Preliminary Calculations
Preliminary Calculations
DESIGN PROJECT
b) SAFETY.
It should have color markings indicating the maximum load that can be handled.
Construction should avoid sharp edges by applying chamfers, fillets and rounded
corners.
c) ENVIRONMENT.
It should be designed to operate to both dusty and high humidity environments to
be suitable in all kinds of workshops.
It should be designed to operate at room temperature.
d) MATERIALS.
Pulleys should be of wear resistant materials due to friction between rope and
pulley.
The slewing support should be made of materials with high stiffness and high
yield strength to prevent bending due to heavy loads.
e) MAINTENANCE.
Components joining and fixing should be of temporary methods using bolts, nuts
and screws to allow easy replacement
It should be made affordable and locally available materials.
f) ERGONOMICS.
The units should contain ergonomic grips for manual operations.
Operation height should be of average human height between 150 cm and 175 cm.
h) INSTALLATION.
All components are to be joined into a single unit.
A single unit is to be mounted on a concrete wall by temporary mounting
methods.
i) QUANTITY.
Production volume required should be about 50 units per year.
CONCEPTUAL DESIGN.
Concept one.
Working principle.
It’s a simple pulley arrangement whereby all of the moving pulleys are moving towards the
anchor at the same speed as the load, it provides a Mechanical advantage , M . A=2 n ,where n is
the number of movable pulleys in a system, Effort is applied by pulling the rope manually from
the pulley system, the load is fixed in place by tying the rope to a fixed hook attached to the
mounting wall.
Concept two.
Working principle.
It’s a compound pulley arrangement whereby several simple pulley systems are stacked
together, it provides a Mechanical advantage , M . A=2 n ,where n is the number of movable
pulleys in a system, Effort is applied by turning the lever which rotates the drum where the rope
is placed, the load is fixed in place by a pawl and ratchet mechanism which stops drum from
turning due to the weight of the load by engaging and disengaging the pawl manually, the drum
and pawl and ratchet mechanisms are also fixed to the mounting wall.
Concept three.
Working principle.
It’s also a simple pulley mechanism with a mechanical advantage of 4 due to two movable
pulleys, additional mechanical advantage is provided by integrating it with a gear system
attached to the drum to increase the effort in the pulley system, Effort is applied by turning the
wheel which start turning the pinion in the gear system for increasing the effort, which rotates the
gear and drum where the rope is placed , the load is fixed in place by a pawl and ratchet
mechanism which stops drum from turning due to the weight of the load by engaging and
disengaging the pawl manually, the drum, gear system and pawl and ratchet mechanisms are also
fixed to the mounting wall.
Concept evaluation.
Below is the matrix for the best concept selection.
Effort Load=250 N
From;
7500 N
M . A=
250 N
M . A=28.57 ≈ 30
n
M . A C =2
Thus;
5
M . A C =2
M . A C =32
Since, M . A C > M . A
DESIGN ANALYSIS
DESIGN CRITERIA.
Maximum Load , P=5 kN
Pd =7.5 kN
COMPONENTS DESIGN.
Wire rope design.
Classified as class 1 hoist mechanism for the rope design as it is manually operated.
From;
MBL=26.25 kN
Pulley design.
Determination of the diameter of the pulley.
For class 1;
D
≥ 18
d
Where ‘D’ and ‘d’ are the pulley and rope diameters.
D ≥18 × d
But, d=8 mm
D ≥18 × 8 mm
D ≥144 mm
a=2.7 × 8 mm
a=21.6 mm
h=1.5 ×8 mm
h=12 mm
r =0.55 ×8 mm
Drum design.
Drum diameter determination
For class 1;
D
≥ 18
d
Where ‘D’ and ‘d’ are the drum and rope diameters.
D ≥18 × d
But, d=8 mm
D ≥18 × 8 mm
D ≥144 mm
h=0.375 ×8 mm
h=0.375 d
h=3 mm
Radius of groove in the drum, r (mm);
r =0.5375 d
r =0.5375 ×8 mm
p=2.18× 4.5 mm
p=9.81 mm say 10 mm
t=12.88 say 13 mm
Dm =176 mm
Ratchet design
P=tangential force
p=allowable pressure per unit length ( mmN )
σ b=allowable bending stress(MPa)
Where;
b P
D=mz , Ψ = , b= , P=
m p
2T
D
and m=2
3 T
Z Ψ σb √
For independent ratchet type brakes, z=12
Ratchet material → Steel
Pawl material→ Steel
Then,
Module of the ratchet, m (mm)
D
m=
z
150
m=
12
b=2 ×14
b=28 mm
Tangential force, P (N)
P=bp
N
P=28 mm× 350
mm
P=9800 N
From,
m=2 3
√ T
Z Ψ σb
8T
σ b= 3
zΨ m
8 ×735000
σ b= 3
12× 2× 14
σ b=89.3 MPa
Since the calculated bending stress is less than the allowable 150 MPa then the design is valid.
Considering the figure below for the tooth profile selection for the ratchet.
Ratchet tooth profile
Pawl design.
Pawl design
Stresses due to eccentric load;
e 1=h=10.5 mm
6 Mb P
σ= 2
+
bx bx
σ yt 450 MPa
σ ≤ σ all and σ all= = =150 MPa
f .s 3
Assuming , x=15 mm
6 Mb P
σ= 2
+
bx bx
6 ×102900 9800
σ= + =121.33 MPa
28 ×15
2
28 × 15
σ < σ all
Pawl-pin design.
Pawl-pin is treated as a cantilever beam subjected to bending.
d=2.71
√
3 P b
(
+a
2 σb 2 1 )
d=2.71
√
3 9800 28
2× 89.3 2
+8 ( )
d=28.85 mm say 30 mm
Where,
M . A Lever =mechanical advantage of the lever
Assuming, E A =250 mm
EA 250 mm
LA= = =149.7 mm say 150 mm
L A M . A Lever 1.67
d=
√(
3 16 M
σb π )
Each rod at each pulley experiences a 2n F load, Where F = 250 N, r = 22.5 mm
Then,
√( )
n
3 16 × 2 F ×r
d n=
σb π
Based on application of the machine, the machine operates 250 days for 5 years with 4 working
hours a day
Then,
L H =5× 250 × 4=5000 hrs
Working hours, L H =5000 hours
( )
1
L 3
C=W −6
10
W =Y .W A . K S
( )
6 1
9 × 10 3
C=7.6 −6
=15808.6 N
10
Design of an I-beam
σ y 450
σ b=σ all= = =150 MPa
f .s 3
And, Bending moment , M =8100 N × 2500 mm=20.25 kN−m
Then,
20250 N −m −4 3 3
Zy≥ =1.35 ×10 m =135 cm
N
150 × 106 2
m
Standard beam suitable sectional modulus based on hot rolled medium-wide I-beam DIN 1025 is
3
146 cm .
Design of hook.
As it operates as a middle duty hoist, it is in A5-A6 crane group, of 0.764 tons
Standard available is 2 tons
Grade
Crane group
level
M - - - - A3 A4 A5 A6 A7 A8
P - - - A3 A4 A5 A6 A7 A8 -
S - - A3 A4 A5 A6 A7 A8 - -
T - A3 A4 A5 A6 A7 - - - -
V A3 A4 A5 A6 A7 - - - - -
Hook
type Crane/hoist capacity (metric tons)
no.
1.6 8 6.3 5 4 3.2 2.5 2 1.6 1.25 1
2.5 12.5 10 8 6.3 5 4 3.2 2.5 2 1.6
4 20 16 12.5 10 8 6.3 5 4 3.2 2.5
5 25 20 16 12.5 10 8 6.3 5 4 3.2
Hook type determination table
From the table above hook no 1.6 is selected.
Hook profile
Hook a1 a2 a3 b1 b2 d1 e3 h1 h2 L
type
no.
1.6 56 45 64 45 38 36 118 56 48 224
2.5 63 50 72 53 45 42 132 67 58 253
4 71 56 80 63 53 48 148 80 67 285
5 80 63 90 71 60 53 165 90 75 318
Hook type dimensions
Considering the above diagram and the table, the hook’s dimensions are as follows,
Feature a1 a2 a3 b1 b2 d1 e3 h1 h2 L
Dimensio
56 45 64 45 38 36 118 56 48 224
n (mm)
Selected hook dimensions
√
Pd
α 1 c=
π
σ
4 all
√
7500
α 1 c= =6.91 mm
π
×200
4
From the data book the standard core diameter is 8.16 mm and the corresponding size of the bolt
is M 12
Therefore, α 1=12 mm
T e =√ M 2 +T 2
From,
d s=
√
3 16 T e
τ max × π
√
d s= 3
16 ×53033
τ max × π
=16.6 mm
Using a standard shaft of diameter 20 mm.
Mounting design
P 10051.21 N
Direct shear load on each bOlt , P s= = =2512. 8 N say 2513 N
n 4
1 1
P t + ( Pt ) + 4 ( P s ) = [ 33.1+ √ ( 33.1 ) + 4 ( 2.513 ) ]
[ √ ]
2 2 2 2
Equivalent tensile load , Pte=
2 2
Pte =33.3 kN
√
Pte
d c=
π
σ
4 all
√
33300
d c= =14.56 mm
π
× 200
4
From the data book the standard core diameter is 14.9 mm and the corresponding size of the bolt
is M 18
Taking thickness of the plates to be 15 mm.
Assuming the distance of the bolt from the mounting plate is l=250 mm∧e=3000 mm
Pel 10051.21 ×3000 ×250
Secondary tensileload , Pt = = =60.31 kN
2 ( l2 ) 2 ( (250 )2 )
P M =70.36 kN
√
PM
d c=
π
σ
4 all
√
70360
d c= =21.16 mm
π
× 200
4
From the data book the standard core diameter is 23.32 mm and the corresponding size of the
bolt is M 27
Pm=43574.63 N
√
Pm
d c=
π
σ
4 all
√
43574.63
d c= =16.66 mm
π
×200
4
From the data book the standard core diameter is 16.933 mm and the corresponding size of the
bolt is M 20
8100 N
Maximum tensile load on each bolt , P b= =2025 N
4
√
Pb
d c=
π
σ
4 all
√
2025
d c= =3.6 mm
π
× 200
4
From the data book the standard core diameter is 4.019 mm and the corresponding size of the
bolt is M 5
DESIGN DRAFT
According to the analysis made and the hand draft drawn, aa design draft was drawn true to scale
for all parts, indicated with surface roughness and tolerances necessary.
The design draft is provided as attachment to the design report.
DETAIL DESIGN
DETAIL PART DRAWINGS
Detail drawings of all parts were prepared with reference to the design draft prepared, the drawn
detail drawings are provided as attachments to the design report.
ASSEMBLY DRAWING
An assembly drawing was prepared true to scale showing how parts are connected together, the
drawn assembly drawing is provided as attachment to the design report.
CONCLUSION
The design was based in considering structural optimization, good load handling, safety during
operation and high operational efficiency, it demonstrates the successful applications of
engineering principles and innovative design strategies to create a workshop slewing swivel
pulley system that is safe to use, powerful and dependable.
REFERENCES
1. KHURMI, R.S and GUPTA (2005). ‘A textbook of Machine Design’ (14th ed). Eurasia
publishing house.
2. ISO 4301-1:2016 Crane classification.
3. Bhandari, V.B (2014). ‘Machine Design Data Book’, McGraw Hill
4. Materego, M (2024). ‘Machine elements and design lecture notes’, University of Dar es
salaam. PowerPoint presentation.
5. Elias, E (2023). ‘Design methodology lecture notes’, University of Dar es salaam.
PowerPoint presentation