UNIT 4.

15 PNEUMATIC HOISTS (2)

Contents

1. Pressure

1.1 Atmospheric pressure

1.2 Working pressure

1.3 Air supply

2. Air supply system

3. Overload protection

4. Limit stops

5. Ancillary equipment

Introduction

In conjunction with this unit, reference should be made to various air hoist
manufacturers’ operating and maintenance instructions.

In this unit we shall consider pneumatic pressure, air supply systems, overload
protection devices, limits and ancillary equipment used with pneumatic hoists.

Lifting machines using pneumatic pressure as the power source are found widely in
industry, although its utilisation is far less common than electricity. It uses a pressure
system, so before going further it is important to consider pressure in more detail.

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1. Pressure
Pressure is a measurement of the force acting on a surface per unit area at right
angles to the surface. If we consider a simple example of a drawing pin, it is easy
enough to push the pin into a piece of wood. The force used to push the pin acts
over the small area of the point of the pin. But if the pin is inverted it is impossible to
push it into the wood by applying the same force as this now acts through the larger
surface of the head onto the wood and the pressure produced is far less. So we can
see that the same force may act on a small point or on a large area, but its effects
will not be the same in each case. We can therefore say:

Pressure = Force / Area and therefore Force = Pressure x Area

Within the SI system the unit of force is the Newton (N) and area is measured in
square metres (m²) or square millimetres (mm²). Therefore we arrive at a unit of
pressure being N/m² or N/mm².

Example 1

Calculate the pressure on a surface 2m x 3m if the total force is evenly distributed

and equal to 1800N.
Area = 2 x 3 = 6 m2

Force 1800
Pressure = = = 300N/ m2
Area 6

Example 2

Calculate the total force on an area of 4m² when acted on by a pressure of 5N/m².

Force = Pressure x Area = 5 x 4 = 20N

1.1 Atmospheric Pressure

The atmosphere acts on the earth’s surface and everything on it, so that at each
point on the earth there is a certain pressure. This changes with the weather and the
height above sea level at which it is measured. Climatic changes are relatively small
and so we take the mean when measured at sea level and this is then known as
Atmospheric Pressure. It is measured with a Barometer and the slight changes in

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readings, which are used when predicting the weather, can be ignored when
considering pressure systems as it acts equally on all of the system. The mean
reading, i.e. Atmospheric Pressure, is equal to 101,300 N/m². It is taken into account
when discussing pneumatics and hydraulics as it is used as the base reading for
pressure measurement. But this is not a convenient figure, so ISO and CETOP (The
European Oil and Pneumatic Committee) both recommend that the BAR is used as
the practical unit for pressure measurement in pneumatic and hydraulic systems.

Now: 1bar = 100,000N/m² = 0.1N/mm²

and Atmospheric Pressure = 101,300N/m²

∴ Atmospheric pressure = 1.013 bar (14.7 lbs/sq. inch)

For practical purposes we can therefore consider that Atmospheric Pressure = 1

bar.

To complicate matters, a much smaller base unit is used for scientific purposes and
may be found in some publications and specifications. This is known as the Pascal
(Pa) and is equal to 1N/m².

So: 1Pa = 1N/m², hence 1 bar = 100,000Pa

1.2 Working Pressure

As already outlined, we can say that Atmospheric Pressure is equal to 1 bar and this
acts all over the earth’s surface and upon everything on the earth’s surface. If we
then consider a simple pressure vessel, when it is empty and no force is applied we
can see that it is in fact being subjected to Atmospheric Pressure. If we create a
Vacuum in the vessel, the internal pressure will be zero. When discussing pressure
systems we can then denote pressure in one of two ways:

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(a) ABSOLUTE PRESSURE - where the pressure is compared to a vacuum and
measured from zero

OR

(b) GAUGE PRESSURE - where the pressure is compared to Atmospheric

pressure: i.e. the gauge is zero at Atmospheric pressure and reads only
applied pressure.

We can therefore say that Absolute Pressure = Gauge Pressure + Atmospheric

Pressure. In practice it is gauge pressure that we usually read and it is this that is of
prime importance to us. This is often referred to as the Working Pressure or the
Working Gauge Pressure.

1.3 Air supply

For any hoist to work efficiently it must receive an adequate supply of clean, dry air.
The supply must be maintained at the required pressure and delivery rate.

Normal factory air supply pressure is 5.5 to 6 bar (80 to 90 lbs/sq. inch) and
pneumatic hoists are generally made to operate in this range.

2. Air Supply System

Let us now consider air supply systems. Figure 1 shows one system of providing the
hoist with an adequate air supply whilst allowing limited free movement of the
hoist/trolley unit. In this case a plastic covered support cable is pulled taut along the
length of the beam. The tension is maintained by a spring loaded tensioning screw.

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 Figure 1
Air supply system to a pneumatic hoist mounted on a runway beam

The preformed spiral PVC hose rests on the wire as shown (Figure 1). It extends and
retracts like a spring when the hoist is moved.

In this installation the air is filtered and regulated before entry to the spiral hose and
finally lubricated prior to entry into the hoist. This arrangement prevents the oil mist
forming droplets in the hose before entry into the hoist.

The above arrangement is only suitable for short straight runs of beam. Where
longer runs or curved track has to be negotiated a tracked hose festooned system is
required; even so, the length of coverage is more restricted than with electrical
supplies.

This is similar to the tracked cable as used in the electric feed system (Unit 4.6). The
hose is fitted to small trolleys at intervals along its length. These trolleys run on the
same track as the hoist trolley. The hose hangs down in loops at the start position
and as the hoist trolley moves so the hose trolleys follow and the hose is extended.

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Hose reeling drums are also available. Again these are similar to electric supply
systems.
As hoses are stiffer and heavier than electrical cables the gathered loops of hose,
when the hoist is at the end of the runway, occupy more space than cables. This is
one of the governing factors on their overall length. A further factor is that over long
runs air pressure is lost. In extreme cases this results in a loss of lifting capacity.
Delays in the arrival of the full pressure at the unit also lead to a delay in response to
control commands. As a result it is necessary to have several supply points along
the length of long runways. This means the hoist has to be disconnected and
reconnected at intervals throughout the travel if long travel distances are involved.

3. Overload protection

Pneumatic hoists, like electric hoists, can be protected against overloads and violent
control movements during lifting. Pneumatic hoists are by design able to withstand
the maximum lifting force they can deliver. However, in instances where loads being
lifted are of unknown weight and where the suspension device or load fasteners
must not be overstrained such an overload provides a useful safety factor.

Figure 2
Sectional view of a pneumatic hoist overload protection device
(Atlas Copco LLA)

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When the pull on the hoist exceeds a set value the air supply to the vane motor is
reduced, thereby decreasing the lifting capacity and preventing further hoisting. The
device shown in Figure 2 consists of two main parts, the hook valve and the overload
valve connected by a length of PVC tubing as shown. The hook valve is connected
via a banjo coupling which allows it to turn about the mounting.

The hook valve is fitted in place of the normal suspension hook and the overload
valve fits into a port of the main valve housing specially provided for the accessory.

The device is normally adjustable between the proof load (i.e. 1.25 x SWL/WLL) and
80% of the SWL/WLL.

In operation the hook is set to the required overload value by the adjusting nut
(Figure 2), which alters the compression in the cup springs. In the overload condition
the cup springs are depressed causing the valve cone to lift from its seat (Figure 2).
This vacates the space above the overload valve piston, causing it to rise and
release the valve attached to its stem.
Some of the inlet air to the vane motor is then released to flow into the silencer
chamber. The pressure to the vane motor is therefore reduced, decreasing the hoist
lifting capacity.

4. Limit stops
To prevent over hoisting or over lowering of the hoist chain the machines have some
form of limiting device. Normally the yoke (Figure 3) is actuated by the hook holder
for hoisting and the tightening of the chain loop at the free end when lowering (Figure
1). However, if adjustable control is required, limit stops may be fitted as shown in
Figure 3. These consist of a collar, which is fitted around the chain and held in place
by a pin. These stops can be fitted to either link or roller chain and can be placed
anywhere along the chain length.

In operation the collar actuates the yoke, which returns the control shaft to the ‘stop’
position.

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 Figure 3
Sectional view of a pneumatic hoist fitted with limit stops

5. Ancillary equipment

In addition to the previously mentioned equipment, pneumatic hoists can also be

fitted with air-powered trolleys for movement of heavy loads and greater control. A
vane motor, pendant controlled and fitted with a brake, normally powers the trolley.

The hoists can also be fitted with piped exhausts where the exhaust air is taken to a
remote area before discharge. This is necessary in food processing and some
chemical works where atmospheric purity is of great importance or the danger of
dust being blown about exists.

Chain bags are another accessory, which is useful when working in confined spaces
over complex machinery.

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