Aacess Equipments

Project : Design Calculations for 35 ton Gantry Crane

PART – B - MECHANICAL DESIGN

1. Hoist Motor Selection

KW = Load x Speed x Cdf x Cv

6.12 E x Cmb.
Total Load = Cap. of EOT + Bot Blc Wt. + Wire rope weight
35000 + 600 +400 Kg = 36000  36 Tons
Hoisting Speed V = 2.5 mtrs. / min.
Duty factor for Cl – II Cdf = 1.5
Deration factor for 50 deg C temp Camb = 0.88
Service factor for AC motors Cv = 0.67
Combined Eff of gears and sheaves E = (0.95) n x (0.99) m
n = no. of pairs of gears, m = no. of rotating sheaves E = (0.95) 3 x (0.99) 6 = 0.80
n = 3 – three stage gear box, m = 6 – for 8 falls

KW = 37 x 2.5 x 1.5 x 0.67

6.12 x 0.80 x 0.88

= 21.57 / 0.746 = 28.92 Hp

Therefore Selecting 30 HP / 925 rpm Motor.

2. Hoist Gear Box

Speed of hoisting = 3 Mtrs./min

Pitch Circle Dia of Rope Drum = 414.8 mm

No. of Falls = 8

Motor Speed = 925 RPM

Gear Ratio Required = ?

Speed of Drum = 2.5 x 1000 x No. of falls
 x 414.8 2
= 1.91 RPM x 8/2 = 7.64 RPM

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Gear Ratio = Motor RPM

Drum RPM
= 925/7.64 = 121.07

Select a Gear Box with GRR- 121 and 30 Hp/ 925 rpm input HP

3. Design of Hoist Coupling & Brake

Motor used - 30 HP / 925 RPM

Torque at Motor = 30 x 4500 = 23.23 Kg m.

2 x 925

Braking Torque = 23.23 x 1.5 = 34.845 kg m

For the above Torque Even though Rx101 Coupling having Torque cap of 100 Kg-M is
Suitable but Motor Shaft is not Matching with the bore we are Selecting R x 102
Coupling with torque transmitting cap of 250 kg.m. for input.

4. Hoist Brake

As the torque is 34.845 Kg – m, choose EHT brake 250-18 Kgs with torque transmitting
cap. of 35 Kg.m.

5. Selection of Motor for Cross Travel

KW = MVS Cdf x ( F + 1100a )

6117 T 981 N

Rated load + Self Wt. of crab ie. M = 37.5 tons

Speed of CT wheel V = 15 mts. / min.
Service Factor for AC motor S = 1.06
Duty Factor for Cl – II crane Cdf = 1.25
Overall Friction Factor for anti friction bearings F = 8 kgf
Factor based on motor pullout torque T = 1.7
Mech. Eff of gears N = 0.95
Ave. Linear Acceleration based on CT speed of 15 M/min a = 8

 KW = 37.5 x 15 x 1.06 x1.25 x (8 + 1100 x 8 )

6117 x 1.7 981 x 0.95
= 1.25 KW/0.746 = 1.676 HP

Therefore Selecting 3 HP / 925 rpm Motor

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6. Design of CT Gear Box

Motor Selected = 3 HP/925rpm

CT Speed = 15 mts./min.

Core dia of CT wheel =  310mm

RPM of wheel = 15x1000 = 15.4 r.p.m

Πx310

Gear Ratio = 925 i.e. Motor Speed = 60

15.4 Wheel Speed

Choose a gear box with 3HP/925 input and 60 GRR which is the standard.

7. Design of CT input & output coupling with Brake

Cap. of CT Motor = 3HP/925 rpm

HP = 2 Π N T/4500

Torque developed by CT Motor

= 3x4500 = 2.32 Kg.m

2Πx925

Braking Torque = 2.32 x 1.25 = 2.9 Kg.m

Final Torque = 2.9 x 60 = 174 Kg.m

Choose 101 coupling with torque cap. of 100 kg.m R x 101 for input and R x 102 with
torque cap. of 250 Kg.m for output.

Choose EHT Brake 150 – 18 Kgs with torque cap. of 9 kg.m for CT Brake.

8. Selection of Motor for Long Travel:

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KW = MVS Cdf x ( F + 1100a )

6117 T 981 N

(Rated load + Self Wt. of crane )/ 2 ie. M = (35 + 65) / 2 = 50 t

Speed of LT wheel V = 20 mts. / min.
Service Factor for AC motor S = 1.06
Duty Factor for Cl – II crane Cdf = 1.25
Overall Friction Factor for anti friction bearings F = 8 kgf
Factor based on motor pullout torque T = 1.7
Mech. Eff of gears N = 0.95
Ave. Linear Acceleration based on LT speed of 20 M/min a = 10

 KW = 50 x 20 x 1.06 x1.25 x (8 + 1100 x 10 )

6117 x 1.7 981 x 0.95

= 2.52 KW/0.746 or = 3.379 HP

Therefore Selecting 10 HP / 925 rpm Motor

9. Design of LT Gear Box

Motor chosen = 10 HP / 925 RPM

LT Speed Required = 20 mts. / min.

Core dia of LT Wheel = 520 mm

The below Value 3.16 is the ratio of Wheel and Pinion

Required RPM of wheel = 20 x 1000 x 3.16

 x 520

= 38.70 RPM

Gear Ratio of GB = 925 = 23.89 = 24

38.70

Choose a gear box with 10 HP/925 Rpm input and 25 GRR which is standard.

10. Design of LT Drive coupling & Brake .

Cap. Of LT Motor = 10 HP / 925 RPM

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Torque at input = 10 x 4500 = 7.74 Kg.m

2 x 925

Braking Torque = 7.74 x 1.25 = 9.675 Kg.m

Final Torque = 9.675 x 25 = 241.87 Kg.m

Choose 102 coupling with torque cap. of 250 kg.m for input and R x 102 with torque
cap. of 250 Kg.m for output.

Choose EHT Brake 150 – 18 Kgs with torque cap. of 9 kg.m for LT Brake.