgs.
1- Skin plate 1 3813.8 4191.0 12.0 1505.7 1505.7 6.0 9034.0
2- Beam 14.17 x 5.51 7 3794.0 360.0 13.0 231.4 1620.0 192.0 311047.3
3- Gate End Plate. 2 4191.0 310.0 20.0 204.0 408.0 192.0 78326.8
4- Stiffener Plate. 2 4191.0 310.0 12.0 122.4 244.8 192.0 46996.1
5- Stiffener Plate. 5 4191.0 360.0 10.0 118.4 592.2 192.0 113700.2
6- Stiffener Plate. 3 2425.0 100.0 12.0 22.8 68.5 378.0 25904.5
7- H. Backing Plate 1 3640.0 75.0 12.0 25.7 25.7 18.0 462.9
8- V.Backing Plate 2 4191.0 55.0 20.0 36.2 72.4 -10.0 -723.8
9- H.Clamping Plate. 1 3640.0 100.0 12.0 34.3 34.3 -26.0 -891.5
10- V. Clamping Plate. 2 4191.0 55.0 12.0 21.7 43.4 -46.0 -1997.6
11- Top Seal Clamping 1 3813.8 55.0 12.0 19.8 19.8 -18.0 -355.7
12- Retaining Bar. 1 3640.8 32.0 32.0 29.3 29.3 -16.0 -468.3
13- Bottom Seal.+Top Seal 2 3640.0 108.0 20.0 8.6 17.1 -10.0 -171.1
14- Side Seal Angle Type 2 4191.0 75.0 20.0 6.8 13.7 -10.0 -136.8
15- Key Plate. 6 150.0 50.0 12.0 0.7 4.2 159.5 676.1
16- Wheel + W.Pin 3 Sets 231.0 693.0 159.5 110533.5
( Spacers , St. Pt. etc. )
17- Dogging Device. 2 18.5 37.0 150.0 5550.0
18 - L. Eye Plate. 4 240.0 150.0 20.0 5.7 22.6 145.0 3278.2
TOTAL 5451.6 700764.7

Total Weight of kgs


5,451.6
Gate =
Total Moments 700764.7 kgs.-mm
Centre of gravity from outer face of Skin Plate of Gate = Total Moment / Total Wt. of Gate.
= 700764.7 / 5,451.6
= 128.534 mm
C. G. = 130 mm

Page 15 of 42
Design of Wheel & Pin
ROLLERS

Let 6 Rollers, to be used in all with 3 rollers on one side.


Let 1st set ( lower) of rollers be fixed at 480mm from the bottom
of the gate ,second set ( middle ) be fixed at 1200mm from the 1st roller set and third set
( upper ) be fixed at 1750mm from the 2nd roller set

d11 ≔ 480 d22 ≔ 1200

d33 ≔ 1750 1640 = 64.567

Load on 1st set of rollers = Average intensity x Area


⎛ d22 ⎞
Load1stR ≔ ω ⋅ ⎛⎝Hb − d11⎞⎠ ⋅ Wg ⋅ ⎜d11 + ―― ⎟ = 55913.439
⎝ 2 ⎠
Load1stR
Load on one roller ( lower ) Load1stR1 ≔ ――― = 27956.719
2
⎛ d22 + d33 ⎞
Load2ndR ≔ ω ⋅ ⎛⎝Hb − ⎛⎝d11 + d22⎞⎠⎞⎠ ⋅ Wg ⋅ ⎜――― ⎟ = 61409.776 ⎛⎝d11 + d22⎞⎠ = 66.142
⎝ 2 ⎠
Load2ndR
Load2ndR1 ≔ ――― = 30704.888
2
⎛ d33 ⎞
Load3rdR ≔ ω ⋅ ⎛⎝Hb − ⎛⎝d11 + d22 + d33⎞⎠⎞⎠ ⋅ Wg ⋅ ⎜Hg − d22 − d11 − ―― ⎟ = 43925.336
⎝ 2 ⎠
Load3rdR
Load3rdR1 ≔ ―――= 21962.668
2

Let A = Width of Head of Track Bar. A ≔ 75 =3

B = Width of tread of Track Bar. B ≔ 63.5

C = Wheel Load in lbs. C ≔ Load2ndR1 = 30704.89

D = Diameter of the Wheel in inches Dwheel = 355

Then Width of tread of Track Bar in inches can be


found by the formula. (Ref.# 2 Machinery' s hand
book)

C
B ≔ ―――
1250 ⋅ A

32362
B ≔ ――― = 8.63
1250 ⋅ 3

Page 16 of 42
Dia of Smallest Track Wheel that will Safely Carry the Load is found by the formula,

A = 2.953 K ≔ 800 Where K = 600 to 800 ( For Steel Casting )

C
Dreq ≔ ――
A⋅K
32363
Dreq ≔ ――― = 13.48 = 13.48 = 342.4
3 ⋅ 800
We are Using Track Bar of Size 75mm x 63.5mm& Gate Wheel of Dia. 355mm
Hence the Design is Safe.

Roller Pin
Let Material of Pin be ASTM A - 276 Type 410 having U.T.S. = fu ≔ 65000

Working Stress for Roller Pin = fs ≔ 0.2 ⋅ fu = 13000

Let us find out the pin diameter.


Reaction R 1 , R 2 and Load W are
acting on the pin as shown in the sketch.
Let length of the Pin is 13 in. from the
point B and C.
Maximum load on the wheel is =

W ≔ Load2ndR1 = 30704.888

ACp = 408
BCp = 351
ABp = 57
ACp
R1 ≔ W ⋅ ―― = 35691.152
BCp
Similarly
ABp
R ≔ W ⋅ ―― = 4986.264
BCp
Maximum Bending Moment at R1 = W x ABp

R1 ≔ W ⋅ ABp = 68904.67 ⋅
R1 3
Section Modulus ( Z ) Z ≔ ― = 86.857 Required
fs
3
Section Modulus ( Shaft) = ― ⋅ dreq Zshaft ≔ Z
32
3 ‾‾‾‾‾‾‾‾ 32
dreq ≔ Zshaft ⋅ ― = 95.999 Required

We are using 100 mm. dia Wheel Pin of ASTM A - 276, type 410.
Hence Selected Pin Dia. is Safe.

Page 17 of 42
RONZE BUSH
Maximum load on the wheel is = W = 30704.888

Allowable Stresses for bronze = fa ≔ 4000


W 2
AreaRequired ≔ ―= 4952.391
fa
Actual area as per recommended pin dia = Bush length x dia

Lbush = 96 dbush = 100


2
Areaactual ≔ Lbush ⋅ dbush = 9600

9600 > 5220 Therefore our design is safe.

Alternative Approach.
Bearing Stress Developed = Max. Load / Wheel Bearing Area.
W
fbearing ≔ ―――― = 2063.496
Areaactual

Page 18 of 42
COUNTER WEIGHT

Length of counter weight = LCW ≔ 3680

Let The Height of Counter Weight. = HCW ≔ 1085

Width of Counter Weight WCW ≔ 530

Total Weight of the Gate. = Wgt ≔ 5451.6

Weight of Counter Weight (100 % of gate Wt. ) = WC ≔ Wgt = 5451.6

5- The counter weight box will be fabricated with 1 /4" thick plates and
angles of size 2 1/2 " x 2 1/2 " x 5/16" will be used as horizontal angles of the box,
at the bottom and at the top. Diagonal and vertical stiffeners will also
be of the same size. The box will be of welded structure.
2
(i) X-sectional area of the angle = 1.46 in.2 Aangle ≔ 1.46

(ii) Effective depth D from C to C of the up and down angle = Deptheff ≔ 26.375
WeightCW ⋅ LCW
(iii) Maximum Bending Moment ( WL/8) = MMax ≔ ―――――― = 217661.871 ⋅
8
MMax
iv) Stress f = B.M. /( D x Area x 2) = f1 ≔ ――――――= 2826.227
Deptheff ⋅ Aangle ⋅ 2
2696.15 < 21600 therefore it is safe.

ACTUAL WEIGHT OF SELECTED SIZE OF COUNTER WEIGHT

Weight of Angle Used


63.5mm x 63.5mm x 8mm Wa ≔ 7.441 ―

Weight of Gate Wgt

Specific Weight of Steel ASTM-A36 ω ≔ 7.85 ――


3

Specific Weight of Concrete ωc ≔ 2400 ――


3

Page 19 of 42
Space Between Vertical Angles l1 ≔ 685

Space Between Vertical Angles l2 ≔ 940

Length of Horizontal Angles lh ≔ 3680

No. of Horizontal Angles Nh ≔ 4

Length of Vertical Angles lv ≔ HCW = 1.085

No. of Verticall Angles Nv ≔ 12

Length of Top and Bottom Angles lt ≔ WCW = 530

No. of Top and Bottom Angles Nt ≔ 12

ld1 ≔ ‾‾‾‾‾‾‾‾‾
2 2
Length of Diagonal Stiffeners l1 + HCW = 1283.141

No. of Diagonal Angles Nd1 ≔ 8

ld2 ≔ ‾‾‾‾‾‾‾‾‾
2 2
Length of Diagonal Stiffeners l2 + HCW = 1435.557

No. of Diagonal Angles Nd2 ≔ 4

Weight of Horizontal Angles Wh ≔ lh ⋅ Nh ⋅ Wa = 109.532

Weight of Vertical Angles Wv ≔ lv ⋅ Nv ⋅ Wa = 96.882

Weight of Top and Bottom Angles Wtb ≔ lt ⋅ Nt ⋅ Wa = 47.325

Weight of Diagonal Angles Wd1 ≔ ld1 ⋅ Nd1 ⋅ Wa = 76.383

Weight of Diagonal Angles Wd2 ≔ ld2 ⋅ Nd2 ⋅ Wa = 42.728

Weight of gusset Plate a ≔ 200 b ≔ 200 t ≔ 10

Wgu ≔ a ⋅ b ⋅ t ⋅ ω = 3.14

Total Weight of Angles Wct ≔ Wh + Wv + Wd1 + Wd2 + Wtb + Wgu = 375.989

Weight of concrete to be filled Wcon ≔ Wgt − Wct = 5075.611


Wcon 3
Actual Volume of Counter Weight Vc ≔ ――= 74.685
Box to be filled with concrete. ωc

Vc
height of concrete to be filled Hcon ≔ ―――― = 1084.31
WCW ⋅ LCW

Height of c / w adopted 1085 mm

Page 20 of 42
Design of Embedded Parts
1- Design of bottom embedded parts

Load on sill beam

Wsb ≔ Weightgate = 12018.721

Trial Section

t1 = 10 w1 = 150
2
A1 ≔ t1 ⋅ w1 = 1500

t2 = 20 w2 = 125
2
A2 ≔ t2 ⋅ w2 = 2500

t3 = 12 w3 = 150
2
A3 ≔ t3 ⋅ w3 = 1800

t4 = 12 w4 = 150
2
A4 ≔ t4 ⋅ w4 = 1800
⎛ w3 ⎞
Y1 ≔ ⎛⎝t1 ⋅ 0.5 + t2 + w3 + t4⎞⎠ Y3 ≔ ⎜― + t4 ⎟
⎝ 2 ⎠
Y1 = 187 Y3 = 87

Y2 ≔ ⎛⎝t2 ⋅ 0.5 + w3 + t4⎞⎠ Y4 ≔ ⎛⎝t4 ⋅ .5⎞⎠

Y2 = 172 Y4 = 6

⎛⎝A1 ⋅ Y1⎞⎠ + ⎛⎝A2 ⋅ Y2⎞⎠ + ⎛⎝A3 ⋅ Y3⎞⎠ + ⎛⎝A4 ⋅ Y4⎞⎠


Y ≔ ――――――――――――― = 115.513
⎛⎝A1 + A2 + A3 + A4⎞⎠

Moment of Inertia I = I1 + I2 + I3 + I4
⎛w ⋅ t 3⎞ ⎛w ⋅ t 3 ⎞
2 2
⎝ 1 1 ⎠ 4 ⎝ 2 2 ⎠ 4
I1 ≔ ―――+ ⎛⎝A1⎞⎠ ⋅ ⎛⎝Y1 − Y⎞⎠ = 767.805 I2 ≔ ―――+ A2 ⋅ ⎛⎝Y2 − Y⎞⎠ = 806.024
12 12
⎛t ⋅ w 3 ⎞ 2 ⎛w ⋅ t 3 ⎞ 2
⎝3 3 ⎠ 4 ⎝ 4 4 ⎠ 4
I3 ≔ ――― + A3 ⋅ ⎛⎝Y − Y3⎞⎠ = 483.84 I4 ≔ ――― + A4 ⋅ ⎛⎝Y − Y4⎞⎠ = 2160.924
12 12

4
I ≔ I1 + I2 + I3 + I4 = 4218.593
4 4
I = 4218.593 I = 4218.59

Page 21 of 42
Wsb = 12018.721

Ec ≔ 3600000

E ≔ 29000000

b = Depth of concrete support bf ≔ 300


I 3
S ≔ ―= 22.286
Y
6
E = ⎛⎝3.6 ⋅ 10 ⎞⎠
c Ec = 24821.126

3 ‾‾‾‾‾‾
E c ⋅ bf
4

k ≔ 0.4 ⋅ Ec ⋅ ―――
E⋅I
6
k = 28572.973 k = ⎛⎝4.14 ⋅ 10 ⎞⎠
1

4
⎛ k ⎞
β ≔ ⎜―――
⎝ 4 ⋅ E ⋅ I ⎟⎠
−1 −1
β = 0.005 β = 0.137
Wsb βx βx
M ≔ ―― e ⋅ (cos (βx) − sin (βx)) e ⋅ (cos (βx) − sin (βx)) = 1
4⋅β

Wsb
M ≔ ―― ⋅1

M = 21.93 ⋅

Bending Stress fb = M/S


M
fb ≔ ―
S
fb = 983.959 < 21600 psi (Allowable)

Concrete Bearing Pressure


Wsb ⋅ β
P° ≔ ――― ⎛⎝Aβx1 + Aβx2 + Aβx3⎞⎠
2 ⋅ bf
The load is uniformly distributed and whole of the term ⎛⎝Aβx1 + Aβx2 + Aβx3⎞⎠ =1
Wsb ⋅ β
So P° ≔ ――― ⋅1
2 ⋅ bf
P° = 0.481

P° = 0.07 This value is very small hence our Design is Safe

Page 22 of 42
Comparative Stress.
Comparative Stress , fc is Calculated by the formula, fc = 0.195 x fck + 2.31MPa

For fck > 18 MPa

In our case fck ≔ 3500 = 24.132

fc ≔ 0.195 ⋅ fck + 2.31

fc = 7.016 fc = 1017.54

fc > P° Hence our Design is Safe

2- Design of Slide Track

Trial Section

t5 = 40 w5 = 75
2
A5 ≔ t5 ⋅ w5 = 3000

t6 = 12 w6 = 200
2
A6 ≔ t6 ⋅ w6 = 2400

t7 = 12 w7 = 100
2
A7 ≔ t7 ⋅ w7 = 1200

t8 = 12 w8 = 150
2
A8 ≔ t8 ⋅ w8 = 1800
⎛ t5 ⎞ ⎛ w7 ⎞
Y5 ≔ ⎜―+ t6 + w7 + t8⎟ Y7 ≔ ⎜― + t8⎟
⎝2 ⎠ ⎝ 2 ⎠
Y5 = 144 Y7 = 62
⎛ t6 ⎞ ⎛ t4 ⎞
Y6 ≔ ⎜―+ w7 + t8⎟ Y8 ≔ ⎜―⎟
⎝2 ⎠ ⎝2⎠
Y6 = 4.64567 Y8 = 6

⎛⎝A5 ⋅ Y5⎞⎠ + ⎛⎝A6 ⋅ Y6⎞⎠ + ⎛⎝A7 ⋅ Y7⎞⎠ + ⎛⎝A8 ⋅ Y8⎞⎠


YST ≔ ――――――――――――― = 95.286
⎛⎝A5 + A6 + A7 + A8⎞⎠

Moment of Inertia I = I5 + I6 + I7 + I8

⎛w ⋅ t 3 ⎞ 2 ⎛w ⋅ t 3 ⎞ 2
⎝ 5 5 ⎠ 4 ⎝ 6 6 ⎠ 4
I5 ≔ ――― + ⎛⎝A5⎞⎠ ⋅ ⎛⎝Y5 − YST⎞⎠ = 18.065 I6 ≔ ――― + A6 ⋅ ⎛⎝Y6 − YST⎞⎠ = 3.044
12 12

Page 23 of 42
⎛t ⋅ w 3 ⎞ 2 ⎛w ⋅ t 3 ⎞ 2
⎝7 7 ⎠ 4 ⎝ 8 8 ⎠ 4
I7 ≔ ―――+ A7 ⋅ ⎛⎝YST − Y7⎞⎠ = 5.597 I8 ≔ ―――+ A8 ⋅ ⎛⎝YST − Y8⎞⎠ = 34.527
12 12
4
IST ≔ I5 + I6 + I7 + I8 = 61.233
4 7 4
IST = 25486914.286 IST = ⎛⎝2.55 ⋅ 10 ⎞⎠

Load on One Roller

W1R ≔ Load2ndR1 = 30704.888

Ec ≔ 3600000

E ≔ 29000000

bST = Depth of concrete support bST ≔ 6


IST 3
SST ≔ ―― = 16.323
YST
6
E = ⎛⎝3.6 ⋅ 10 ⎞⎠
c Ec = 24821.126

3 ‾‾‾‾‾‾‾
Ec ⋅ bST
4

k ≔ 0.4 ⋅ Ec ⋅ ―――
E ⋅ IST
6
k = 13700.103 k = ⎛⎝1.99 ⋅ 10 ⎞⎠
1

4
⎛ k ⎞
β ≔ ⎜―――⎟
⎝ 4 ⋅ E ⋅ IST ⎠
−1 −1
β = 0.005 β = 0.129
W1R βx βx
MST ≔ ―― e ⋅ (cos (βx) − sin (βx)) e ⋅ (cos (βx) − sin (βx)) =1
4⋅β

W1R
MST ≔ ―― ⋅1

MST = 59.35 ⋅

Bending Stress fb = M/S


MST
fb ≔ ――
SST
fb = 3636.37 < 21600 psi (Allowable)

Page 24 of 42
Concrete Bearing Pressure
W1R ⋅ β
P° ≔ ――― ⎛⎝Aβx1 + Aβx2 + Aβx3⎞⎠
2 ⋅ bST
The load is uniformly distributed and whole of the term ⎛⎝Aβx1 + Aβx2 + Aβx3⎞⎠ =1
W ⋅β
SoP° ≔ ―――
1R
⋅1
2 ⋅ bST
P° = 0.331 This value is very small hence our Design is Safe

Computation of Hoist Load and Design of Lifting Device.


Weight of Gate = Weightgate = 12018.721

Seal Friction

Friction on side seal

Hydrostatic Pressure on Gate = Ps = 1352.832

Hydrodynamic Pressure on Gate = Pd = 177.559

Total Pressure on Gate = Pt ≔ Ps + Pd = 1530.391

Fs = μNs

Where μ ≔ .9

and Reaction force of the seal


P⋅L 2 2
Ns = ――⎛⎝b + a + a ⋅ ts⎞⎠
2b

Where a ≔ 20 b ≔ 26 ts ≔ 12

Length of side seal Ls ≔ Hg = 4191


Pt ⋅ Ls 2 2
Ns ≔ ―― ⎛⎝b + a + a ⋅ ts⎞⎠ = 1747.2
2b
Fs ≔ 2 μ ⋅ Ns = 3144.961 2 x μNs for two seals

Page 25 of 42
Friction on top seal

Ft = μNt

Where μ ≔ .9

and Reaction force of the seal


P⋅L 2 2
Nt = ――⎛⎝b + a + a ⋅ tt⎞⎠
2b
Where a ≔ 20 b ≔ 26 tt ≔ 12

Length of top seal Lt ≔ Wg = 3833.8


Pt ⋅ Lt 2 2
Ns ≔ ―― ⎛⎝b + a + a ⋅ tt⎞⎠ = 1598.286
2b
Ft ≔ μ ⋅ Ns = 1438.458

Wheel Friction

Width of gate Wg = 3833.8

Head of Water Hb = 6.608

Height of Gate Hg = 4191


Hg
Water Load on Gate Wt ≔ Pt ⋅ ―― ⋅ Wg = 132339.55
2
Dia of Wheel Dw ≔ 355
(Reference Pics)
Dw
Radius of Wheel Rw ≔ ―― = 177.5
2
Friction Coefficient of Bearing or Bushing μs ≔ 0.2

Dia of Shaft Ds ≔ 100


Ds
Radius of Shaft Rs ≔ ― = 50
2
Coefficient of Rolling Friction f ≔ .02

Wt
Total Wheel Friction Fr ≔ ―― ⎛⎝μs ⋅ Rs + f⎞⎠ = 7.605
Rw

Total friction Ff ≔ Fs + Ft + Fr = 12188.283

Page 26 of 42
CALCULATIONS FOR EYE BOLT DIA AND PIN DIA
In. dia eye bolt and dia of pin

(i)Let Eye pin dia depin = 45

(ii)Total Load on each rope ( Mat. :- ASTM A - 276 Series 400 )

Total Load WDW ≔ Weightgate + Ff = 24207.003

No of Roops Nr ≔ 2
WDW
Loadr ≔ ―― = 12103.502
Nr

W ( 2 a + b)
Bending Force R1= ――――
2l
W ≔ Loadr = 12103.502
a ≔ 20
b ≔ 55
l ≔ 95

W (2 a + b)
R1 ≔ ――――= 6051.751
2l
⎛ R1 ⎞
Mmax ≔ R1 ⋅ ⎜a + ――⎟ = 8041.204 ⋅
W
⎜ 2 ―⎟
⎝ b ⎠

Y
σmax = Mmax ⋅ ―
I
depin
Y ≔ ―― = 0.886
2
4 4
I ≔ ― ⋅ depin = 0.484
64
Y
σmax ≔ Mmax ⋅ ―= 14729.392
I

Vmax ⋅ S
τmax = ―――
I ⋅ dEyepin
Vmax ≔ R1 = 6051.751
3
depin 3
S ≔ ―― = 0.463
12
4 4
I ≔ ― ⋅ depin = 0.484
64
Vmax ⋅ S
τmax ≔ ――― = 3273.198
I ⋅ depin
Allowable Shear Stress = 16250 psi

The Stresses in the Eye Bolt and Pin are Safe because these are Less than Allowable Shear Stresses.
Ultimate tensile strength of ASTM A276 Series 400 is 65,000 psi, therefore, Fy= 65,000 × 0.25 =16250 psi

Page 27 of 42
CALCULATION FOR STEEL WIRE ROPE

Maximum Vertical Load WDW = 24207.003


WDW
(i) Maximum Load On each Rope Drum LoadRD ≔ ――= 12103.502
2
(ii) Maximum Load On each Rope LoadR ≔ LoadRD = 12103.502

(iii) Factor of Safety FS ≔ 5

(iv) Total bearing strength of wire rope Bearingstrength ≔ LoadR ⋅ FS = 60517.508

Therefore we can use Wire Rope dia = 15/16 in.


The breaking strength of wire rope = 40.00 Tons. ( 1 Ton = 2000 lbs. )
(Zinc - Coated Steel Structural Wire Rope ASTM - A 603 Class A )= 80000 lbs.
Hence the Design is safe.

CALCULATIONS FOR HOIST

Input Torque = Average force applied by one man x Arm.= 40 x 12 = 480 in. - lbs.

Fapplied ≔ 40

Larm ≔ 12

Tinput ≔ Fapplied ⋅ Larm = 480 ⋅

OUTPUT LOAD
Weight of Gate = Weightgate = 12018.7

Weight of c/w = WeightCW = 12018.7

Frictional force =. Ff = 12188.283

Net load = Wnet ≔ Ff = 12188.283

Net Vertivcal load = Wv ≔ Wnet = 12188.283


PCDRD
Radius of roop drum = RRD ≔ ――― = 254
2
Output torque = Toutput ≔ Wnet ⋅ RRD = 121882.827 ⋅

Considering 65% efficiency at input then min. reduction

Minimum Reduction Required is = Reqd. output Torque / Input Torque x 0.65


Toutput
ReductionRequired ≔ ―――― = 390.65
Tinput ⋅ 0.65
We are using the Gear Box with three stage reduction hoisting system
and the reduction is 1 : 596
Page 28 of 42
Hoisting Efforts

Weightgate = 12018.721 = Weight of gate


Weightgate
EB ≔ ―――― = 1530.54 = Buoyancy
7.8526
Ff = 12188.283 = Friction force

Hoisting Load Whoisting ≔ Weightgate − EB + Ff − WeightCW = 10657.742

Hoisting Efforts for lifting Gate. =


T2 = T1 x n/c

Where
PCDRD
Torque on Rope Drum = T2 ≔ Whoisting ⋅ ――― = 106577.42 ⋅
2
T1 = Torque on Handle Wheel (Handle) = ?
n = Eff. Of Worm , Worm Gear , Bearings,
Spur Gear, Rope Drum / Pulley etc. n ≔ 50% = 0.5
1
c = Reduction Gear Ration c ≔ ―― = 0.002
596
T2 = T1 x n/c
T1 = T2 x c/n
c
T1 ≔ T2 ⋅ ―= 357.642 ⋅
n
T1 = P x r
Where

P = Pull req. at Handle Wheel

r = Radius of Handle Wheel r ≔ 15

P = T1 / r
T1
PWheel ≔ ― = 23.843
r
1
RPM ≔ 30 ――
min

{
Lifting Speed of Gate = Liftingspeed ≔ RPM ⋅ c ⋅ ⋅ PCDRD = 3.163 ――
Manual Hg
Opening Time of Gate Openingtime ≔ ―――― = 52.171
Liftingspeed

Page 29 of 42
Reqd. H.P. to Lift the Gate
We have the general formula for H. P.

H. P. = 2 π N T / 33,000 ( 1 HP = 33000 ft. lbs. / Min.


H. P. = Horse Power required to Lift the Gate
N = Revolutions of Rope Drum per minute.
12 12 1
N ≔ ――――= N ≔ ――= 0.191 N ≔ 0.191 ⋅ ――
⋅ PCDRD ⋅ 20 min
We are required to Lift the Gate at a speed of 12 in. / min.
So there should be 0.212 Revolutions of Rope Drum per minute.

T2 = Torque applied on rope drum to Lift the Gate = T2 = 8881.452 ⋅

HP ≔ 2 ⋅ N ⋅ T2 = 0.323
1
we are using 1.5 hp Motor RPMmotor ≔ 120 ⋅ ――
min

{
Lifting Speed of Gate = Liftingmotor ≔ RPMmotor ⋅ c ⋅ ⋅ PCDRD = 12.651 ――
Motorized H
g
Opening Time of Gate= Openingmotor ≔ ――――= 13.043
Liftingmotor

ROPE DRUMS
1- Pitch dia of Rope Drum = PCDRD = 508

2- Maximum travel of Gate = Gatetravel = 4191

3- Dia. of Steel Wire Rope. dr ≔ 23.8


Gatetravel
4- No. of turns required for Gate = Turnsrequire ≔ ――――
⋅ PCDRD
Turnsrequire = 2.626 Nos.

= 2.626 Say 3

5- No. of turns for counter weight = 3


6- Total No. of turns ( min ) = 3+ 3 +2+2= 10 Adopted = 10 turns
7- Rope Drum Length adopted = 356 mm

Page 30 of 42
Design of Rope Drum
T = Total Torque T ≔ T2 = 106577.424 ⋅
T
Torque on each Drum τ ≔ ―= 53288.712 ⋅
2
PCDRD
D = Min. dia. of rope drum PCDRD = 20 RRD ≔ ――― = 10
2
7
Rope diameter ,d dRoop ≔ ―
8
τ
Tension in Rope = T/R TRoop ≔ ―― = 5328.871
RRD
TP = Total pull on one rope = T / R TP ≔ TRoop = 5328.871

TP
Radial pressure on drum P PRadial ≔ ―――― = 609.014
RRD ⋅ dRoop
Outside radius of drum R2 ≔ RRD = 10

Inside radius of drum Rin = 9

Wall Thickness , t ≔ R2 − Rin = 1


2
2 PRadial ⋅ R2
Compressive Stress developed fc ≔ ――――― = 6410.67
2 2
R2 − Rin
Actual Stress is less than Allowable Stress. ( Material of Rope Drum is Carbon Steel. )
Hence the Rope Drum is OK .

Design For Rope Drum Axle


Maximum Vertical Load Whoisting = 10657.742
Whoisting
Load on each rope WR ≔ ―――= 5328.871
2

Maximum Torque τ ≔ WR ⋅ RRD = 53288.71 ⋅

Un-supported length of shaft LAxle = 22


LAxle
Maximum Bending Moment Mmax ≔ WR ⋅ ―― = 29308.79 ⋅
4
Mmax 3
Reqd. Section Modulus of shaft Zreq ≔ ――= 1.357
fb
3 3
Z for shaft dia , d Zshaft = 0.196 ⋅ DAxle = 6.124
1

3
⎛ Zreq ⎞
dshaft ≔ ⎜――⎟ = 48.409 We are using Shaft of dia = DAxle = 80
⎝ 0.196 ⎠

Page 31 of 42
Checking the shaft against combined bending and torsion.
Considering Keyway Effect

Width of keyway bkw1 = 22

Thickness of keyway tkw1 = 14

3 2
⋅ DAxle bkw1 ⋅ tkw1 ⋅ ⎛⎝DAxle − t⎞⎠ 3
Z ≔ ―――― − ――――――― = 5.785
16 2 ⋅ DAxle
Maximum stress
‾‾‾‾‾‾‾‾‾
2
Mmax + τ
2

τmax ≔ ――――― = 8410.9


Z ⋅ 1.25
Checking of the shaft against Torsion only.
τ
Torsional Stress = ft ≔ 1.25 ⋅ ―= 11515.257
Z
Allowable shear stress for SAE 1045 is = 45,000 x 0.4 =18000 psi
Hence Rope Drum Axle Dia 3.0in is safe

Design of Cross Shaft.


Maximum Vertical Load Whoisting = 10657.742
Whoisting
Maximum Load On each Rope Drum WRD1 ≔ ――― = 5328.871
2
Load on each rope WR = 5328.871

Pitch dia of Rope Drum = PCDRD = 20


WR PCDRD
Torque ( ) τ ≔ ――― ⋅ ――― = 59104.605 ⋅
.92 ⋅ .98 2
Let diameter of cross shaft Dcs = 80

Width of keyway bkw2 = 22

Thickness of keyway tkw2 = 14

3 2
⋅ Dcs bkw2 ⋅ tkw2 ⋅ ⎝⎛Dcs − tkw2⎠⎞ 3
Z ≔ ――― − ―――――――― = 5.623
16 2 Dcs
τ
ft ≔ ―= 10511.085 < 18000 psi (Allowable)
Z
Which is safe (Mat: SAE 1045)

(Allowable Shear Stress for SAE 1045 = 45,000 x 0.4 = 18,000 psi)

We are using Dia 3.5in shaft which is safe

Page 32 of 42
Design of Rope Drum Supports
Maximum Load on Rope Drum

Impect load on Rope Drum Wimpect ≔ 0.5 ⋅ Weightgate = 6009.36

WRD ≔ Weightgate + WeightCW + WeightRD + Ff + Wimpect = 42909.699


WRD
Maximum Load On each rope drum W1RD ≔ ―― = 21454.849
2
W1RD
Load on each support Wsupport ≔ ――= 10727.425
2
Maximum Length of Support Lsup = 1000
Wsupport ⋅ Lsup
Bending Moment. MuSC ≔ ――――― = 105584.889 ⋅
4
MuSC 3
Section Modulus Required. Sreq ≔ ―― = 80.1
fb
3
We are using Channel 10"x 20lb/ft. Sxx = 280

Hence the Selected Support is Safe.

HOISTING M/C DESIGN


Spur Gear Design. (Refer Machinery Handbook)

Item no. 22 ( From Shop Drawing No. S.E.T. 688 (8/9 )

Pinion No of Teeth Tp = 17

Module of gear and


pinion is same = m = m1 = 4

Pitch diameter of pinion PD ≔ Tp ⋅ m1 = 68


PD
Dp ≔ ―― = 2.677
25.4

Tp
P ≔ ―― = 6.35
Dp
1
a = Addendum = apinion ≔ ―= 0.157
P
1.25
b =Duodenum = bpinion ≔ ―― = 0.197
P
2
hk = Working depth = hk ≔ ―= 0.315
P
.25
C = Clearance = C ≔ ―― = 0.039
P
⎛⎝Tp + 2⎞⎠
Do = Outside diameter = Do ≔ ――― = 2.992
P
Tp − 2.5
DR = Root diameter = Dr ≔ ――― = 2.283
P
Page 33 of 42
Pinion HP for wear
Material = A-322, Grade 8620

Sc = Surface stress factor Sc ≔ 1400

X c = Speed factor for wear Xcp ≔ 0.935

Pressure angle θ ≔ 20

Z = Zone factor Zp ≔ 1.75

F = Face Width Fp ≔ 1.339

N = Rpm = Revolutions per minute Np = 120

No. of teeth Tp = 17

P = Pitch diameter = P = 6.35


0.8
K = Pitch factor = Kp ≔ (P) = 4.388

Pinion HP for wear = Sc Xc Z F N T / 126,000 K P


Sc ⋅ Xcp ⋅ Zp ⋅ Fp ⋅ Np ⋅ Tp
HPwear ≔ ――――――― = 1.782
126000 ⋅ Kp ⋅ P
Data of Spur Gear.

Item no. 21 ( From Shop Drawing No. S.E.T. 688 (8/9 )

TGear = Teeth of Spur Gear TG = 65

Module of Pinion = m = m1 = 4

Pitch diameter of pinion PD ≔ TG ⋅ m1 = 260


PD
DPGear ≔ ―― = 10.236
25.4

TG
PGear ≔ ――― = 6.35
DPGear
1
a = Addendum = agear ≔ ――= 0.157
PGear
1.25
b =Duodenum = bgear ≔ ――= 0.197
P
2
hk = Working depth = hk ≔ ――= 0.315
PGear

.25
C = Clearance = C ≔ ――= 0.039
PGear

Page 34 of 42
⎛⎝TG + 2⎞⎠
Do = Outside diameter = Do ≔ ――― = 10.551
PGear
TG − 2.5
DR = Root diameter = Dr ≔ ―――= 9.843
PGear
Gear HP for wear
Material = A-322, Grade 8620

Sc = Surface stress factor Sc = 1400

X c = Speed factor for wear Xcg ≔ 0.935

Pressure angle θ ≔ 20

Z = Zone factor Zg ≔ 2

F = Face Width FG ≔ 1.575


Tp ⋅ Np
N = Rpm = Revolutions per minute NG ≔ ――― = 31.385
TG
No. of teeth TG = 65
P = Pich diameter = PGear = 6.35
0.8
K = Pitch factor = KG ≔ ⎛⎝PGear⎞⎠ = 4.388

HP for wear (Pinion) = Sc * Xc * Z *F*N *T / 126,000 *K* P

Sc ⋅ Xcg ⋅ Zg ⋅ FG ⋅ NG ⋅ TG
HPwear ≔ ―――――――― = 2.3962
126000 ⋅ KG ⋅ PGear

Horse power for strength (Pinion)

Material = A-322, Grade 8620

Sb = Bending Stress Sb ≔ 17000

X b = Speed factor for wear Xbp ≔ 0.6

Y = Strength factor Yp ≔ 0.7

F = Face Width Fp = 1.339

N = Rpm = Revolutions per minute Np = 120

No. of teeth Tp = 17

P = Pitch diameter = PGear = 6.35


0.8
K = Pitch factor = KP ≔ (P) = 4.388

Page 35 of 42
HP for Strength (Pinion ) = Sc * Xc * Z* F* N* T / 126,000 * P^2

Sb ⋅ Xbp ⋅ Yp ⋅ Fp ⋅ Tp ⋅ Np
HPStrength ≔ ―――――――― = 3.84
2
126000 ⋅ P

Horse power for strength (Gear)

Material = A-322, Grade 8620

Sb = Bending Stress Sb ≔ 17000

X b = Speed factor for wear Xbg ≔ 0.55

Y = Strength factor Yg ≔ 0.57

F = Face Width FG = 1.575


Tp ⋅ Np
N = Rpm = NG ≔ ――― = 31.385
TG
No. of teeth TG = 65

P = Pitch diameter = PGear = 6.35

HP for Strength (Pinion ) = Sc * Xc * Z* F* N* T / 126,000 * P^2

Sb ⋅ Xbg ⋅ Yg ⋅ FG ⋅ TG ⋅ NG
HPStrength ≔ ―――――――― = 3.4
2
126000 ⋅ P

Design Spur Gear 2 . (Refer Machinery Handbook)

Item no. 16 ( From Shop Drawing No. S.E.T. 688 (8/9 )

Pinion No of Teeth TP2 = 20

Module of gear and


pinion is same = m = m2 = 5

Pitch diameter of pinion PD ≔ TP2 ⋅ m2 = 100


PD
Dp ≔ ―― = 3.937
25.4

TP2
PP2 ≔ ―― = 5.08
Dp
1
a = Addendum = apinion ≔ ――
= 0.197
PP2

Page 36 of 42
1.25
b =Duodenum = bpinion ≔ ――= 0.246
PP2

2
hk = Working depth = hk ≔ ―― = 0.394
PP2

.25
C = Clearance = C ≔ ―― = 0.049
PP2

⎛⎝TP2 + 2⎞⎠
Do = Outside diameter = Do ≔ ――― = 4.331
PP2

TP2 − 2.5
DR = Root diameter = Dr ≔ ――― = 3.445
PP2
Pinion HP for wear
Material = A-322, Grade 8620

Sc = Surface stress factor Sc ≔ 1400

X c = Speed factor for wear Xcp2 ≔ 0.935

Pressure angle θ ≔ 20

Z = Zone factor Zp2 ≔ 1.875

F = Face Width Fp2 ≔ 2.756

N = Rpm = Revolutions per minute Np2 ≔ NG = 31.385

No. of teeth TP2 = 20

P = Pitch diameter = PP2 = 5.08


0.8
K = Pitch factor = KP2 ≔ ⎛⎝PP2⎞⎠ = 3.67

Pinion HP for wear = Sc Xc Z F N T / 126,000 K P


Sc ⋅ Xcp2 ⋅ Zp2 ⋅ Fp2 ⋅ Np2 ⋅ TP2
HPwear ≔ ――――――――― = 1.807
126000 ⋅ KP2 ⋅ PP2

Data of Spur Gear 2 .

Item no. 15 ( From Shop Drawing No. S.E.T. 688 (8/9 )

TGear = Teeth of Spur Gear TG2 = 52

Module of Pinion = m =5

Pitch diameter of pinion PD ≔ TG2 ⋅ m2 = 260

Page 37 of 42
PD
DPG2 ≔ ―― = 10.236
25.4

TG2
PG2 ≔ ―― = 5.08
DPG2
1
a = Addendum = agear ≔ ―― = 0.197
PG2
1.25
b =Duodenum = bgear ≔ ――= 0.246
PG2
2
hk = Working depth = hk ≔ ―― = 0.3937
PG2
.25
C = Clearance = C ≔ ―― = 0.049
PG2
⎛⎝TG2 + 2⎞⎠
Do = Outside diameter = Do ≔ ――― = 10.63
PG2

TG2 − 2.5
DR = Root diameter = Dr ≔ ――― = 9.744
PG2
Gear HP for wear
Material = A-322, Grade 8620

Sc = Surface stress factor Sc = 1400

X c = Speed factor for wear Xcg2 ≔ 0.935

Z = Zone factor Zg2 ≔ 1.875

F = Face Width FG2 ≔ 2.17

Tp ⋅ Np TP2
N = Rpm = Revolutions per minute NG2 ≔ ――― ⋅ ―― = 12.071
TG TG2
No. of teeth TG2 = 52

P = Pitch diameter = PG2 = 5.08


0.8
K = Pitch factor = KG2 ≔ ⎛⎝PG2⎞⎠ = 3.67

HP for wear (Pinion) = Sc * Xc * Z *F*N *T / 126,000 *K* P

Sc ⋅ Xcg2 ⋅ Zg2 ⋅ FG2 ⋅ NG2 ⋅ TG2


HPwear ≔ ――――――――― = 1.423
126000 ⋅ KG2 ⋅ PG2

Horse power for strength (Pinion 2 )

Material = A-322, Grade 8620

Sb = Bending Stress Sb = 17000

X b = Speed factor for wear Xbp2 ≔ 0.6

Page 38 of 42
Y = Strength factor Yp2 ≔ 0.583

F = Face Width Fp2 = 2.756

N = Rpm = Revolutions per minute Np2 = 31.385

No. of teeth TP2 = 20

P = Pich diameter = PP2 = 5.08


0.8
K = Pitch factor = Kp2 ≔ ⎛⎝PP2⎞⎠ = 3.67

HP for Strength (Pinion ) = Sc * Xc * Z* F* N* T / 126,000 * P^2

Sb ⋅ Xbp2 ⋅ Yp2 ⋅ Fp2 ⋅ TP2 ⋅ Np2


HPStrength ≔ ――――――――― = 3.164
2
126000 ⋅ PP2
Horse power for strength (Gear 2)

Material = A-322, Grade 8620

Sb = Bending Stress Sb ≔ 17000

X b = Speed factor for wear Xbg2 ≔ 0.60

Y = Strength factor Yg2 ≔ 0.583

F = Face Width FG2 = 2.17

N = Rpm = NG2 = 12.071

No. of teeth TG2 = 52

P = Pich diameter = PG2 = 5.08

HP for Strength (Pinion ) = Sc * Xc * Z* F* N* T / 126,000 * P^2

Sb ⋅ Xbg2 ⋅ Yg2 ⋅ FG2 ⋅ TG2 ⋅ NG2


HPStrength ≔ ―――――――――= 2.491
2
126000 ⋅ PG2

Worm Gear Design

Item no. 5 ( From Shop Drawing No. S.E.T. 688 (8/9 )

C = Center Distance = C ≔ 294 = 11.575

Module = m = mworm ≔ 8 = 0.315

Pressure angle θ ≔ 20

Page 39 of 42
mworm
Axial pitch = p P ≔ ――― = 0.9895
.3183
No of worm starts = t≔1

L = Lead of worm thread = NxP L ≔ t ⋅ P = 0.9895

T = No of worm wheel teeth T ≔ 60


T⋅P
D = Pitch Dia of worm wheel Dworm ≔ ―― = 18.898

Pitch Dia of worm = 2C - D PCDworm ≔ 2 ⋅ C − Dworm = 4.251

Lead angle (Worm) = Tan. La = L / π d


⎛ L ⎞
La =tan-1 (L / π d ) La ≔ atan ⎜――――⎟ = 4.237
⎝ ⋅ PCDworm ⎠
T
R = Ratio R ≔ ―= 60
t
a = Addendum a ≔ 0.3183 ⋅ P = 0.315

W = Whole depth W ≔ .623 ⋅ P = 0.616

d o = Outside dia of worm do ≔ PCDworm + 2 ⋅ a = 4.881

F = Face width, worm wheel F ≔ (2.38 ⋅ P) + 0.25 ⋅ = 2.605

F = Actual Factual ≔ 3.7795

Cl = Clearance Cl ≔ 0.2 ⋅ mworm ⋅ cos (La) = 0.06282

G = Worm thread length G ≔ P ⋅ (4.5 + 0.02 ⋅ 60) = 5.64

Actual G = Gactual ≔ 8
1
RPM = n ≔ NG2 = 12.071 n ≔ 5.574 ⋅ ――
min
‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾‾
⎛ Dworm ⎞
2
2
Rubbing speed = V = V ≔ 0.262 ⋅ n ⋅ PCDworm + ⎜――― ⎟ = 6.226 ――
⎝ R ⎠
f ≔ 0.09
100 ⋅ L
Efficiency = 100 x L / ( L + f π d ) Efficiency ≔ ――――――= 45.151 %
L + f ⋅ ⋅ PCDworm
Material :-
Phosphor Bronze. Sand Cast

S ≔ 700

Xw ≔ 0.575

fe ≔ 3.465

Page 40 of 42
Dworm = 18.898
1.8
Wear load (Wheel) WearLoad ≔ 0.18 S ⋅ Xw ⋅ fe ⋅ Dworm
1.8
WheelWearLoad ≔ 0.18 ⋅ 700 ⋅ 0.575 ⋅ 3.465 ⋅ 18.898 = 49806.973 lbf ⋅ in
Material :-
Corbon steel, Normalized

S ≔ 2000

Xw ≔ 0.575

fe ≔ 3.465

Dworm = 18.898
1.8
Wear load (Worm) WearLoad ≔ 0.18 S ⋅ Xw ⋅ fe ⋅ Dworm
1.8
WormWearLoad ≔ 0.18 ⋅ 2000 ⋅ 0.575 ⋅ 3.465 ⋅ 18.898 = 142305.637 lbf ⋅ in

Strength load (wheel)


Material :- Phosphorus Bronze. Sand Cast

Sb = 7,000 Psi

Xs = 0.55

Q = Arc length of teeth at root= 3.76

m = 0.315

D = 18.898

La = 4.232

Strength load (Wheel) = 0.625 x Sb xXs x Q x m x D cos (La)

StrengthLoadWheel ≔ 0.625 ⋅ 7000 ⋅ 0.55 ⋅ 3.76 ⋅ 0.315 ⋅ 18.898 ⋅ cos (4.232 ) = 53711.741 lbf ⋅ in

Page 41 of 42
Strength load (Worm)
Material :- Corbon steel, Normalized

Sb = 20,000 Psi

Xs = 0.50

Q = 3.76

m = 0.315

D = 18.898

La = 4.232

Strength load (Worm) = 0.625 Sb Xs Q mD cos La

StrengthLoadWorm ≔ 0.625 ⋅ 20000 ⋅ 0.50 ⋅ 3.76 ⋅ 0.315 ⋅ 18.898 ⋅ cos (4.232 ) = 139511.017 lbf ⋅ in

Horsepower Rating
considering the minimum of values i.e. Strength load ( wheel ).

hp = Mn / 63,000
Tp TP2 1
WheelWearLoad ⋅ Np ⋅ ――⋅ ―― ―
TG TG2 60
hp ≔ ―――――――――――= 0.159
63000
Required Hp = Lift x Load

Requiredhp ≔ Liftingspeed ⋅ Whoisting = 0.085

References:
1- Design of Hydraulic Gate . ( by Paullo C. F. Erbisti )
2- Steel Construction Manual. ( by AISC. )
3- Mech. Engineer's Hand Book ( By Kents. )

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