Beruflich Dokumente
Kultur Dokumente
Gate
Width (clear span) = B ≔ 12.25
Gatetravel ≔ Hg = 4191
Water and Water Head
Design Head = Hw ≔ FSL − Elsl = 21.68
Head at Bottom = Hb ≔ Hw
Section Properties
Page 3 of 42
Wheel , Wheel Pin and Lifting pin
Diameter of the Wheel Dwheel ≔ 355
Dpin ≔ 100
ACp ≔ 408
BCp ≔ 351
ABp ≔ 57
Hoisting Machine
Module of first pinion and gear m1 ≔ 4 mm Module of second pinion and gear m2 ≔ 5 mm
Sill Beam
Thickness of Sill Plate t1 ≔ 10
Page 4 of 42
Second Stage Embedded Parts
Slide track
Thickness of track bar t5 ≔ 40
Rope Drum
Pitch dia of Rope Drum = PCDRD ≔ 20 = 508
Page 5 of 42
Allowable Stresses for the design of Gate Equipment
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.
4- Stainless Steel( plates, sheet & strips) ASTM-A-240, " Specification for heat resisting
chromium & chromium - nickel stainless steel plates,
sheet & strip.
Page 6 of 42
Loading
Hg = 4191
B = 3733.8
Hw = 21.68
Hb = 21.68
Htop = 7.93
Ps = 1352.832
7 .5
2- Hydrodynamic Pressure Pd ≔ ―⋅ ⎛⎝Hw ⋅ Hb⎞⎠ ⋅ ω ⋅ ag
8
Pd = 177.559
Page 7 of 42
Beam Spacing
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
7 .5
Hydrodynamic Pressure , Pd = ―⋅ ω ⋅ ag ⋅ ⎛⎝Hbottom ⋅ Hn⎞⎠
8
LoadG7 ⋅ B
Mu7 ≔ ―――― = 551217.434 ⋅
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.
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
Mu ≔ Mu6 = 567940.113 ⋅
Mn ≔ 0.9 ⋅ Fy ⋅ Zc = 3429878.705 ⋅
Mn > Mu
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
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
d6 = 510 d5 = 540
⎛ 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 ⎠
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
Page 15 of 42
Design of Wheel & Pin
ROLLERS
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,
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
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
Alternative Approach.
Bearing Stress Developed = Max. Load / Wheel Bearing Area.
W
fbearing ≔ ―――― = 2063.496
Areaactual
Page 18 of 42
COUNTER WEIGHT
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.
Page 19 of 42
Space Between Vertical Angles l1 ≔ 685
ld1 ≔ ‾‾‾‾‾‾‾‾‾
2 2
Length of Diagonal Stiffeners l1 + HCW = 1283.141
ld2 ≔ ‾‾‾‾‾‾‾‾‾
2 2
Length of Diagonal Stiffeners l2 + HCW = 1435.557
Wgu ≔ a ⋅ b ⋅ t ⋅ ω = 3.14
Vc
height of concrete to be filled Hcon ≔ ―――― = 1084.31
WCW ⋅ LCW
Page 20 of 42
Design of Embedded Parts
1- Design of bottom embedded parts
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 = 172 Y4 = 6
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
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
4β
M = 21.93 ⋅
Page 22 of 42
Comparative Stress.
Comparative Stress , fc is Calculated by the formula, fc = 0.195 x fck + 2.31MPa
fc = 7.016 fc = 1017.54
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
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 ⎞⎠
Ec ≔ 3600000
E ≔ 29000000
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
4β
MST = 59.35 ⋅
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
Seal Friction
Fs = μNs
Where μ ≔ .9
Where a ≔ 20 b ≔ 26 ts ≔ 12
Page 25 of 42
Friction on top seal
Ft = μNt
Where μ ≔ .9
Wheel Friction
Wt
Total Wheel Friction Fr ≔ ―― ⎛⎝μs ⋅ Rs + f⎞⎠ = 7.605
Rw
Page 26 of 42
CALCULATIONS FOR EYE BOLT DIA AND PIN DIA
In. dia eye bolt and dia of pin
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
Input Torque = Average force applied by one man x Arm.= 40 x 12 = 480 in. - lbs.
Fapplied ≔ 40
Larm ≔ 12
OUTPUT LOAD
Weight of Gate = Weightgate = 12018.7
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 = 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.
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
= 2.626 Say 3
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
Page 31 of 42
Checking the shaft against combined bending and torsion.
Considering Keyway Effect
3 2
⋅ DAxle bkw1 ⋅ tkw1 ⋅ ⎛⎝DAxle − t⎞⎠ 3
Z ≔ ―――― − ――――――― = 5.785
16 2 ⋅ DAxle
Maximum stress
‾‾‾‾‾‾‾‾‾
2
Mmax + τ
2
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)
Page 32 of 42
Design of Rope Drum Supports
Maximum Load on Rope Drum
Pinion No of Teeth Tp = 17
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
Pressure angle θ ≔ 20
No. of teeth Tp = 17
Module of Pinion = m = m1 = 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
Pressure angle θ ≔ 20
Z = Zone factor Zg ≔ 2
Sc ⋅ Xcg ⋅ Zg ⋅ FG ⋅ NG ⋅ TG
HPwear ≔ ―――――――― = 2.3962
126000 ⋅ KG ⋅ PGear
No. of teeth Tp = 17
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
Sb ⋅ Xbg ⋅ Yg ⋅ FG ⋅ TG ⋅ NG
HPStrength ≔ ―――――――― = 3.4
2
126000 ⋅ P
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
Pressure angle θ ≔ 20
Module of Pinion = m =5
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
Tp ⋅ Np TP2
N = Rpm = Revolutions per minute NG2 ≔ ――― ⋅ ―― = 12.071
TG TG2
No. of teeth TG2 = 52
Page 38 of 42
Y = Strength factor Yp2 ≔ 0.583
Pressure angle θ ≔ 20
Page 39 of 42
mworm
Axial pitch = p P ≔ ――― = 0.9895
.3183
No of worm starts = t≔1
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
Sb = 7,000 Psi
Xs = 0.55
m = 0.315
D = 18.898
La = 4.232
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
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
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. )
Page 42 of 42