‫‪Table of Content‬‬

‫‪Team‬‬
‫إسراء محمد خليل توفيق‬ ‫‪1‬‬ ‫‪9220140‬‬
‫جورج نبيل جرجس ابراهيم‬ ‫‪2‬‬ ‫‪9220232‬‬
‫حسن مجدي حسن‬ ‫‪2‬‬ ‫‪9213155‬‬ ‫‪Team Leader‬‬
‫عبدهللا جمال عبدالرحيم تمر‬ ‫‪3‬‬ ‫‪9210604‬‬
‫مريم امين محمد زكي‬ ‫‪5‬‬ ‫‪9220817‬‬ ‫‪George Nabil Gerges‬‬
‫مريم عمرو السيد علي‬ ‫‪5‬‬ ‫‪9220826‬‬
‫منة هللا محمد عبد العليم‬ ‫‪5‬‬ ‫‪9211236‬‬

‫‪1‬‬
Table of Content

Table of Content

1. Introduction......................................................................................................................4
2. Design Assumptions......................................................................................................... 5
2.1. Material..................................................................................................................... 5
2.2. Motor.........................................................................................................................7
Recourses....................................................................................................................... 12
3. Force analysis................................................................................................................. 13
3.1. Force Analysis for the Wire Rope Drum...................................................................13
3.2. Force Analysis for the Drum Shaft............................................................................15
4. Shaft design.................................................................................................................... 18
4.1. Preliminary design................................................................................................... 18
4.2. Detailed design........................................................................................................ 18
4.3. Key design................................................................................................................19
4.4. Stress concentration in keyway...............................................................................19
Preliminary design..........................................................................................................20
Detailed design...............................................................................................................20
5. Wire Rope Drum Design.................................................................................................21
5.1. Wire Rope Drum Calculations..................................................................................21
5.2. Pulley and Hook (Snatch block) Selection................................................................22
5.3. Wire rope calculations.............................................................................................24
Assumptions...................................................................................................................24
Calculations.................................................................................................................... 24
Recommendation for better stability.............................................................................26
References.............................................................................................................................. 27
6. Shaft Elements Design....................................................................................................28
6.1. Bearing Design......................................................................................................... 28
6.1.1. Bearings Calculations........................................................................................29
6.2. Bearings Fitting Method Calculations......................................................................32
6.2.1. Preparation.......................................................................................................32

2
Table of Content

6.2.2. Force necessary to press fit or remove bearings..............................................32

6.3. Drum Fixation.......................................................................................................... 35
6.3.1. Specifications....................................................................................................35
6.3.2. Installation........................................................................................................35
6.3.3. Screw tightening sequence:..............................................................................35
6.3.4. Removal............................................................................................................36
6.3.5. Reusing the locking device................................................................................36
6.3.6. Calculations for Selection.................................................................................36
6.4. Coupling...................................................................................................................38
6.4.1. Hub Design........................................................................................................38
6.4.2. Bolts Design:.....................................................................................................39
7. Further Design Analysis..................................................................................................40
7.1. Types of Hoist Mechanism in the Market................................................................40
Resources from our Market Research............................................................................43
7.2. Manufacturing Analysis........................................................................................... 44
7.2.1. Drum Shaft........................................................................................................44
7.2.2. Key....................................................................................................................49
7.2.3. Flange............................................................................................................... 52
7.2.4. Items to Buy......................................................................................................52
7.3. Fits and Tolerances..................................................................................................52
Shaft & locking device:................................................................................................... 52
Shaft & Bearing:..............................................................................................................53
Shaft & drum:................................................................................................................. 53
Shaft & Flange :.............................................................................................................. 54
7.4. Future Work.............................................................................................................54
7.4.1. Advanced Load Analysis for the Wire Rope on the Drum.................................55
7.4.2. Optimizing the Shaft.........................................................................................55
7.4.3. Body Design......................................................................................................55
7.4.4. More Safety Features.......................................................................................55
8. Drawings.........................................................................................................................55

3
Table of Content

1.Introduction
A hoist is an essential mechanical tool that is widely used in industrial settings to
efficiently and precisely lift or lower heavy goods. Hoists are devices that enable the vertical
or horizontal transportation of weights in warehouses, factories, building sites, and other
industrial locations. They work by wrapping a rope or chain around a drum or lift-wheel.
A hoist's primary goal is to expedite material handling procedures by making it easier
to transfer large, dangerous, or awkward objects that would be dangerous to move by hand.
Hoists provide adaptability in lifting activities by utilizing many power options, including
electric, manual, or pneumatic systems. This allows them to accommodate a wide range of
weight capacities and operational requirements.
Hoists are essential for improving efficiency, safety, and production in industrial
settings. They minimize manual labor, speed material handling operations, and lower the
risk of workplace hazards related to physical lifting. Additionally, hoists help the
manufacturing, shipping, and construction industries maximize operational throughput,
guarantee timely delivery of items, and optimize workflow operations.
The hoist mechanism is an essential part of contemporary industrial operations, and
it is always evolving to meet the increasing needs of material handling jobs and industrial
output. It incorporates cutting-edge technologies and engineering breakthroughs. The work
here will outline our process for creating a functional hoist using our design at a reasonable
cost through iteration and scratch design.

4
Table of Content

2.Design Assumptions

2.1. Material
1. Shaft iteration material:
1.1. Steel, stainless AISI 302 1/4 hard
Sy =517 MPA
Sult = 860 MPA
E= 180 GPA
F.S=2.5
Keyway shaft F.S = 1.3
This material is commonly used in manufacturing for several reasons:

 Corrosion Resistance: Stainless steel AISI 302 offers excellent corrosion

resistance, making it suitable for applications in corrosive environments such
as marine, chemical, and food processing industries
 Strength and Ductility: Even in the 1/4 hard condition, AISI 302 stainless steel
retains good strength and ductility, allowing it to withstand mechanical stress
and deformation without fracturing
 Versatility: It can be easily fabricated into various shapes and forms, including
wires, strips, and forgings, providing versatility in manufacturing applications
 Sustainability: Steel is a sustainable material with high recyclability,
contributing to environmentally friendly manufacturing practices
 Longevity: Its durability and resistance to wear and tear ensure longevity in
manufactured products, reducing the need for frequent replacements
 Cost-effectiveness: Stainless steel AISI 302 provides a cost-effective solution
for various manufacturing needs due to its durability, longevity, and low
maintenance requirements

Overall, the use of steel, stainless AISI 302 1/4 hard in manufacturing offers a
combination of strength, corrosion resistance, versatility, and cost-effectiveness,
making it a preferred choice for a wide range of industrial applications.

1.2. Steel AISI 4030 annelid (final iteration )

Sy =470 MPA
Sult = 745 MPA
F.S=2.5
Keyway shaft F.S = 1.3

5
Table of Content

Steel 4030 annealed is favored in manufacturing due to its desirable mechanical

properties, including high strength, toughness, and wear resistance, making it
suitable for various industrial applications such as machining, forging, and casting

2. Drum :
2.1. Steel 1020 G10200 CD
Sy =390 MPA
Sult = 470 MPA
F.S=2

3. Key
3.1. Steel 1020 G10200 HR
Sy =210 MPA
Sult = 380 MPA
S.F=1.2
Keyway height = 4mm
Keyway fillet=1.5mm
Commonly used in manufacturing for several reasons:
 Versatility: Research indicates the use of carbon steel, including AISI 1020
(UNS G10200), in manufacturing due to its versatility and wide range of
applications across different industries.
 Strength and Hardness: While research papers may not directly specify
Steel 1020 G10200 HR, carbon steels in general gain hardness and strength
with heat treatment, making them suitable for manufacturing applications
where these properties are required.
 Machinability: HR steel, including AISI 1020, exhibits good machinability,
enabling ease of machining processes such as drilling, turning, milling, and
tapping, which are essential in manufacturing.
These factors collectively contribute to the widespread use of Steel 1020 G10200 HR
in manufacturing processes.
In this arrangement, the key functions as a mechanical fuse; if the load is too great, it will
fail before the shaft or drum.
NOTE: Since the shaft and drum are the most vital parts of the mechanism, we can alter the
safety factor to make the shaft and drum the most secure parts of the mechanism.

6
Table of Content

2.2. Motor
2.2.1. Electric Motor IP41 308W Brake Power (first iteration)

After-sales with
Service:

Warranty: 6 Months

Type: Traction System

Suitable for: Elevator

Load Capacity: 630~1000kg

7
Table of Content

The IP41 308W motor typically does not require a gearbox. It is commonly
used as a gearless motor in elevator systems, where it provides sufficient power to lift
loads ranging from 630kg to 1000kg. Gearless motors are designed to directly drive
the elevator traction sheave without the need for a gearbox, resulting in a simpler
and more efficient system. Therefore, in most elevator applications, the IP41 308W
motor operates effectively without the use of a gearbox.
In our use we will control its torque with our torque (T=780N.m) to be safe in our design
It was too heavy in our mechanism so we search for another method

2.2.2. V SERIES: Type VR473.1K-100L/4b-L04 VR273.1K-E100LUD (final iteration )

V series gear units are three stage, helical-geared hoist drum drive units. Input and
output center distances are as far apart as possible to allow the use of larger drums to
achieve longer rope service life. The V series gear units are designed for higher ISO/FEM
classes with longer gear face widths compared to other products of a similar size. The
housing material is GGG40 spheroid cast iron and gears are made of high-quality case-
hardened steel. The gearboxes have a solid output shaft with spline according to DIN 5480
and are produced to various dimensions. V series gear units are designed for double-and
single-speed brake motors. They are available in five different sizes with a load range from
0.5 to 50 tones.

 Lifting Speed Vh [m/min]= 0,5 / 2,8

 Crane*Class ISO (FEM) = M8 (5m)
 Power =0,37 / 2,5
 Output Speeds n2 [rpm] =4,2 / 26
 Torque 775 / 855rpm
Ratio 113.02
Radial load = 16595
Weight = 53kg

In our use we will control its torque with our torque (T=780N.m) to be safe in our design

8
Table of Content

9
Table of Content

Recourses
 https://sh-esunny.en.made-in-china.com/product/SNGJkPlDfKWF/China-Load-630-
1000kg-Gearless-Motor-for-Elevator-IP41-308W-Brake-Power.html
 https://www.researchgate.net/publication/
236347132_Deep_cryogenic_treatment_of_AISI_302_stainless_steel_Part_II_-
_Fatigue_and_corrosion
 https://www.researchgate.net/publication/376683649_Microstructure_macro-
_and_nano-hardness_assessment_of_AISI_302_steel_aged_at_1000C
 https://www.xometry.com/resources/materials/what-is-aluminum/
 https://www.researchgate.net/publication/
293653225_Aluminium_The_metal_of_choice
 https://www.azom.com/article.aspx?ArticleID=6114
 https://www.researchgate.net/publication/370799981_Deposition_of_Ti-
Based_Thin_Films_on_AISI_1020_Steel_Substrates_Using_the_Cathodic_Cage_Plas
ma_Deposition_Technique
 https://edisciplinas.usp.br/mod/resource/view.php?id=2271706
 Motor specification :
https://medialibrary.dana-industrial.com/wp-content/uploads/DC3A1E1_0000000-
Catalogue-Brevini-Gearmotors-V-Series.pdf

 https://onlinelibrary.wiley.com/doi/full/10.1111/gcb.16134

10
Table of Content

3.Force analysis

3.1. Force Analysis for the Wire Rope Drum

It was challenging to analyze the loads by a wire rope wrapped around a wire drum,
there were many approaches, many papers to go with. However, we used practical and
mental approach to solve this problem, and ended up with these assumptions to be valid for
this system and the ones that fit this cased in applicable manner.
1. The load on the wire rope is distributed along the whole wire
2. The wire rope applies a radial (Normal) force on the drum
3. The wire will resist the wrapping condition due to the elasticity of its material, thus a
force opposite to the radial force is present.
4. There is a level of friction between the wire rope and the drum
5. In each turn of the wire rope the radial forces are reduced due to friction loses
6. The other end of the wire rope will still hold a tension (this is why f 0 is not zero)
Considering all these assumptions, and other evidences found in many research papers,
and similar projects, we found out that a triangular load distribution is the fittest solution to
our case. To achieve equilibrium we made this distribution with this property:
0.375

∫ w ( x ) dx=W
0

NOTE: other types of distributions were used in other similar projects, but this distribution is
still justified and valid for our application.
The other aspect of the solution is what is the position that applies the highest stress
on the system? To answer this question we used our experience in other projects, and also
utilized custom software tools developed by our team to get precise results. We found if the
load is acting at the middle of the length of the drum this give the most stress.
NOTE: this result still not the most accurate, as we made some simplifications on the
system. Please see the future work section for more details.

f1

fo

MA MB

RA RB

11
Table of Content

Where:
W= 4978.575 N
0.2 w 0.2× 4978.575
f 0= =¿ =2655.24 N
0.375 0.375
1.8 w 1.8× 4978.575
f 1= =¿ =2 3897.16 N
0.375 0.375
As we have four unknown reaction, we will use integration method to find the unknowns R A,
RB, MA and MB
We have the following boundary conditions (at the middle point)
θR = θL , VR =VL
We consider A and B to be fixed supports.
θA = θB = 0 , VA = VB = 0
NTOE: We know in advance that all constants of integration will be equal to zero, as we
consider A and B to be fixed supports
Now, we should term four equations to solve for the unknowns.

EQ1: ∑ M A =0
2
1 (0.375)
RB × 0.75 + MB = fo (0.375)2 × + (f1-fo) ×
2 3

EQ2: ∑ F y= 0

RA + RB= w
Integration methods:

EQ3: ∫ M 1 dx = -∫ M 2 dx

EQ4: ∬ M 1 dx dx =∬ M 2 dx dx

Integration M1 and M2 are forming this equation:

x
3
x
2
x
4
( f 1−f o ) x 5 x
3
x
2
fo + MB = fo + – RA - MA
6 2 24 0.375 120 6 2
By substituting for x=0.375 and solve all four equations:
MA = 387.084206 N.m
MB = 359.702044 N.m
RA = 2922.4235 N.m
RB = 2056.1515 N.m

12
Table of Content

3.2. Force Analysis for the Drum Shaft

We used the reactions that we calculated at A and B, then we added the weight of
the drum which is roughly 98kg, and distributed these loads at A and B where each
distribution is 30mm long (the thickness of the flange at these points), now we have two
different load distributions W A and W B. As we have also four unknown reactions (at the
bearings) as we consider each bearing to have only one degree of freedom. As we have to
solve this undetermined system, we will use the integration method, but now we divide the
shaft into seven sections.

WA= 113437.1175 WB= 84561.3833 N/m

N/m
MA MB MD
MC

C A B D
RC RD

55mm 750mm 55mm

We have:

 4 boundary conditions
 2 equilibrium equations
 12 continuity equations (two at each point except the two ends)
Now, we defined the moment equation of each section of these seven sections so we can
proceed in solving the system:

m1 = M 0 C −RC x , from x=0 to x=0.04

2
m2 = M 0 C −RC x +56718.55875 ( x −0.04 ) , from x=0.04 to x=0.055
2
m3 = M 0 C −RC x +56718.55875 ( x −0.04 ) −387.08420625, from x=0.055 to x=0.07

m4 = M 0 C −RC x +3403.113525 x−574.255450125, from x=0.07 to x=0.79

2
m5 = M 0 C −RC x +3403.113525 x +42280.69125 ( x−0.79 ) −574.255450125, from x=0.79 to
x=0.805
2
m6 = M 0 C −RC x +3403.113525 x +42280.69125 ( x−0.79 ) −214.553406375, from x=0.805 to
x=0.82

m7 = M 0 C −RC x +5939.955 x −2256.71079375, from x=0.82 to x=0.86

13
Table of Content

After forming all these equations and developing a software to solve this 16-equaion
system, we reached these final equations to be solved:
c1 =c 2−1.21
c 1=c 2 +25 c 8−25 c 9−0.90749694
c2 =c 3+ 21.28963
c 10=0.055 c 2+ 0.055 c3 −c 9−0.58546
c 3=c 4 +6.484821
c 10=c11 + 0.07 c 3−0.074 c 4 +0.3404531
c 4 =c 5−6948.676
c11 =c 12+ 0.79 c 4−0.79 c 5−4117.09087
c 5=c 6−289.5601
c 12=c 13+0.805 c5−0.805 c 6−116.547958
c6 =c 7 +7770.7402
c13=c14 + 0.82c 6 −0.82 c7 + 4779.0051
−7
M C −3.33333 ⋅10 R C + 2000000 c1 +2 c 8
M C −0.28667 R C + 2.704171c 14 +2.325584 c7 −553.92567
−7
M C −5 ⋅10 RC +1000000 c 1
M C −0.43 RC +1.16279 c 7 +297.4669
RC + R D−5939.955
M C −M D + 0.86 RD −2256.7108

Solving this system gives:

RC =3381.2718 N

R D=255806832 N

M C =506.3993 N . m

M D =56.24327 N . m

Maximum moment=506.4 N . m@ x=0.07

And now we have fully defined all the loads acting on the shaft and next we will
design the shaft and test it against

14
Table of Content

15
Table of Content

4.Shaft design

4.1. Preliminary design

 1st iteration

( √( ) ) =42 mm
1

)(
2 2
32∗2.5 517 517 3
d= 6
∗ ∗506.4 + ∗780∗1.5
π∗517∗10 0.5∗745 0.5∗860

 2nd iteration

( √( ) ) =44 mm
1

)(
2 2
d= 32∗2.5 470 470 3
6
∗ ∗506.4 + ∗780∗1.5
π∗470∗10 0.5∗745 0.5∗550

4.2. Detailed design

 Static
3
506.4∗10 ∗25
¿ =41.265 Mpa
σ π 4
∗¿ 50
64
3
780∗10 ∗25
¿ =31.78 Mpa
τ π 4
∗¿50
32

σ¿
41.265
2 √ ( )
+ 31.782+
41.265 2
2
=58.5 Mpa

√
− 28.52 +(
2 )
2
41.265 2 41.265
σ¿ =−17.3 Mpa
2
σ 1=58.5 Mpa σ 2=0 σ 3=−17.3 Mpa
(tresca)
sy
σ1 – σ3 ¿
n.s
470
58.5+17.3 ¿
n.s
n.s = 6
 Fatigue
σmax= 41.265 Mpa σmin= -41.265 Mpa
τ max= 31.78 Mpa τmin= 31.78 Mpa
41.265−41.265
σm= 2
=0
41.265+ 41.265
σa= 2
= 41.265Mpa

16
Table of Content

31.78−31.78
τm = 2
=0
31.78+31.78
τm = 2
= 31.78 Mpa

σm/ = 0
σa/ = √ 41.265 2+3∗31.782= 68.79 Mpa
Se/= 0.29 * 745 = 216.05 Mpa
Kf = 4.51*470−0.265=0.88
Ks= 1.248 * 48−0.112=0.8
Kr = 0.9
Se=0.9*0.9*0.88*216.05=154 Mpa
1 64.36 0
. = +
n . s 154 470
n.s=2.4

4.3. Key design

Assume :-
w= d/4 = 13 mm
h= d/6 = 8 mm
n.s = 1.2

 Shear force
50∗210∗l∗13
780 * 103 =
4∗1.2
L=27.4 mm
 Compressive force
50∗210∗l∗8
780 * 103 =
4∗1.2
L = 44.5 mm → the nearest to standard dimension

Rectangular key 13 * 8 * 44.5

4.4. Stress concentration in keyway

Assumptions:
t : depth of keyway = 4 mm

17
Table of Content

d: diameter of shaft = 50 mm (from previous final design)

r: keyway fillet radius = 1.5 mm
r/d =0.03
t/d =0.08
From the following graph we can get the
stress concentration factor to be:
K t = 2.4

And the notch factor is then obtained as

follows:
q=0.82

Preliminary design
d=

( √( ) ) =35 mm
1
2
32∗1.3 470 3
6
∗ ∗780∗1.5
π∗470∗10 0.5∗745

Detailed design
 Static
3
2.6∗780∗10 ∗25
¿ =82.628 Mpa
τ π 4
∗¿ 50
32
sy
τ ¿
2∗n . s
470
82.628 ¿
2∗n . s
n.s= 2.8
 Fatigue
31.78−31.78
τm= =0
2
31.78+31.78
τa= = 31.78 Mpa
2
σm/ = 0
σa/= √ 3∗31.78 2= 55.046 Mpa
kf=1+(2.2-1)*0.82=1.984
Se=0.9*0.9*0.88*745*0.29=154 Mpa

18
Table of Content

1 1.984∗55.046 0
. = +
n.s 154 470
n.s = 1.4

19
Table of Content

5.Wire Rope Drum Design

5.1. Wire Rope Drum Calculations

To design the drum we should reduce the unknowns so we can reach a solvable
system, we did that systematically by assuming some of the dimensions that are not crucial
to the design and solving for the ones that affect the design and the mechanism. Also, some
of the ratios are assumed based on the common practices in the industry and other designs
that are available in the market (see References)
An important aspect of the design is the commitment to only one layer of the wire
rope on the drum, this is to prevent the wire rope from overlapping and to avoid any
damage that can happen to the steel wire rope because of slippage. This is a common
practice in the industry and it is a good practice to follow.
Assumptions:
1. As we use one pulley, the length of the wire is 40m + 40m + 2m, the 2 meters are
added for the sake of the flexibility and reliability of the mechanism.
2. The pitch of the groove is 1.06∗d where d is the diameter of the wire rope.
3. The thickness of the drum body is given as 0.02 × D + (6 to 10 mm), a value of 16mm
is chosen
4. The design of the flanges of the drum is done based on the common practices in the
industry (a more complicated design is not necessary in this case)
As we have calculated the wire rope diameter to be 8 mm, now we can calculate the drum
diameter as follows:
We have these relations:
π × ( D+0.15 d ) ×n ¿ 40+ 40+2
n∗p ¿L
p ¿ 1.06∗d=8.48 mm
h ¿ 0.35∗d=2.8 mm
After making multiple iterations to get a suitable value for L and D, we found that the
following values are the best:
L ¿ 750 mm
D ¿ 300 mm
L 750
n ¿ = =88.4434 → 88
p 8.48
Where:
• D is the drum diameter
• n is the number of turns of the wire rope

20
Table of Content

• d is the wire rope diameter

• p is the pitch of the wire rope drum
• L is the effective length of the drum

NOTE: to reduce the weight of the drum, some modifications are made to the flanges of the
drum, also some fillets are added to prevent the presence of sharp edges that can cause
stress concentration.

References
Digvijay D. Patil, P. K. (November 2015). Design and Finite Element Analysis of Rope Drum
and Drum Shaft for Lifted Material Loading Condition.
Tawanda Mushiria, M. J. (2017). Design of a hoisting system for a small scale mine.
Yu Zhen-liang, L. W.-m. (Jul, 2017). CAE Optimization Design of Mine Hoist Spindle Device.
College of Mechanical Engineering & Automation , Liaoning University of Technology.

5.2. Pulley and Hook (Snatch block) Selection

We chose a wire rope pulley with a single sheave to be used in the mechanism, for
many reasons, the most important of which is to achieve a mechanical advantage also this
gives another advantage of distributing the load lifted by dividing it into two parts. we could
have used multiple pulleys but as it achieves more mechanical advantage, it also increases
the length of the wire and thus the complexity of the whole system.
For this application, the design of the wire rope pulley is not necessary, as many available
options in the market can be used for this application. Thus, the pulley is selected based on
the following criteria:
1. The weight capacity of the pulley should be more than 1000 kg but less than 2000 kg
2. The pulley wire groove should be compatible with the wire rope diameter
After searching the market, and comparing the available options, we found a manufacturer
that provides a pulley with the following specifications:

21
Table of Content

B(mm) A(mm) C(mm) D(mm) E(mm) WIRE SWL Weight (kg) Product Code
(mm) Ton
76 295 40 87 15 8 0.5 1.65 SBH075
102 338 50 112 19 10 1.0 3.10 SBH100
127 386 56 140 21 13 1.5 4.40 SBH125
152 455 60 168 31 16 2.0 8.20 SBH150
178 518 70 190 35 19 3.0 11.50 SBH175
203 602 78 205 42 22 4.0 17.50 SBH200
252 753 82 270 44 25 5.0 25.00 SBH250
305 890 106 330 45 25 6.0 35.00 SBH300

Final selection: SBH100

NOTE: other products are very similar to the one mentioned above, and they are all
available in the market at relatively cheap prices.

5.3. Wire rope calculations

Assumptions
 F . S=7

Figure 1
22
Table of Content

6:8 is usual safety factor in the design of electric overhead travelling cranes and
hoists. [1] (Digvijay D. Patil, Design and Finite Element Analysis of Rope Drum and
Drum Shaft , 2015)
 6*37 GALVANISED I.W.R.C (Figure 1)
The most commonly used wire rope constructions for the design of hoists are
6/19, 6/24 (with fiber), and 6/37. Out of these three, 6/37 is
preferred due to its greater flexibility and reduced diameter
compared to the others the 6*37 wire rope consists of 6 strands
with 37 wires in each strand. IWRC wire ropes are known for their high
strength and resistance to crushing, making them a good choice for
heavy-duty applications. If the hoisting operation involves frequent
lifting and lowering of the 1-ton load.

 Consider a 2 rope fall system for rope drum design (Figure 2)

To reduce the load on the wire to 50%.
 Rope length = 82 m
 Efficiency of wire rope when it is bent around rope drum, η=0.94
 Mass to be lifted = 1000 + 5 (Hook mass) = 1005 Kg
Figure 2
Calculations
¿ 1005∗9.81
F=weight ¿ be lifted = =5244 N
nomber of rope falls∗η 2∗0.94
Breaking load=F∗F . S=5244∗7=36.7 KN

23
Table of Content

Recommendation for better stability

Rotation-resistant wire ropes can be suitable for certain hoisting applications, especially
when there is a risk of the load spinning during lifting. These ropes are designed to minimize
rotation, making them ideal for use with certain types of hoists and cranes where load
stability is crucial.

24
Table of Content

References

[1 P. S. Dhakar, "COMPONENTS DESIGN OF HOISTING MECHANISM OF 5 TONNE EOT

] CRANE," January 2016. [Online]. Available:
https://www.researchgate.net/publication/336196656_COMPONENTS_DESIGN_OF_HOI
STING_MECHANISM_OF_5_TONNE_EOT_CRANE.

[2 P. K. M. N. Digvijay D. Patil, "Design and Finite Element Analysis of Rope Drum and Drum
] Shaft," 22 November 2015.

25
Table of Content

6.Shaft Elements Design

6.1. Bearing Design

Using SKF standard table bearing matching the shaft diameter and the inner race of the
bearing

A deep groove ball bearing is a suitable choice for an electric hoist shaft carrying a 1-ton
load due to several key factors:
Load Capacity: Deep groove ball bearings are designed to handle
both radial and axial loads. In the case of an electric hoist, where the load is
typically vertical, the bearing can efficiently support the weight of the load.
Smooth Operation: These bearings have a low torque and provide smooth rotation,
which is crucial for lifting heavy loads. The reduced friction ensures that the hoist
operates efficiently and minimizes wear and tear.
Deep Groove Design: The deep groove structure allows the bearing to accommodate
both radial and axial forces effectively. It provides stability and prevents
misalignment during operation.
Durability: Deep groove ball bearings are known for their long service life. They can
withstand continuous use and heavy loads without premature failure.
Vibration Reduction: The design of deep grooves provides better load distribution,
reducing vibration and ensuring stable performance during lifting operations.
Vertical Lift: These bearings offer true vertical lift, which is essential for hoists. They
maintain alignment and prevent lateral movement, ensuring safe and reliable
lifting.

26
Table of Content

From table1 @ page 601 Machine Design with CAD and Optimization by Metwalli, Sayed M. 1

6.1.1. Bearings Calculations

Radial loads only

Parameters

P Equivalent load (KN)

d=50 Shaft diameter (mm)

Fr Radial force (KN)

C Dynamic basic load rating

K sf =1.5 Factor of safety

L=14000 Bearing life (hr)

n=215 Rotational speed of the shaft (RPM)

27
Table of Content

P=F r
¿
P =K sf ∗P

( )
1/ 3
60∗L∗n
¿
C=P ∗ 6
10

Bearing C
P=F r =3.38 KN
¿
P =1.5∗3.38=4.88 KN

( )
1 /3
60∗14000∗215
C=4.88∗ 6
=27.58 KN
10

Next value in tables is 37.1 KN

Designation is *6210 [1]
Bearing D
P=F r =2.56 KN
¿
P =1.5∗2.56=3.84 KN

( )
1 /3
60∗14000∗215
C=3.84∗ 6
=21.7 KN
10

Next value in tables is 22.9 KN

Designation is *6010 [2]

28
Table of Content

29
Table of Content

6.2. Bearings Fitting Method Calculations

We decided to use press fit [3] because of the following reasons:
Ease: Press fits are generally easier to disassemble because they don’t involve heating or
cooling processes.
Process: You can use bearing removal tools or other methods to extract the components.

6.2.1. Preparation
Before mounting, avoid removing bearings from their packaging to prevent
contamination and rust. If the bearings are pre-lubricated or used for normal operation,
retain the anti-corrosion oil. However, for applications involving measuring instruments or
high rotation speed, clean the oil off with a detergent. After oil removal, avoid leaving the
bearings exposed for an extended period to prevent rust.

6.2.2. Force necessary to press fit or remove bearings

30
Table of Content

Assume ∆=10 μm

( )
2
50 3
K a ( press fitting)=9.8∗4∗10∗20∗ 1− 2
∗10 =2824 N
62.51

( )
2
50 3
K a (removal)=9.8∗6∗10∗20∗ 1− 2
∗10 =4236 N
62.51

References

[1] SKF, "*6210 Deep groove ball bearing," SKF, [Online]. Available:
https://www.skf.com/in/products/rolling-bearings/ball-bearings/deep-gro.

[2] SKF, "*6010 Deep grove ball bearing," SKF, [Online]. Available:

31
Table of Content

https://www.skf.com/in/products/rolling-bearings/ball-bearings/deep-groove-ball-
bearings/productid-6010.

[3] JTEKT, "Bearing mounting," [Online]. Available:

https://koyo.jtekt.co.jp/en/support/bearing-knowledge/15-3000.html.

32
Table of Content

6.3. Drum Fixation

To fix the drum with the drum shaft, we thought of many options

 Snap rings
 Shrink fitting
 Welding
And several other options. After thinking practically in each option and evaluate it based
these criteria:

 Maintenance considerations
 Failure considerations
 Transmitted torque moment
 Complexity
 Cost
 Availability
We ended up choosing from locking devices as they provide easy maintenance, able to be
replaced, and overall suitable for the application.
There were many types of locking devices, but we decided to design and select a simple
locking device, as we fully determined all the loads that can occur and also the environment
of the mechanism is relatively stable.
We chose a keyless self-centering internal locking device. After searching for existing
manufacturers, we found a good and reliable series of locking devices called SIT-LOCK® 12
internal locking device - self-centering (manufactured by a company called Sit Lock) [1] [2]

6.3.1. Specifications
 Self-centering
 Quick installation and removal
 Available for shaft diameters of 18 to 90 mm
 Reduced axial dimensions
 Axial displacement when tightening screws
 Excellent shaft-hub concentricity and perpendicularity
 Medium to high transmissible torques

6.3.2. Installation
The locking device is supplied ready to assemble. Clean the shaft contact surfaces
thoroughly and apply oil. Mount the shaft, hub and locking device in the desired position.

6.3.3. Screw tightening sequence:

Tighten two opposite screws until the locking device contacts the shaft and hub, then
tighten all screws to 50% of the specified torque in a criss-cross pattern. Repeat to
reach 100% of the specified torque and ensure it's achieved continuously.

33
Table of Content

6.3.4. Removal
Loosen the clamping screws gradually, remove them, and insert into special removal
threads on the inner ring flange. Tighten the screws in a criss-cross pattern to release
the locking device.

6.3.5. Reusing the locking device

When the locking device is being reuse, make sure that all the surfaces are clean and show
no obvious signs of deformation or seizing. Clean and oil all surfaces and threads. Check the
screws have not been deformed. Oil the screws and assemble the locking device as
originally supplied.

6.3.6. Calculations for Selection

Parameters
Mt The transmissible torque stated in table (N.m)
Ms Screws tightening torque
N Radial force on the shaft and hub contact surfaces
μ The coefficient of friction
Pv Axial force
d Shaft diameter (mm)
M tam Permissible torque (N.m)
F AXR Required axial force (N)
∆ Pn additional pressure on hub (N/mm²)
Fr radial force applied (N)
D external diameter of the locking device (mm)
H locking device outer ring width (mm)
Dmin minimum hub diameter
K application coefficient
σ 0 ,2 hub material elastic limit in (N/mm²)
X factor depending on hub shape and width
Pn surface pressure on the hub
F ax Transmissible axial force
Pw Pressure on shaft

34
 Table of Content

Dimensions [mm] Clamping screws DIN 912 12.9 Values with tolerances for shaft h8/hub H8

Ms Mt Fax Pw Pn
dxD H H0 H1 H2 Number Type [Nm] [N/mm²] [N/mm²]
[Nm] [kN]
18 x 40 12 15 20 24 6 M4 5 218 24 297 135
19 x 41 12 15 20 24 6 M4 5 230 24 282 130

50 x 78 19 23 30 36 8 M6 17 1824 73 204 130

55 x 83 19 23 30 36 8 M6 17 2.006 73 185 125
56 x 84 19 23 30 36 8 M6 17 2.043 73 182 120
Elastic load of hub material σ0,2
Pressure on hub X factor [N/mm²]
150 180 200 220 250 270 300 350 400 450 500 600
Pn Hub material
[N/mm²] Application type
GG25 GG30 GS45 GGG40 St50-2 GGG50 GGG60 GGG70
GG20 Tempering steels
GS38 GTS35 St37-2 GS52 C35 St60-2 St70-2 C60
A X=1 3,00 2,24 2,00 1,84 1,69 1,61 1,53 1,43 1,36 1,31 1,28 1,22
120 B X=0,8 2,13 1,81 1,69 1,60 1,50 1,45 1,39 1,33 1,28 1,24 1,21 1,18
C X=0,6 1,69 1,53 1,46 1,40 1,34 1,31 1,28 1,23 1,20 1,18 1,16 1,13

A X =1 3,74 2,49 2,17 1,97 1,78 1,69 1,59 1,48 1.40 1,35 1,30 1,25
130
B X=0,8 2,35 1,93 1,78 1,67 1,56 1,50 1,44 1,36 1,30 1,27 1,24 1,19
C X=0,6 1,78 1,59 1,51 1,45 1,38 1,35 1,30 1,25 1,22 1,19 1,17 1,14

From the manuals provided

N∗μ∗d
Mt=
2
The coefficient of friction μ used to calculate the locking device transmissible torque Mt is
0.12 (oiled surfaces) for internal locking devices

√ ( )
2
F ∗d
M tam = M + AXR 2
t
2000
Fr
∆ P n=
D∗H
Dmin ≥ D∗K

K=
√ σ 0 ,2 + ( X∗Pn )
σ 0 ,2−( X∗Pn )
K=
√ 390+ ( 1∗130 )
390− (1∗130 )
=1.4 (as ¿tables)

Dmin ≥ 1.4∗78=109.2mm

 We will use one sit lock

 Axial forces couldn’t be bigger than F ax =73 KN
 The selection is safe because the torque on shaft is 700 N . m≤ M t =1824 N . m

References

35
Table of Content

[1] S. S.p.A.. [Online]. Available: https://sitspa.com/.

[2] S. S.p.A., "SIT-LOCK® Keyless Locking Devices," [Online]. Available:

https://sitspa.com/locking-devices/sit-lock-locking-devices/.

6.4. Coupling
Assumptions for the rigid flange coupling

 The Diameter of shaft d= 50 mm.

 Torque = 780 N.M
 Coupling dimensions are proportional to the shaft

6.4.1. Hub Design

The hub is designed by considering it as a hollow shaft, transmitting the same torque (T) as
that of a solid shaft.
Assume:
Hub diameter D1=1.5d= 75 mm.
Hub Length L =d= 50 mm.

T = π /16∗τ { D 14 – d 4
D1 }
3
780∗10
τ=
{ } =11.73 Mpa
4 4
π 75 −50
∗
16 75

The choosen material is steel AISI 1006 sy=170 ,

τ all=85 mpa
85
n . s= =7.25
11.73
That means that the hub is safe under
Flange Design:
The flange at the junction of the hub is under shear while transmitting the torque.
Therefore, the troque transmitted,
Assume:

36
Table of Content

 Pitch circle diameter Dp = 2.5d = 125 mm.

 Flange Outer Diameter Df = 3.5d = 175 mm.
 Flange thickness tf=0.5d = 25mm.

T = Circumference of hub × Thickness of flange × Shear stress of flange × Radius of hub

T¿ π D 1∗tf ∗τ∗D1 /2={(πD 2)/2 }∗τ∗tf

( 780∗103 )
τ= =3.53 mpa
π∗75∗25∗37.5
The choosen material is steel AISI 1006 sy=170 ,
τ all=85 mpa
85
n . s= = 24
3.53
So flange is safe under stress

6.4.2. Bolts Design:

No. of bolts =n =0.02d+3 = .02*50+3 = 4
Choose material steel AISI 1006 sy=170 , τ all=85 mpa
Shear on bolts:
T
τ bolt =
()
π
4
∗d
2 bolt∗Dp
2

3
780∗10
τ bolt = =62 mpa
() π
4
2
∗8 ∗125

τ all 85
n . s= = =1.37
τ bolt 62

37
Table of Content

7.Further Design Analysis

7.1. Types of Hoist Mechanism in the Market

The type of hoist can vary depending on its application and design. Common types include:

1. Manual Hoists:
Operated by hand, these hoists are lever-actuated or hand-
operated lifting devices. They use a hand chain or lever to control
lifting .
Pros of Manual Hoists:
 Versatility: Manual hoists are versatile and can be used in
various applications, including construction, maintenance,
and industrial settings
 Portability: They are often lightweight and portable,
making them suitable for use in remote locations or areas
with limited access Figure 3:manual hoists
 Simple Operation: Manual hoists are easy to operate and
require minimal training, allowing for quick setup and use .
 Cost-Effective: They tend to have lower initial costs compared to powered hoists,
making them a cost-effective option for certain lifting needs .
Cons of Manual Hoists:
 Limited Capacity: Manual hoists typically have limited lifting capacities compared to
powered hoists, restricting their use for heavier loads
 Physical Effort Required: Operating manual hoists involves physical effort from the
operator, which can be tiring and may not be suitable for prolonged use or heavy
loads
Use Cases:
 Manual hoists are commonly used in scenarios where:
 Lifting requirements are relatively light to moderate.
 Portability and ease of setup are essential, such as in construction sites or
maintenance tasks.
 Power sources are unavailable or impractical
2. Powered Hoists:
These hoists are powered by electricity or other energy sources.
They offer increased lifting capacity and may be more suitable for
heavy-duty applications .
Pros Powered Hoists
 Increased Efficiency: Powered hoists, such as electric or
pneumatic hoists, offer higher lifting capacities and faster
lifting speeds compared to manual hoists, resulting in
increased productivity

Figure 4:Powered Hoists

38
Table of Content

 Reduced Physical Strain: Workers experience less physical strain and fatigue as
powered hoists require minimal manual effort for lifting and lowering heavy loads,
leading to improved safety and reduced risk of injury
 Versatility: Electric hoists can be easily operated with a push-button control,
allowing precise positioning of loads and enabling applications in various industries,
including manufacturing, construction, and warehousing
 Suitable for Indoor Use: Powered hoists, especially electric ones, are suitable for
indoor use as they do not emit exhaust gases, making them ideal for environments
with limited ventilation
Cons
 Dependence on Power Source: Powered hoists rely on electricity or compressed air
for operation, limiting their use in remote or outdoor locations without access to
power or air supply
 Initial Cost: The initial investment for powered hoists is higher compared to manual
hoists due to the need for electric motors or pneumatic systems, along with
associated control mechanisms
 Maintenance Requirements: Powered hoists require regular maintenance to ensure
proper functioning of motors, electrical components, and pneumatic systems,
adding to ongoing operational costs
Common Applications
 Powered hoists are commonly used in:
 Manufacturing plants for assembly line operations.
 Warehouses for material handling and storage.
 Construction sites for lifting heavy building materials.
 Automotive repair shops for engine and vehicle component handling.
3. Mobile Hoists:
Also known as floor hoists or mobile patient lifts, these hoists are
used to lift and transfer individuals who lack mobility. They are
commonly found in healthcare settings .
Pros
 Portability: Mobile hoists are portable and can be easily
moved from one location to another, providing flexibility
in caregiving situations
 Versatility: They can be used in various environments,
including homes, hospitals, and care facilities,
accommodating different patient needs
 Safety Features: Mobile hoists are designed with multiple
Figure 5:Mobile Hoists
safety mechanisms to prevent accidents and injuries,
ensuring patient safety during transfers
Cons
 Space Requirements: They require floor space for maneuvering, which can be a
limitation in smaller environments
 Battery Maintenance: For battery-powered models, regular charging is necessary to
maintain functionality, and forgetting to charge can lead to operational issues
 Storage Needs: Storage space is required when the hoist is not in use, which may
pose challenges in crowded settings
Use Cases

39
Table of Content

 Mobile hoists are commonly used in:

 Homecare settings where transferring individuals between rooms or areas is
required
 Care facilities such as nursing homes and hospitals for patient transfers and mobility
assistance
 Emergency situations where quick and efficient lifting of individuals is necessary
4. Ceiling Hoists:
Installed on ceilings, these hoists utilize tracks or rails to
facilitate lifting and transferring individuals, offering a space-
saving and efficient solution
Pros:
 Space-saving: Ceiling hoists maximize floor space,
making them ideal for environments with limited
room for maneuverability
 Permanent installation: Once installed, ceiling hoists
provide a fixed transfer solution, eliminating the need
for repetitive setup and dismantling Figure 6:Ceiling Hoists
 Safety: They reduce the risk of falls associated with manual transfers, enhancing
patient safety
 Convenience: Ceiling hoists facilitate efficient transfers, reducing strain on
caregivers and promoting ease of use
Cons:
 Installation time: Ceiling hoists require time-consuming installation compared to
mobile hoists, delaying immediate use
 Limited portability: Once installed, ceiling hoists are fixed in place, limiting their
flexibility for use in different locations .
 Cost: Initial setup costs for ceiling hoists may be higher compared to mobile hoists,
depending on the complexity of the installation
Applications:
Ceiling hoists are commonly used in healthcare facilities, rehabilitation centers, and
residential settings where a permanent and safe transfer solution is required. They are
particularly beneficial for transferring patients with limited mobility or those requiring
frequent transfers, such as elderly individuals or individuals with disabilities.

5. Hydraulic Hoists:
These hoists use hydraulic power to lift heavy loads.
They are often used in industrial settings where precise
control and high lifting capacity are required
Pros:
 Cost-effective: Hydraulic hoists are often
cheaper to install compared to other types of
hoists, making them a preferred choice for
budget-conscious projects
 Space-saving: They require less space in a
building, typically occupying almost 10% less
Figure 7:Hydraulic Hoists
area than other elevator types, making them
suitable for installations where space is limited

40
Table of Content

 Energy-efficient: Hydraulic lifts use less electricity compared to other lift types, as
the motor only operates during upward travel, contributing to lower operational
costs
 Versatility: Hydraulic hoists can be used in various applications and environments
due to their wide range of capabilities and adaptability
Cons:
 Maintenance: They may require more frequent maintenance compared to other
types of hoists due to the complexity of hydraulic systems
 Potential leaks: Hydraulic systems are susceptible to oil leaks, which can lead to
environmental hazards and require prompt attention for repair
 Limited travel height: Hydraulic hoists are typically limited in terms of travel height
compared to other lift types, which may restrict their use in taller buildings or
structures
Cases of Use:
 Hydraulic hoists are commonly used in various industries, including automotive,
construction, and manufacturing, for lifting and moving heavy loads such as engines,
machinery, and materials
 They are also utilized in building construction projects for temporary lifting
applications, such as installing beams and structural components

Resources from our Market Research

 https://www.researchgate.net/publication/
315463159_Design_of_a_Hoisting_System_for_a_Small_Scale_Mine
 https://www.researchgate.net/publication/
327288149_Design_of_Automotive_Engine_Hoisting_Device_for_Mechanical_Applications
 https://www.researchgate.net/publication/
237062016_It's_not_about_the_hoist_A_narrative_literature_review_of_manual_handling_
in_healthcare
 https://www.researchgate.net/publication/
288495327_Review_It's_not_about_the_hoist_A_narrative_literature_review_of_manual_h
andling_in_healthcare
 https://www.researchgate.net/publication/
343743597_Structure_Design_and_Analysis_of_Portable_Hoisting_Equipment
 https://www.researchgate.net/publication/
294105466_Modeling_Power_Flow_in_a_Hoist_Motor_of_a_Rubber-Tired_Gantry_Crane
 https://iopscience.iop.org/article/10.1088/1742-6596/1605/1/012061/pdf
 https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6936941/
 https://www.researchgate.net/publication/
343334580_Bariatric_patients_and_the_use_of_mobile_hoists_user_experiences_from_thr
ee_hospitals_in_South_Australia
 https://www.researchgate.net/publication/
26257745_Evaluation_of_ceiling_lifts_Transfer_time_patient_comfort_and_staff_perceptio
ns
 https://www.researchgate.net/publication/
285029694_Evaluation_of_Ceiling_Lifts_in_Health_Care_Settings_Patient_Outcome_and_Pe
rceptions

41
Table of Content

 https://www.researchgate.net/publication/
266651435_Study_on_Vibration_and_Noise_For_the_Hydraulic_System_of_Hydraulic_hoist
 https://www.researchgate.net/publication/
328081866_Analytical_and_experimental_research_on_stability_of_large_slenderness_rati
o_horizontal_hydraulic_hoist

7.2. Manufacturing Analysis

After searching for suitable manufacturing processes and even considering them in the
design process. We decided these process for the parts we have designed

7.2.1. Drum Shaft

Drum shaft will be manufactured using machining on a center-lathe machine. Here is the
costing sheet and the G-Code for the shaft machining:
G-Code
O0001
N1 G21
N2 (6MM CRB 2FL 19 LOC)
N3 G91 G28 X0 Y0 Z0
N4 T01 M06
N5 S3606 M03
N7 G90 G54 G00 X-10.124 Y-10.45
N8 G43 Z.5 H01 M08
N9 G01 Z-3.35 F73.273
N10 G17 G03 X10.124 I10.124 J10.45 F293.091
N11 G01 X-10.124
N12 Y-8.05
N13 X-14.916
N14 G03 X14.916 I14.916 J8.05
N15 G01 X-10.124
N16 Y-5.65
N17 X-18.507
N18 G03 X18.507 I18.507 J5.65
N19 G01 X-10.124
N20 Y-3.25
N21 X-21.506
N22 G03 X21.506 I21.506 J3.25
N23 G01 X-10.124
N24 X-21.506
N25 G03 X21.506 I21.506 J3.25
N26 G01 X-10.124
N27 G00 Z.5
N28 Y-10.45
N29 Z-.85
N30 G01 Z-3.6 F73.273
N31 G03 X10.124 I10.124 J10.45 F293.091
N32 G01 X-10.124
N33 Y-8.05
N34 X-14.916
N35 G03 X14.916 I14.916 J8.05
N36 G01 X-10.124
N37 Y-5.65
N38 X-18.507

42
Table of Content

N39 G03 X18.507 I18.507 J5.65

N40 G01 X-10.124
N41 Y-3.25
N42 X-21.506
N43 G03 X21.506 I21.506 J3.25
N44 G01 X-10.124
N45 X-21.506
N46 G03 X21.506 I21.506 J3.25
N47 G01 X-10.124
N48 G00 Z.5
N49 Z25.
N51 X-21.506
N52 Z.5
N53 G01 Z-3.35 F73.273
N54 G03 X-20.363 Y-7.642 I21.506 J3.25 F293.091
N55 G02 X-17.321 Y-3.25 I3.043 J1.142
N56 G01 X-21.506
N57 G00 Z.5
N58 Z-.85
N59 G01 Z-3.6 F73.273
N60 G03 X-20.363 Y-7.642 I21.506 J3.25 F293.091
N61 G02 X-17.321 Y-3.25 I3.043 J1.142
N62 G01 X-21.506
N63 G00 Z.5
N64 X17.321
N65 G01 Z-3.35 F73.273
N66 G02 X20.363 Y-7.642 I0 J-3.25 F293.091
N67 G03 X21.506 Y-3.25 I-20.363 J7.642
N68 G01 X17.321
N69 G00 Z.5
N70 Z-.85
N71 G01 Z-3.6 F73.273
N72 G02 X20.363 Y-7.642 I0 J-3.25 F293.091
N73 G03 X21.506 Y-3.25 I-20.363 J7.642
N74 G01 X17.321
N75 G00 Z.5
N76 Z25.
N78 X3.23 Y-5.382
N79 Z1.
N80 G01 Z-3.6 F73.273
N81 G41 D21 X1.024 Y-3.176 F219.818
N82 G03 X.6 Y-3. I-.424 J-.424
N83 G01 X-21.794 F293.091
N84 G03 X21.794 I21.794 J3.
N85 G01 X-.6
N86 G03 X-1.024 Y-3.176 I0 J-.6
N87 G40 G01 X-3.23 Y-5.382
N88 G00 Z1.
N89 Z25. M09
N90 G91 G28 Z0
N91 G28 X0 Y0
N92 M30

Costing Report for Shaft Manufacturing

43
Table of Content

7.2.2. Key
The key will be made in two steps
1. Machining of the key parallelogram shape
2. Forging to obtain the fillets of the key
We made a study for the key as if it manufactured using only machining, and this is the cost
report in this case:
Costing Report for Key Manufacturing

44
Table of Content

45
Table of Content

7.2.3. Flange
We will manufacture flange with casting method
Process of Manufacturing Flanges with Casting
1. Pattern Making: First, a template in the shape of the intended flange design is
created. Usually, this is done with wood.
2. Mold Preparation: The pattern is used to build a mold. The final flange's dimensions
and shape will be determined by this mold. Sand will be used to make the mold.
3. Metal Melting: steel a furnace is used to melt metal to the appropriate temperature.
4. Pouring: The prepared mold cavity is filled with molten metal. To prevent flaws in
the finished product and allow room for a bolt and nut, care must be taken to ensure
that the mold is properly filled.
5. Solidification and Cooling: The molten metal inside the mold begins to solidify and
cool after pouring, assuming the shape of the mold cavity. The complexity and size of
the flange will determine how long this operation takes.
6. Extracting the Casting: After the metal has set completely, the casting is taken out of
the mold.
7. Cleaning and Finishing: The casting is cleaned to get rid of any surface flaws and
leftover mold material. To obtain the flange's final size and surface polish, machining
procedures may be used.
8. Examination: To make sure the completed flanges fulfil quality requirements and
standards; a comprehensive examination is conducted. Dimensional checks, visual
examination, and non-destructive testing techniques might be examples of this.
After the casing process, the threads will be made in the flange with drilling methods.

7.2.4. Items to Buy

For each system that will be manufactured, we will buy these stander items
 Drum with diameter 30 cm and length 860 mm
 4 Bolts M8
 4 Nuts M8
 1 SKF 6210 deep groove ball bearing
 1 SKF 6010 deep groove ball bearing

7.3. Fits and Tolerances

Shaft & locking device:
Fit type: clearance fit
Tolerance: 50 H8/h8

46
Table of Content

1- Tolerance on shaft = 0.039mm

Tolerance on hole = 0.039mm

2- Limits of hole : 50.000 / 50.039 mm

Limits of shaft: 49.961 / 50.000 mm

3- Fundamental deviation of hole = zero (since H)

Fundamental deviation of shaft = zero (since h)

4- Maximum clearance = 50.039 – 49.961= 0.078 mm

Minimum clearance = 50.000 – 50.000 = zero

Mean clearance = (Maximum clearance + Minimum clearance)/2 = (0.078 +

0.000)/2 = 0.039 mm

Shaft & Bearing:

Fit type: transition fit
Tolerance: 50 P6/h5
1- Tolerance on shaft = 0.039mm
Tolerance on hole = 0.016mm

2- Limits of hole : 49.975 / 49.991 mm

Limits of shaft: 49.961 / 50.000 mm

3- Fundamental deviation of hole = -.026 mm

Fundamental deviation of shaft = zero (since h)

4- Maximum clearance = 49.991 – 49.961= 0.03 mm

Minimum clearance = 49.975 – 50.000 = 0.025 mm

Mean clearance = (Maximum clearance + Minimum clearance)/2 = (0.03 +

0.025)/2 = 0.0275 mm

Shaft & drum:

Fit type: interference fit
Tolerance: 50 P7/h6
1- Tolerance on shaft = 0.016mm
Tolerance on hole = 0.025mm

2- Limits of hole : 49.974 / 49.949 mm

Limits of shaft: 49.984 / 50.000 mm

47
Table of Content

3- Fundamental deviation of hole = -.026 mm

Fundamental deviation of shaft = zero (since h)

4- Maximum clearance = 49.949 – 49.984= -.035 mm

Minimum clearance = 49.974 – 50.000 = -.026 mm

Mean clearance = (Maximum clearance + Minimum clearance)/2 = (-.035 + -.026)/2 = -.0305

mm

Shaft & Flange :

Fit type: interference fit
Tolerance: 50 H7/g6
Turn it to shaft basis system: 50 G7/h6

5- Tolerance on shaft = 0.016mm

Tolerance on hole = 0.025mm

6- Limits of hole : 50.009 / 50.034 mm

Limits of shaft: 49.984 / 50.000 mm

7- Fundamental deviation of hole = .009 mm

Fundamental deviation of shaft = zero (since h)

8- Maximum clearance = 50.034 – 49.984= 0.050 mm

Minimum clearance = 50.009 – 50.000 = 0.009 mm

Mean clearance = (Maximum clearance + Minimum clearance)/2 = (0.050 +

0.009)/2 = 0.0205 mm

7.4. Future Work

We have done tons of searching in this project, but as are restricted with deadlines
for the handover some of our ideas are weren’t applicable for this scale. In this section we
introduce some of the ideas we came up with to enhance the design and make it more
efficient in terms of cost and maintenance and also more applicable in terms of usage and
manufacturing.

48
Table of Content

7.4.1. Advanced Load Analysis for the Wire Rope on the Drum
As the precise analysis of the load transmitted to the wire rope drum from the load
acting on the wire rope is very complex (actually some research papers are covering only
such analyses) we thought of preforming FEA analysis to study the load distribution more
accurate and in several cases and also with different loads.
This can be beneficial for the design of the drum, the shaft, and also the number of
pulleys to reach the maximum mechanical advantage per cost possible.

7.4.2. Optimizing the Shaft

There are several ways to optimize the shaft, like using hollow shafts or diving the
shaft and optimize its cross section. This would lead to less cost pre system and also
manufacturing improvements.

7.4.3. Body Design

The body that will hold this system and fixing it to some reference level should be
designed carefully for easy manufacturing and low costs. We thought of this design process
depending on the models we found in the market and came up with these ideas:

 The body can have an actuator to move it horizontally which is important for many
use-cases
 The body will be fixed with two supports to hold its weight and the weight lifted by
the system.

7.4.4. More Safety Features

We thought of adding multiple safety features, we have already added a failure fuse
(the key and bolts), however, more safety will always be better. Breaking systems and load
measuring are one of the ideas we thought of.

8.Drawings

49