CHAPTER 2: CAR AND COUNTERWEIGHT

A. CAR
2.1. Car structure:
2.1.1 Car structure:
The car carries passengers and other loads. It should be easily assembled so that the
components can be taken apart and then installed in the hoistway. It is composed of
the sling, a metal framework connected to the means of suspension, the platform
which forms the floor of the car and directly supports the load and the car enclosure
attached to the car platform.

Car frame
1. Vertical frame

2. Horizontal frame 3. Wedge

5. Suspension device

6. Cable clip

4.Guide shoes

7.Lever arm 8. Links

Car frame (platform) consist of vertical frame 1 and horizontal frame 2 connected
to each other by bolts. Vertical frame 1 is constructed from two vertical bar made

of equal-leg angle steel and two horizontal beam made of U steel. Horizontal
frame 2 is constructed from equal leg angle steel and the car floor is placed on it.
The upper beam of the vertical frame is connected to the suspension device 5,
make sure that all the suspension ropes have the same stretch. Since the car frame
has large dimensions, the horizontal and vertical frames should also be connected
by the links 8. The lever arm 7 and the wedge 3 of the safety gear are also attached
to the car frame. The lever arm 7 is connected with the cable of the overspeed
governor through the cable clip 6. If the speed of the car exceeds a predetermined
value, the safety gear will be activated and the car will be stopped, resting on the
guiding rails.
The guide shoes 4 are fixed to the endings of the upper and lower beams,
providing guiding for the car sling along the car trajectory.
2.1.2 Car dimensions determination:
Car dimensions determination should consider the service ability and economic
factor. The car dimensions can be determined from the rated load and the service
ability. The elevator designed in this thesis has the rated load Q=500kg and rated
velocity v=0.63m/s. We choose an elevator with the dimensions: Width x Length x
Height = 1110 x 1400 x 2200 mm (Reference:?). The width of the door is 800mm.
2.2 Calculation of the weight of the car:

1220

3
0
0
0

3
1
8
0

1280

1220

Car frame dimensions

To calculate the strength of the car frame, we choose the dimensions of the beams
first and then examine their strength.
Upper beam: Pressed U steel

180

25

90

260
440

Upper beams cross section

We have:
A = 3900 mm2
Jx =20142500mm4
Wxk Wxn

2 J x 2.20142500

223805mm3
h
180

The mass of the upper beam:

G = 3900.1280.7852.10-9 =39 kg
Lower beam: Pressed U steel

1
8
0

2
5

420

90

260
440

Lower beams cross section

We have:
A =8100 mm2
Jx = 56087500 mm4
Wxk Wxn

2 J x 2.56087500

590394mm3
h
190

The mass of the lower beam:

G =8100.1280.7852.10-9 =81 kg

Uprights (Vertical beams): equal-leg angle steel

80

260

Uprights cross section

We have:
A =1550 mm2
Sx =28125 mm3
yc =18 mm
Jx =972617 mm4
972617
16769mm3
58
972617
Wxn
44210mm3
22
Wxk

The mass of the uprights:

G =1550.3000.2.7852.10-9 =73 kg

Horizontal frame: pressed steel, four U75x75x5 and two U60x40x5

60

75

40

75

Cross section of bars of horizontal frame.

A1 =725 mm2
G1 = 725.(1400+1120)..7852.10-9=14,8 kg
A1 =650 mm2
G1 = 650.1250.7852.10-9=6,5 kg
The mass of the horizontal frame:
G =2.G1 + 2.G2 =42,6 kg
For the car floor we use 3mm tole. Then the mass of the car floor is:
3.1120.1400.7852.109 40kg

For car enclosure we use 2mm tole. Then the mass of the car enclosure is:
(1400.2150.2 1100.2150 360.2150).

2.7852.10-9=143 kg

The mass of the door is about 50kg.

Then the total mass of the car is:
39 + 81 + 73 + 42.6 + 40 + 143 + 50 = 468.6 kg
The car also has other accessories such as: links, guide shoes, wedge of the safety
gear, etc. Therefore, we take the mass of the car as 500Kg.
2.3 Cases of forces applying on the car:
2.3.1 General principle to calculate the strength of car:

The calculate the strength of the mechanisms that always function during the
activating time of the elevator, we have to consider their operation in several
cases:
-

Case 1: Nominal load

Case 2: The safety gear and/or the buffer is assembled
Case 3: Technical examine, 150200 % of nominal load.
Case 4: The car is stuck on the guiding rails.

The general principle to calculate the strength of car is based on the permissible
max

stress:

n
n

Where:
max

- maximum stress applied on the part

- permissible stress

- ultimate strength, fatigue strength or yield strength ( depends on each

case).
n- smallest factor of safety.
Material of the car frame: Shaped pressed steel: CT3
Yield strength: y = 240N/mm2
Ultimate strength: u = 400N/mm2
2.3.2 Cases for calculation:
Case 1:

Qt= Q.kd
Gt= Gcar. kd

Where
Qt Rated load Qt=500 (kg)

Gcar Mass of the car: Gcar =500 (kg)

a: acceleration of the car a=1,5 (m/s2)
g: free-fall acceleration g=9,81(m/s2)
kd: dynamic factor
kd 1

a
1,5
1
1,15
g
9,81

Then : Qt = 5000.1,15=5750 N
Gt = 5000.1,15=5750 N
Case 2: Increase Q by 10%, increase kd by 2030%
-

The car is assembled with the safety gear:

Qt= 1,1.Q.kd
Gt= Gcar. kd
Force from the wedges act on the car frame at two ends of the vertical
beam:
P

1,1Q Gcab
kd
2

kd=1,15+1,15.0,3=1,495
P

Then:
-

1,1.5000 5000
.1, 495 7849 N
2

Qt = 8223 N
Gt = 7475 N
The car is assembled with the buffer:
amax
).kn
g
9,81
(1,1.5000 5000)(1
).1 21000 N
9,81
P (1,1Q Gcab )(1

Qt=1,1.Q.kd = 11000 N
Gt= Gcar. kd = 10000N
Case 3: Technical examine

Qt= Q.kol
Gt= Gcar. kol
Where : kol Overload factor. kol=2 for traction drive with sheave
Then :

Qt=10000 N
Gt=10000 N

Case 4: Car stuck on the guiding rails

Pmax =Qt + Gcar + Gcable + W Gcw =292,34 (kg) =2923,4 N
2.3.3 Calculation of strength of the car:
Case 1:

Qt+Gt

3741027

61027

61027

M1

M1
J1

(Nmm)
J2

J2
Gt Qt
A

M2

J3

12101

M2 12101

2846785
3050299

Force diagram on the car frame in case 1

The equilibrium equations:
Qt Gt . A2 M 1. A

M .H M .H

1 2
16 EJ1

2 EJ1

3EJ 2

6 EJ 2

Gt . A2 4 Qt . A2 M 2 . A M 2 .H M 1 .H
.

16 EJ 3 81 EJ 3
2 EJ 3
3EJ 2 6 EJ 2

For Qt =5750N, Gt=5750N, J1 =20142500 mm4, J2 =972617 mm4, J3 =56087500

mm4, A=1280 mm, H=3000 mm. Then we have: M1= 61027 Nmm, M2 =-12101 Nmm
Case 2:
-

Car assembles with the safety gear:

M1

M1

15656

15656

J1

(Nmm)
J2

J2
Gt Qt

M2
P

J3

M2 32281

32281
3929424
4175641

Force diagram on the car frame in case 2

The equilibrium equations:

M 1. A M 1.H M 2 .H

2 EJ1 3EJ 2 6 EJ 2

Gt . A2 4 Qt . A2 M 2 . A M 2 .H M 1 .H
.

16 EJ 3 81 EJ 3
2 EJ 3
3EJ 2 6 EJ 2

For Qt =8223N, Gt=7475N, P=7849N J1 =20142500 mm4, J2 =972617 mm4,

J3 =56087500 mm4, A=1280 mm, H=3000 mm, we have:
M1= 15656 Nmm, M2 =32281 Nmm
-

Car assembles with the buffers:

7387138

Qt+Gt
M1 987138

M1

987138

J1

(Nmm)

J2

J2
Qt+Gt

453027

M2

J3

M2

453027

5946973

The equilibrium equations:

M 1. A M 1.H M 2 .H

2 EJ1 3EJ 2 6 EJ 2

Gt . A2 4 Qt . A2 M 2 . A PA2
M .H M .H
.

2 1
16 EJ 3 81 EJ 3
2 EJ 3 16 EJ 3 3EJ 2 6 EJ 2

For Qt =11000N, Gt=10000N, P=21000N, J1 =20142500 mm4, J2 =972617

mm4, J3 =56087500 mm4, A=1280 mm, H=3000 mm, we have:
M1= -7875 Nmm, M2 =-16238 Nmm
Case 3: Technical examination:

7387138

Qt+Gt
M1 987138

M1

987138

J1

(Nmm)

J2

J2
Qt+Gt

453027

M2

J3

M2

453027

5946973

Force diagram on the car frame in case 3

The equilibrium equations:

Qt Gt . A2 M 1. A

M .H M .H

1 2
16 EJ1

2 EJ1

3EJ 2

6 EJ 2

(Gt Qt ). A2 M 2 . A M 2 .H M 1.H

16 EJ 3
2 EJ 3 3 EJ 2 6 EJ 2

For Qt =10000N, Gt=10000N, J1 =20142500 mm4, J2 =972617 mm4, J3 =56087500

mm4, A=1280 mm, H=3000 mm.We have: M1= 987138 Nmm, M2 =-453027 Nmm
2.4 Strength examining:
Upper beam: only bending moment
The maximum stress in the beam:

M max

Wx

Taking data from case 3 for examination, we have:

Permissible stress :
Where:

ch

M max 7387138

33N / mm 2
Wx
223805

ch
n

- yield strength

ch

=240N/mm2

n- factor of safety n =23

Since :

ch 240

80 N / mm 2
n
3

, the upper beam satisfies the requirement.

Uprights(vertical bars): both stress and bending moment

Qt Gt M

2F
Wx

Taking data from case 3 for examination

Maximum and minimum stress inside the bars:
max

Qt Gt M max 20000 987138

65 N / mm 2
k
2F
Wx
2.1550 16769

min

Qt Gt M max 20000 987138

29 N / mm 2
n
2F
Wx
2.1550 44210

Permissible stress :
Where:

ch

ch
n

- yield strength

ch

=240N/mm2

n- factor of safety n =23

ch 240

80 N / mm 2
n
3

Slenderness of the uprights:

.l
imin

Where: - coefficient of connection between two ends = 0,5

l- length of the uprights l=3000mm
imin

imin- minimum radius of gyration

Then

J min
972617

25mm
F
2.775

0,5.3000
60 120
25

We also have:

max , min

, the uprights satisfy the requirements

Lower beam: bending moment and torque. Bending moment caused by P, G t, Qt,
torque caused by Qt placed eccentric by a distance C1 ( C1 =B/6 =1400/6 =233mm)
Taking data from case 2, the car assemble with the safety gear.
Mtorque =8223.223 =1833729 Nmm

Shear stress:
With

M xoan 1833729

3, 7 N / mm2
2.t. 2.5.49025

-area enclosed by the middle lines of the cross section.

265.185 49025mm 2

M max 4175641

7, 6 N / mm 2
W
568018

Stress caused by the bending moment :

Then :

td 2 4. 2 10, 6 N / mm2 60 N / mm 2

The lower beam satisfies the requirements.

B COUNTERWEIGHT:
To reduce the power requirement of the motor and the load applied on the elevator
machine, as well as maintaining the friction between the ropes and the sheave, we have to
use the counterweight. The counterweight and the car are connected to the same ropes.
The weight of the counterweight is determined by the following formula:
Gdt Gcab Q

Where: Q:maximum load

Gcab: weight of the car
: coefficient taking account of the percentage of the rated load balanced
by the counterweight.
If the weight of the counterweight equals the weight of car combined with the load,
the motor only has to overcome the friction force and inertia force to raise or to
lower the car. But when there is no load, the motor will have to overcome a
resistance force which equals the load Q. Therefore, we have to choose the
counterweight with coefficient which can satisfies that the force needed to raise a
car with maximum load equals the force needed to lower a car with no load.
The maximum static moment applied on the diverting pulley when raising the car
with full load from the lowest floor:
M tg (Q Gcb Gcapcb Gdt )

D
D
Q( ) Gcapcb
2
2

Gcapcb

: weight of the ropes suspense the car

: coefficient of lifting power utilizing of elevator

D: diameter of the diverting pulley

When lower the car from the highest floor with no load:
M 'tg (Gdt Gcapdt Gcabin )

D
D
(Q Gcapdt )
2
2
M tg

This moment has the opposite sign to

Gcapdt

In this formula

: weight of the ropes suspense the counterweight

M tg

Equalizing

and

M ' tg

we have:

The balancing coefficient is often taken as =0,5 corresponds to =1.

Then the weight of the counterweight is:
Gdt

500 0,5 500 750Kg

2.1 General design:

A counterweight normally consists of a frame and counterweight plates. The frame
is made of U steel, joined by bolts. Similar to the car, counterweight also has
guiding shoes to guide it sliding follow the guide rails.
The counterweight plates are made of concrete with the mass 30kg each.
2.2 Number of counterweight plates:
The approximate weight of the frame is 90 kg
The number of plates is : n = (750-90)/30 = 22 (plates)
The dimensions of the plates is showed in the following picture.

130

70
70

830

Counterweight plate

Chapter 3: Elevator machine

Elevator has two kind of traction drive:
- Without gearbox: traction sheave are fixed directly to the shaft of the
motor
- With gearbox: auxiliary transmission mechanism between the motor and
the sheave or drum.

Diagram of elevator machine with gearbox and sheave

Elevator machine consists of motor 1, brake 2, worm gear box 5 and traction sheave
3. All components are attached to the steel frame 4.
To reduce the noise during operating time of the elevator, the gearbox should use
the worm gear transmission. Worm gear transmission has the advantage of high gear
ratio, small size and self braking.
Worm gear box can use the cylindrical worm or globoidal worm. Globoidal worm
gear are widely used for elevator machines thanks to its smaller dimensions in
comparison to the cylindrical type with the same power rating.
The worm gear box can be manufactured with the worm placed above or below the
worm gear. Traction sheave is attached directly to the worm. The wear of the traction
sheave is usually high, therefore the sheave collar should be easily disassembled for
replacement. The shaft of the worm is placed on the bearing. At an end of the worm
which is opposite to the motor, a hand crank is attached so that we can control the
machine manually. It is also removable.

The worm gear boxes are now manufactured according to the standard. We only
have to select the suitable one based on the torque and the gear ratio.
3.1 Specification and selection of elevator ropes:
Elevator ropes always bear the load during the operation of the elevator, changing
state between straight and curving over the traction sheave. Two important factors that
can affect the strength of the ropes is the maximum tension and curvature radius. To
calculate and select the rope, we have the following formula:
Smax .k Sd

Where:
Smax- maximum stretch (tension)
k- factor of safety, take k=10.

Sd

-tensile strength of the ropes

The maximum stretch Smax can be calculated by the following formula:

S max

Gcab Q Gcap
a.i

Where:
Q- rated load Q=500 Kg
Gcar mass of the car, Gcar= 500 Kg
Gcab- mass of the rope when the car is at the lowest floor
i-. Number of ropes i=35, take i=3
a- scale factor, a=1
According to ISO 4344, we choose the round-strand equal lay 6x19 (9/9/1) rope. The
construction 6x19 (9/9/1) means 6 strands, 19 wires in each strand, namely 9 wires in the
outer layer, 9 inner wires and 1 central wire (king wire) in the strand. The same number
of both the outer and inner wires is typical for the Seale construction. The outer wires are

of larger diameter, which results in larger contact area and lower unit pressure between
the wires of both layers and, as a consequence, a considerable improvement in rope life is
achieved in comparison with ropes of normal construction used earlier such as 6x19
(12/6/1).

Cross-sectional view of the rope

The specification:

b 1600 N / mm 2

, dc= 10 mm,

Sd

=49,5 KN

The mass of the rope: Gcab = 14,5.0,352.3=15.3 kg

S max

Then:

5000 5000 153

3384 N
3

Smax .k 3384.10 33840 N 33,84 KN Sd 49,5 KN

The rope satisfies the strength requirement.

3.2 Specification and selection of traction sheave and diverting pulley:
3.2.1 Traction sheave:
The minimum diameter of the traction sheave is determined by the following formula:
D d.e
d- diameter of the rope
e- coefficient depends on the kind of elevator and rated speed, take e=40
Then: D 40.10=400 mm

3.2.2 Diverting pulley:

Diameter of the diverting pulley can be about 70% of the traction sheave: Ddp=0,7.D
3.2.3 Sheave groove:
To prevent the ropes from slipping on the traction sheave, the sheave must have groove
which results in increasing friction between the sheave and the ropes.
The sheave groove might has one of the following profiles:
-

Channel shape (semi-circle):

Semi-circular shape
This kind of shape has a good advantage in prevent the rope from wearing.
However, because of the small coefficient of friction, it is mostly used for the
sheaves with large contacting angle, for instance: elevator machine without the
gearbox.
-

Semi-circular shape with slot:

Semi-circular shape with slot

The sharp edges of the slot may affect the strength and durability of the ropes
-

Wedge shape:

Wedge shape
This kind of shape is most commonly used. For this profile, the angle of the
undercutting of the groove is

0 300 400

The coefficient of friction between the ropes and the sheave without the groove is:
0 = 0,12
The coefficient of friction between the ropes and the sheave without the groove is:

0
0,12

0, 35

40
sin
sin
2
2

The sheave groove has the following dimensions:

400

1
0

14

10

Sheave groove
3.3 Examining the contacting condition between the ropes and the sheave:
Cases for examining:
-

Operating under rated load

Operating under sample load
Operating with no load

3.3.1Operation under rated load:

The coefficient taking account of the percentage of the rated load balanced by the counter
0.5

weight
The car is pulled up from the first floor. Without the compensating cable, the maximum
tension S1 in the travelling cable connected to the car at starting time is:
a
S1 (Q Gcab Gc )(1 ) W
g
Tension S2 of the cable connected to the counterweight:

S 2 Gdt (1

a
a
) (Q G )(1 )
g
g

Where:
Q rated load
Gcar, Gc, Gdt mass of the car, rope and counterweight
W resistance forces
a starting acceleration
coefficient taking account of the rated load balanced by the counterweight

The resistance forces:

W (Wdh W pl ).1,1

The friction forces at the guide rails:

Wdh Q..

A B
3h

Where: A width of the car A=1220mm

B length of the car B=1400mm
h vertical distance between the centers of the guiding shoes
h=3100mm
- coefficient of friction between the guiding shoes and the guiding
rails, with the guiding shoes made of steel = 0,12.
Then:

Wdh 5000.0,12.

1220 1400
170 N
3.3100

The friction forces at the sheave and pulley:

W pl .S .sin

Where: buckling factor, =0,02

angle of wrap of the traction sheave =150
S3

S3

S1
S2
Fqt2 S2
S1
Gt
Fqt1 Q+Gcab+Gc

S total stretch of the cable wrap over the diverting

pulley

Force diagram when operating with rated load

S2 = Gdt =7500 N ,

*
S3
e
S2

Where: - coefficient of friction between the cable and diverting pulley,

=0,12
angle of the undercutting of the pulley groove

sin

0,12
0,35
40
sin
2

Then:
*

S3 S 2 .e . 7500.e 0,35.0,78 9850 N

W pl .( S2 S3 ).sin

450
0, 02.(7500 9850).sin
133 N
2
2

The total resistance force:

W (170 133).1,1 333, 3 N

Then:

S1 (5000 5000 153)(1

S2 7500.(1

1,5
) 333 12040 N
9,81

1, 5
) 8650 N
9,81

To prevent the rope from slipping on the sheave, the following condition must
be satisfied:
*
S1
e .
S2

Where: angle of wrap of the traction sheave (rad), =150 (2,26rad)

* - coefficient of friction between the ropes and the traction sheave with =
40
Then:

sin

0,12
0,35
40
sin
2

We have:
*

e e 0,352,62 2,5
S1 12040

1,39
S 2 8650

S1
e 0
S2
Therefore the angle of undercutting of the groove = 40 can prevent the
ropes from slipping on the sheave groove.
3.3.2 Operating under the sample load:

S1 Q.kqt Gcab Gcap 5000.1,15 5000 153 10903 N

S1 Gdt 7500 N
*

e e0,352,62 2,5
S1 10903

1, 45
S 2 7500

S1
e 0
S2
Therefore the angle of undercutting of the groove = 40 can prevent the
ropes from slipping on the sheave groove.

3.3.3 Operating with no load:

The counterweight is pulled up from the lowest floor.

S3
S1
Fqt S1

Gcab

S3
S2

S2

Fqt2
Gt+Gcap

Force diagram when operating with no load.

a
S1 Gcab (1 )
g
a
S 2 (Gdt Gcap )(1 ) W
g

Resistance force:
W (Wdh W pl ).1,1

Wdh Q..

A B
3h

W pl .S .sin

Then

=0

=133N

W (0 133).1,1 146,3 N

S1 5000(1

1,5
) 5760 N
9,81

S 2 (7500 153).(1

We have:

1,5
) 146,3 8970 N
9,81

e e 0,352,62 2,5

S 2 8970

1,56
S1 5760
*
S2
e
S1

The angle of undercutting of the groove = 40 can prevent the ropes from
slipping on the sheave groove.
3.4 Specification and selection of motor:
3.4.1 Requirements for the motor of the elevator:

Based the speed of the elevator, we choose the motor with one speed or
multi speed.
Guarantee that the elevator stop at the exact position according to technical
specification.
Initial acceleration is not too high ( a < 1,5m/s2)
Motor is suitable for repeatedly short term working, reversible
Simple structure, light, sufficient power rating.
Dimensions does not depend on the height of lifting

We choose the elevator machine with traction sheave, placing on top of the
building, satisfies all the features above.
3.4.2 Power of the motor:
Applying the formula:

P.v
1000.td p

Where:
P load on the traction sheave (N)
v speed of the car, v = 0,63m/s
td efficiency of the machine. = 0,6 0,8 for worm gear box, take td = 0,65.
p efficiency of the sheave, p = 0,96 0,98. take p = 0,96
We calculate the power of the motor in case that the load on the sheave is largest:
Pmax = Q + Gcar + Gcablecar + W Gdt
= 5000 + 5000 + 153 + 333,3 7500 = 2986,3 N

2986,3.0, 63
3kW
1000.0, 65.0,96

Power of the motor:

3.4.3 Elevator machine:

Based on the calculated power and the rated speed, we choose the elevator machine
TW63 of Thyssen Aufzugswerke Elevator Gmbh, with the following parameters:

TW63 Machine
-

Traction sheave: Diameter D=450mm

Width b=96mm
The sheave groove has the wedge shape profile with angle of undercutting 0=40
and rope diameter d=10mm

Profile of the sheave groove

Diverting pulley: Diameter: Ddp = 0,7.450 = 360mm; the other parameters are
similar to the traction sheave
Brake:
Type: 2 clamp, normal closed
Maximum braking moment: 2*90Nmm
Brake disk: 200mm
Clamping force: 2*2500N

Motor: From the catalogue of Thyssen Aufzugswerke Elevator Gmbh, we choose

the motor with the following parameters:
Power: 4,5kW
R.p.m: 1360
Mass: 37,35kg
Working moment: 31Nm
Initial moment: 78Nm
Gearbox:
Type: worm gear
Gear ratio: 48:1
Shaft length: 155mm
Mass of the machine: 370Kg
Efficiency: 0,65 0,76

Required r.p.m of the sheave:

n pl

v
0, 63.60

27r / m
.D pl .0, 45

Roping factor:
i

ndc 1360

50, 4
n pl
27

For the selected machine ic = 48, then:

i ic
50, 4 48
.100%
.100% 4, 7%
i
50, 4

Since i < 5%, the selected machine satisfies the requirement.