UNIT 4.

9 LIMIT SWITCHES AND DEVICES

Contents

1. Slipping clutch

2. Oversize link type limit switch

3. Limit bar operated by rope band or guide

4. Weighted lever

5. Worm and wheel type limit switch

6. Geared limit switch – rotary

7. Control and power circuit limit switches

7.1 Power limit switches

7.2 Control limit switch

7.3 Ultimate limit switch

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Introduction

In this unit we will consider the main types of device used to limit the travel of the
chain or wire when hoisting and/or lowering with power hoists. The device may be
mechanical, electrical or electro-mechanical. The devices are necessary to prevent
the hoist motor from becoming overloaded and to protect the accessories from
excessive stress.

BS 466 requires that wire rope hoists are fitted with an upper (hoisting) limit. In
practice it will be found that modern hoists, both chain and wire rope, are fitted with
some type of limit device to prevent the over travel in both the hoist and lower
modes. Older units may only be fitted with an upper limit and special care is needed
when operating these to prevent over lowering which can result in a reversal of
control sense and the non-operation of the hoisting limit.

The main types of limiting device are:

1. Slipping Clutch
2. Oversize Link Type
3. Limit Bar Type
4. Weighted Lever
5. Worm and Wheel Type
6. Geared Limit - rotary

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1. Slipping Clutch

. Slipping Clutch

Figure 1a
Section through a Demag chain block showing slipping clutch

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Figure 1a shows a slipping clutch fitted to a Demag electric chain hoist. The clutch
operates in conjunction with a stop on the chain and the hook shackle or bottom
block. It limits chain travel and at the same time protects the block from excessive
overloading and incorrect chain feed due to chain elongation, twisting etc.

The slipping clutch is not designed for continuous duty. Where frequent use of chain
travel limits is essential (e.g. to position the hook on a production line), additional
externally fitted limit switches should be employed. The clutches are normally factory
set and require only minimum adjustment. They should be tested at least monthly
with a 125% test load, checking that the hoist is capable of lifting this load without
slip.

The clutch is situated between the motor and the gearbox and normally consists of
two discs each positively fixed to one side of the transmission system. At the
interface a friction lining is bonded to one disc and they are held together under
spring pressure.

Figure 1b
Typical slipping clutch assembly

Depending on usage the clutch will need adjusting. This is usually achieved by
tightening a spring and checking that the test load can be raised. NB It is important
that the hoist manufacturer’s instructions are followed as they differ from model to
model.

If a hoist fails to lift its SWL in service then the clutch (if fitted) must be considered a
possible cause.

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2. Oversize link type limit switch

Figure 2
Combined automatic load chain guard and limit switches
(King Mytemin and Marvex Hoists)

Figure 2 shows one type of oversize link limit switch as fitted on older models of King
Hoists. Many other designs are available. The device shown not only operates the
upper and lower limits of travel but also protects against mishandling of the load
chain through twisting or excessive angular lifting. It also safeguards against damage
resulting from incorrect seating of the load chain in the sprocket through persistent
overloading or insufficient lubrication of the chain.

The device comprises two independent spring-loaded guards (A), arranged on the
load and slack side of the sprocket and pivoted at (B) in such a manner as to be
deflected by trips fitted on the chain. The deflection of either guard results in the
operation of a limit micro switch (C) which breaks the control circuit, thus
de-energising the contactor which stops the hoist motor and applies the brake. In the
event of this happening the mechanism may be automatically reset, by operating the
block in the direction opposite to that in which the chain was moving when the guard
was tripped.

The limits are in the form of small pressed or cast trips which are attached in pairs to
the chain links. Alternatively they may comprise an oversize link.

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The whole mechanism is robust and needs little attention during service. However,
provision is made however for adjustment to the limit switch operating position. This
is achieved on the King hoists by set screws and locking nuts (D). These can be
adjusted to limit the travel of the guards and the point of operation of the micro
switch.

When checking the operation of these electrical limits, the examiner should listen for
a distinct ‘click’ which is a good indication that the micro switch is in order.

3. Limit bar operated by rope band or guide

Figure 3 shows a typical limit bar operated limit switch arrangement. This design is
common with electric wire rope hoists for control of upper and lower hook positions.
The mechanism comprises a bar (A) spring loaded into the neutral position. The bar
carries two stops (B) which are actuated by the rope guide (C) as it moves along the
drum and reaches the upper or lower limits of travel. Two micro switches with roller
followers are situated at the end (D). When the bar is moved by the guide contacting
a stop, one micro switch is depressed, stopping the motor and applying the brake.
The mechanism is reset by operating the block in the opposite direction. On most
blocks the micro switches are easily accessible for maintenance and adjustment.

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 C

Figure 3
Electric hoist with limit bar operated by rope band
(Morris Hoist)

4. Weighted lever
Figure 4 shows an exploded view of a typical weighted lever operated hoist limit
switch used on an electric wire rope hoist. This type of hoist limit is also used
extensively on electric chain hoists.

In operation the knock off weight assembly (A) is suspended from lever arm (B) and
is raised by the bottom block of the hoist which in turn rotates the shaft (C) and cam
(E). The rotation of the cam opens the limit switch (D), the hoist contactor drops out,
the motor is de-energised and the hoist brake applied.

The mechanism is reset automatically by reversing the direction of the hoist.

The mechanism is situated beneath the hoist and is readily accessible for
maintenance and adjustment. However, being external it is liable to damage if the
hoist is incorrectly used.

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 Figure 4

5. Worm and wheel limit switch

The worm and wheel limit switch was used on early models of power hoists. It is not
very common today but is still worthy of mention.

The device consists of a worm and wheel reduction unit driven from the drum shaft.

When the hoist reaches either its upper or lower limit of travel adjustable stops would
be set on the wheel plate opening spring closed copper contacts.

This type of limit switch was normally of the series type thus requiring some form of
manual reset once operated.

6. Geared limit switch – rotary

It is fairly common practice to fit rotary limit switches to modern hoist units. This type
of limit switch is usually driven by gearing from the hoist gearbox and is set up to
recognise where the hook block is in relation to the upper and lower limits of travel

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required. These limits may also incorporate slow-down limits for maximum lift
approach and also for phase sequence supervision. This prevents the bottom hook
from travelling into the hoist body at its uppermost travel. This could happen if the
power phases to the hoist motor were accidentally reversed during installation.

Drive gear to rotary limit

from the hoist drum

Figure 5a
Konecranes hoist gearbox showing rotary hoist limit

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 Figure 5a
CM Loadstar rotary limit switch

Figure 5b
Typical chain hoist rotary limit switch arrangement

7. Control and power circuit limit switches

7.1 Power limit switches

This type of limit switch is connected in series with the main 3 phase power supply to
the hoist motor. The power limit breaks either two or all three of the phases (usually
all 3).
It is often assumed that the power limit switch is an ultimate limit switch, but many
power limit switches are still found in older hoist units acting as the only limit fitted to
control hoisting motion.

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7.2 Control limit switch

This type of limit is connected in series with the contactor coil of the hoist, lower or
mains contactor. When activated it breaks control voltage supply to the relevant
contactor.

7.3 Ultimate limit switch

The ultimate limit switch acts as a safeguard in the event of the normal hoist service
limit switch failing.
It can be connected either as a power or control type limit switch. In both cases, the
limit switch should be latched open until it is manually reset after the failure has been
investigated and rectified.

Power

Control

Figure 6
Circuit diagram showing control and power limit switches

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