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Mini Project 1 Report E1
Mini Project 1 Report E1
Mini Project 1 Report E1
Team
إسراء محمد خليل توفيق 1 9220140
جورج نبيل جرجس ابراهيم 2 9220232
حسن مجدي حسن 2 9213155 Team Leader
عبدهللا جمال عبدالرحيم تمر 3 9210604
مريم امين محمد زكي 5 9220817 George Nabil Gerges
مريم عمرو السيد علي 5 9220826
منة هللا محمد عبد العليم 5 9211236
1
Table of Content
Table of Content
Table of Contents
Team .......................................................................................................................................... 1
Table of Content ........................................................................................................................ 2
1. Introduction ....................................................................................................................... 4
2. Design Assumptions ........................................................................................................... 5
2.1. Material ....................................................................................................................... 5
2.2. Motor .......................................................................................................................... 7
Recourses ......................................................................................................................... 12
3. Force analysis ................................................................................................................... 13
3.1. Force Analysis for the Wire Rope Drum .................................................................... 13
.3.2 Force Analysis for the Drum Shaft ............................................................................ 15
4. Shaft design...................................................................................................................... 18
4.1. Preliminary design ..................................................................................................... 18
4.2. Detailed design .......................................................................................................... 18
4.3. Key design ................................................................................................................. 19
4.4. Stress concentration in keyway ................................................................................ 19
Preliminary design ........................................................................................................... 20
Detailed design ................................................................................................................ 20
5. Wire Rope Drum Design .................................................................................................. 21
5.1. Wire Rope Drum Calculations ................................................................................... 21
5.2. Pulley and Hook (Snatch block) Selection ................................................................. 22
6. Shaft Elements Design ..................................................................................................... 24
6.1. Bearing Design ........................................................................................................... 24
6.1.1. Bearings Calculations ......................................................................................... 25
6.2. Bearings Fitting Method Calculations ....................................................................... 28
6.2.1. Preparation ........................................................................................................ 28
6.2.2. Force necessary to press fit or remove bearings ............................................... 28
.6.3 Drum Fixation ............................................................................................................ 31
6.3.1. Specifications ..................................................................................................... 31
6.3.2. Installation ......................................................................................................... 31
2
Table of Content
3
Introduction
1. Introduction
A hoist is an essential mechanical tool that is widely used in industrial settings to
efficiently and precisely lift or lower heavy goods. Hoists are devices that enable the vertical
or horizontal transportation of weights in warehouses, factories, building sites, and other
industrial locations. They work by wrapping a rope or chain around a drum or lift-wheel.
A hoist's primary goal is to expedite material handling procedures by making it easier
to transfer large, dangerous, or awkward objects that would be dangerous to move by hand.
Hoists provide adaptability in lifting activities by utilizing many power options, including
electric, manual, or pneumatic systems. This allows them to accommodate a wide range of
weight capacities and operational requirements.
Hoists are essential for improving efficiency, safety, and production in industrial
settings. They minimize manual labor, speed material handling operations, and lower the
risk of workplace hazards related to physical lifting. Additionally, hoists help the
manufacturing, shipping, and construction industries maximize operational throughput,
guarantee timely delivery of items, and optimize workflow operations.
The hoist mechanism is an essential part of contemporary industrial operations, and
it is always evolving to meet the increasing needs of material handling jobs and industrial
output. It incorporates cutting-edge technologies and engineering breakthroughs. The work
here will outline our process for creating a functional hoist using our design at a reasonable
cost through iteration and scratch design.
4
Design Assumptions
2. Design Assumptions
2.1. Material
1. Shaft iteration material:
1.1. Steel, stainless AISI 302 1/4 hard
Sy =517 MPA
Sult = 860 MPA
E= 180 GPA
F.S=2.5
Keyway shaft F.S = 1.3
This material is commonly used in manufacturing for several reasons:
Overall, the use of steel, stainless AISI 302 1/4 hard in manufacturing offers a
combination of strength, corrosion resistance, versatility, and cost-effectiveness,
making it a preferred choice for a wide range of industrial applications.
5
Design Assumptions
2. Drum :
2.1. Steel 1020 G10200 CD
Sy =390 MPA
Sult = 470 MPA
F.S=2
3. Key
3.1. Steel 1020 G10200 HR
Sy =210 MPA
Sult = 380 MPA
S.F=1.2
Keyway height = 4mm
Keyway fillet=1.5mm
Commonly used in manufacturing for several reasons:
Versatility: Research indicates the use of carbon steel, including AISI 1020
(UNS G10200), in manufacturing due to its versatility and wide range of
applications across different industries.
Strength and Hardness: While research papers may not directly specify
Steel 1020 G10200 HR, carbon steels in general gain hardness and strength
with heat treatment, making them suitable for manufacturing applications
where these properties are required.
Machinability: HR steel, including AISI 1020, exhibits good machinability,
enabling ease of machining processes such as drilling, turning, milling, and
tapping, which are essential in manufacturing.
These factors collectively contribute to the widespread use of Steel 1020 G10200 HR
in manufacturing processes.
In this arrangement, the key functions as a mechanical fuse; if the load is too great, it will
fail before the shaft or drum.
NOTE: Since the shaft and drum are the most vital parts of the mechanism, we can alter the
safety factor to make the shaft and drum the most secure parts of the mechanism.
6
Design Assumptions
2.2. Motor
2.2.1. Electric Motor IP41 308W Brake Power (first iteration)
Warranty: 6 Months
7
Design Assumptions
The IP41 308W motor typically does not require a gearbox. It is commonly
used as a gearless motor in elevator systems, where it provides sufficient power to lift
loads ranging from 630kg to 1000kg. Gearless motors are designed to directly drive
the elevator traction sheave without the need for a gearbox, resulting in a simpler
and more efficient system. Therefore, in most elevator applications, the IP41 308W
motor operates effectively without the use of a gearbox.
In our use we will control its torque with our torque (T=780N.m) to be safe in our design
It was too heavy in our mechanism so we search for another method
V series gear units are three stage, helical-geared hoist drum drive units. Input and
output center distances are as far apart as possible to allow the use of larger drums to
achieve longer rope service life. The V series gear units are designed for higher ISO/FEM
classes with longer gear face widths compared to other products of a similar size. The
housing material is GGG40 spheroid cast iron and gears are made of high-quality case-
8
Design Assumptions
hardened steel. The gearboxes have a solid output shaft with spline according to DIN 5480
and are produced to various dimensions. V series gear units are designed for double-and
single-speed brake motors. They are available in five different sizes with a load range from
0.5 to 50 tones.
In our use we will control its torque with our torque (T=780N.m) to be safe in our design
9
Design Assumptions
10
Design Assumptions
11
Design Assumptions
Recourses
https://sh-esunny.en.made-in-china.com/product/SNGJkPlDfKWF/China-Load-630-
1000kg-Gearless-Motor-for-Elevator-IP41-308W-Brake-Power.html
https://www.researchgate.net/publication/236347132_Deep_cryogenic_treatment_
of_AISI_302_stainless_steel_Part_II_-_Fatigue_and_corrosion
https://www.researchgate.net/publication/376683649_Microstructure_macro-
_and_nano-hardness_assessment_of_AISI_302_steel_aged_at_1000C
https://www.xometry.com/resources/materials/what-is-aluminum/
https://www.researchgate.net/publication/293653225_Aluminium_The_metal_of_c
hoice
https://www.azom.com/article.aspx?ArticleID=6114
https://www.researchgate.net/publication/370799981_Deposition_of_Ti-
Based_Thin_Films_on_AISI_1020_Steel_Substrates_Using_the_Cathodic_Cage_Plas
ma_Deposition_Technique
https://edisciplinas.usp.br/mod/resource/view.php?id=2271706
Motor specification :
https://medialibrary.dana-industrial.com/wp-content/uploads/DC3A1E1_0000000-
Catalogue-Brevini-Gearmotors-V-Series.pdf
https://onlinelibrary.wiley.com/doi/full/10.1111/gcb.16134
12
Force analysis
3. Force analysis
NOTE: other types of distributions were used in other similar projects, but this distribution is
still justified and valid for our application.
The other aspect of the solution is what is the position that applies the highest stress
on the system? To answer this question we used our experience in other projects, and also
utilized custom software tools developed by our team to get precise results. We found if the
load is acting at the middle of the length of the drum this give the most stress.
NOTE: this result still not the most accurate, as we made some simplifications on the
system. Please see the future work section for more details.
13
Force analysis
f1
fo
MB
MA
RA RB
Where:
W= 4978.575 N
0.2 𝑤 0.2 × 4978.575
𝑓0 = 0.375 = = 2655.24 𝑁
0.375
1.8 𝑤 1.8 ×4978.575
𝑓1 = 0.375 = = 23897.16 𝑁
0.375
As we have four unknown reaction, we will use integration method to find the unknowns RA,
RB, MA and MB
We have the following boundary conditions (at the middle point)
𝜃R = 𝜃L , VR =VL
We consider A and B to be fixed supports.
𝜃A = 𝜃B = 0 , VA = V B = 0
NTOE: We know in advance that all constants of integration will be equal to zero, as we
consider A and B to be fixed supports
Now, we should term four equations to solve for the unknowns.
EQ1: ∑ 𝑀A =0
1 (0.375)2
RB × 0.75 + MB = fo (0.375)2 × 2 + (f1-fo) × 3
EQ2: ∑ 𝐹 y= 0
RA + RB= w
Integration methods:
EQ3: ∫ 𝑀1 dx = -∫ 𝑀2 dx
EQ4: ∬ 𝑀1 dx dx =∬ 𝑀2 dx dx
Integration M1 and M2 are forming this equation:
14
Force analysis
𝑥3 𝑥2 𝑥4 (𝑓1 −𝑓𝑜 ) 𝑥 5 𝑥3 𝑥2
fo + MB = fo 24 + – RA - MA
6 2 0.375 120 6 2
C A B D
RC RD
We have:
4 boundary conditions
2 equilibrium equations
12 continuity equations (two at each point except the two ends)
Now, we defined the moment equation of each section of these seven sections so we can
proceed in solving the system:
m1 = 𝑀0𝐶 − 𝑅𝐶 𝑥, from x=0 to x=0.04
15
Force analysis
After forming all these equations and developing a software to solve this 16-equaion
system, we reached these final equations to be solved:
𝑐1 = 𝑐2 − 1.21
𝑐1 = 𝑐2 + 25𝑐8 − 25𝑐9 − 0.90749694
𝑐2 = 𝑐3 + 21.28963
𝑐10 = 0.055𝑐2 + 0.055𝑐3 − 𝑐9 − 0.58546
𝑐3 = 𝑐4 + 6.484821
𝑐10 = 𝑐11 + 0.07𝑐3 − 0.074𝑐4 + 0.3404531
𝑐4 = 𝑐5 − 6948.676
𝑐11 = 𝑐12 + 0.79𝑐4 − 0.79𝑐5 − 4117.09087
𝑐5 = 𝑐6 − 289.5601
𝑐12 = 𝑐13 + 0.805𝑐5 − 0.805𝑐6 − 116.547958
𝑐6 = 𝑐7 + 7770.7402
𝑐13 = 𝑐14 + 0.82𝑐6 − 0.82𝑐7 + 4779.0051
𝑀𝐶 − 3.33333 ⋅ 10−7 𝑅𝐶 + 2000000𝑐1 + 2𝑐8
𝑀𝐶 − 0.28667𝑅𝐶 + 2.704171𝑐14 + 2.325584𝑐7 − 553.92567
𝑀𝐶 − 5 ⋅ 10−7 𝑅𝐶 + 1000000𝑐1
𝑀𝐶 − 0.43𝑅𝐶 + 1.16279𝑐7 + 297.4669
𝑅𝐶 + 𝑅𝐷 − 5939.955
𝑀𝐶 − 𝑀𝐷 + 0.86𝑅𝐷 − 2256.7108
Solving this system gives:
𝑅𝐶 = 3381.2718 𝑁
𝑅𝐷 = 255806832 𝑁
𝑀𝐶 = 506.3993 𝑁. 𝑚
𝑀𝐷 = 56.24327 𝑁. 𝑚
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑚𝑜𝑚𝑒𝑛𝑡 = 506.4 𝑁. 𝑚 @ 𝑥 = 0.07
And now we have fully defined all the loads acting on the shaft and next we will
design the shaft and test it against
16
Force analysis
17
Shaft design
4. Shaft design
2nd iteration
1
41.265 41.265 2
σ= + √31.782 + ( 2 ) = 58.5 𝑀𝑝𝑎
2
41.265 41.265 2
σ= − √28.522 + ( 2 ) = −17.3 𝑀𝑝𝑎
2
𝜎1 = 58.5 𝑀𝑝𝑎 𝜎2 = 0 𝜎3 = −17.3 𝑀𝑝𝑎
(tresca)
𝑠𝑦
σ1 – σ3 =
𝑛.𝑠
470
58.5+17.3 = 𝑛.𝑠
n.s = 6
Fatigue
σmax= 41.265 Mpa σmin= -41.265 Mpa
𝜏max= 31.78 Mpa τmin= 31.78 Mpa
41.265−41.265
σm= =0
2
41.265+41.265
σa= = 41.265Mpa
2
31.78−31.78
τm = =0
2
31.78+31.78
τm = = 31.78 Mpa
2
18
Shaft design
σm/ = 0
σa/ = √41.2652 + 3 ∗ 31.782 = 68.79 Mpa
Se/= 0.29 * 745 = 216.05 Mpa
Kf = 4.51*470−0.265=0.88
Ks= 1.248 * 48−0.112=0.8
Kr = 0.9
Se=0.9*0.9*0.88*216.05=154 Mpa
1 64.36 0
.𝑛.𝑠 = + 470
154
n.s=2.4
Shear force
50∗210∗l∗13
780 * 103 = 4∗1.2
L=27.4 mm
Compressive force
50∗210∗l∗8
780 * 103 = 4∗1.2
L = 44.5 mm → the nearest to standard dimension
19
Shaft design
Preliminary design
32∗1.3
d = ( 𝜋∗470∗106 ∗
1
470 2 3
√( ∗ 780 ∗ 1.5) ) = 35 𝑚𝑚
0.5∗745
Detailed design
Static
780∗103 ∗25
τ= 2.6 ∗ 𝜋 = 82.628 𝑀𝑝𝑎
∗∗504
32
𝑠𝑦
τ =
2∗𝑛.𝑠
470
82.628 = 2∗𝑛.𝑠
n.s= 2.8
Fatigue
31.78−31.78
τm = =0
2
31.78+31.78
τa= 2
= 31.78 Mpa
/
σm = 0
σa/= √3 ∗ 31.782 = 55.046 Mpa
kf=1+(2.2-1)*0.82=1.984
Se=0.9*0.9*0.88*745*0.29=154 Mpa
1 1.984∗55.046 0
.𝑛.𝑠 = + 470
154
n.s = 1.4
20
Wire Rope Drum Design
An important aspect of the design is the commitment to only one layer of the wire
rope on the drum, this is to prevent the wire rope from overlapping and to avoid any
damage that can happen to the steel wire rope because of slippage. This is a common
practice in the industry and it is a good practice to follow.
Assumptions:
1. As we use one pulley, the length of the wire is 40m + 40m + 2m, the 2 meters are
added for the sake of the flexibility and reliability of the mechanism.
2. The pitch of the groove is 1.06 ∗ 𝑑 where d is the diameter of the wire rope.
3. The thickness of the drum body is given as 0.02 × D + (6 to 10 mm), a value of 16mm
is chosen
4. The design of the flanges of the drum is done based on the common practices in the
industry (a more complicated design is not necessary in this case)
As we have calculated the wire rope diameter to be 8 mm, now we can calculate the drum
diameter as follows:
We have these relations:
𝜋 × (𝐷 + 0.15𝑑) × 𝑛 = 40 + 40 + 2
𝑛∗𝑝 =𝐿
𝑝 = 1.06 ∗ 𝑑 = 8.48𝑚𝑚
ℎ = 0.35 ∗ 𝑑 = 2.8𝑚𝑚
After making multiple iterations to get a suitable value for L and D, we found that the
following values are the best:
𝐿 = 750𝑚𝑚
𝐷 = 300𝑚𝑚
𝐿 750
𝑛 = = = 88.4434 → 88
𝑝 8.48
Where:
• 𝐷 is the drum diameter
• 𝑛 is the number of turns of the wire rope
• 𝑑 is the wire rope diameter
21
Wire Rope Drum Design
NOTE: to reduce the weight of the drum, some modifications are made to the flanges of the
drum, also some fillets are added to prevent the presence of sharp edges that can cause
stress concentration.
References
Digvijay D. Patil, P. K. (November 2015). Design and Finite Element Analysis of Rope Drum
and Drum Shaft for Lifted Material Loading Condition.
Tawanda Mushiria, M. J. (2017). Design of a hoisting system for a small scale mine.
Yu Zhen-liang, L. W.-m. (Jul, 2017). CAE Optimization Design of Mine Hoist Spindle Device.
College of Mechanical Engineering & Automation , Liaoning University of Technology.
For this application, the design of the wire rope pulley is not necessary, as many available
options in the market can be used for this application. Thus, the pulley is selected based on
the following criteria:
1. The weight capacity of the pulley should be more than 1000 kg but less than 2000 kg
2. The pulley wire groove should be compatible with the wire rope diameter
After searching the market, and comparing the available options, we found a manufacturer
that provides a pulley with the following specifications:
22
Wire Rope Drum Design
B(mm) A(mm) C(mm) D(mm) E(mm) WIRE SWL Weight (kg) Product Code
(mm) Ton
76 295 40 87 15 8 0.5 1.65 SBH075
102 338 50 112 19 10 1.0 3.10 SBH100
127 386 56 140 21 13 1.5 4.40 SBH125
152 455 60 168 31 16 2.0 8.20 SBH150
178 518 70 190 35 19 3.0 11.50 SBH175
203 602 78 205 42 22 4.0 17.50 SBH200
252 753 82 270 44 25 5.0 25.00 SBH250
305 890 106 330 45 25 6.0 35.00 SBH300
23
Shaft Elements Design
A deep groove ball bearing is a suitable choice for an electric hoist shaft carrying a 1-ton
load due to several key factors:
Load Capacity: Deep groove ball bearings are designed to handle
both radial and axial loads. In the case of an electric hoist, where the load is
typically vertical, the bearing can efficiently support the weight of the load.
Smooth Operation: These bearings have a low torque and provide smooth rotation,
which is crucial for lifting heavy loads. The reduced friction ensures that the hoist
operates efficiently and minimizes wear and tear.
Deep Groove Design: The deep groove structure allows the bearing to accommodate
both radial and axial forces effectively. It provides stability and prevents
misalignment during operation.
Durability: Deep groove ball bearings are known for their long service life. They can
withstand continuous use and heavy loads without premature failure.
Vibration Reduction: The design of deep grooves provides better load distribution,
reducing vibration and ensuring stable performance during lifting operations.
Vertical Lift: These bearings offer true vertical lift, which is essential for hoists. They
maintain alignment and prevent lateral movement, ensuring safe and reliable
lifting.
24
Shaft Elements Design
From table1 @ page 601 Machine Design with CAD and Optimization by Metwalli, Sayed M. 1
Parameters
25
Shaft Elements Design
𝑃 = 𝑭𝒓
𝑃∗ = 𝑲𝒔𝒇 ∗ 𝑃
60 ∗ 𝐿 ∗ 𝑛 1/3
∗
𝐶 =𝑃 ∗( )
106
Bearing C
𝑃 = 𝑭𝒓 = 3.38 𝐾𝑁
𝑃∗ = 1.5 ∗ 3.38 = 4.88 𝐾𝑁
26
Shaft Elements Design
27
Shaft Elements Design
6.2.1. Preparation
Before mounting, avoid removing bearings from their packaging to prevent
contamination and rust. If the bearings are pre-lubricated or used for normal operation,
retain the anti-corrosion oil. However, for applications involving measuring instruments or
high rotation speed, clean the oil off with a detergent. After oil removal, avoid leaving the
bearings exposed for an extended period to prevent rust.
28
Shaft Elements Design
Assume ∆= 10 𝜇𝑚
502
𝐾𝑎 (𝑝𝑟𝑒𝑠𝑠 𝑓𝑖𝑡𝑡𝑖𝑛𝑔) = 9.8 ∗ 4 ∗ 10 ∗ 20 ∗ (1 − ) ∗ 103 = 2824 𝑁
62.512
502
𝐾𝑎 (𝑟𝑒𝑚𝑜𝑣𝑎𝑙) = 9.8 ∗ 6 ∗ 10 ∗ 20 ∗ (1 − ) ∗ 103 = 4236 𝑁
62.512
References
[1] SKF, "*6210 Deep groove ball bearing," SKF, [Online]. Available:
https://www.skf.com/in/products/rolling-bearings/ball-bearings/deep-gro.
29
Shaft Elements Design
[2] SKF, "*6010 Deep grove ball bearing," SKF, [Online]. Available:
https://www.skf.com/in/products/rolling-bearings/ball-bearings/deep-groove-ball-
bearings/productid-6010.
30
Shaft Elements Design
Snap rings
Shrink fitting
Welding
And several other options. After thinking practically in each option and evaluate it based
these criteria:
Maintenance considerations
Failure considerations
Transmitted torque moment
Complexity
Cost
Availability
We ended up choosing from locking devices as they provide easy maintenance, able to be
replaced, and overall suitable for the application.
There were many types of locking devices, but we decided to design and select a simple
locking device, as we fully determined all the loads that can occur and also the environment
of the mechanism is relatively stable.
We chose a keyless self-centering internal locking device. After searching for existing
manufacturers, we found a good and reliable series of locking devices called SIT-LOCK® 12
internal locking device - self-centering (manufactured by a company called Sit Lock) [1] [2]
6.3.1. Specifications
Self-centering
Quick installation and removal
Available for shaft diameters of 18 to 90 mm
Reduced axial dimensions
Axial displacement when tightening screws
Excellent shaft-hub concentricity and perpendicularity
Medium to high transmissible torques
6.3.2. Installation
The locking device is supplied ready to assemble. Clean the shaft contact surfaces thoroughly
and apply oil. Mount the shaft, hub and locking device in the desired position.
31
Shaft Elements Design
6.3.4. Removal
Loosen the clamping screws gradually, remove them, and insert into special removal
threads on the inner ring flange. Tighten the screws in a criss-cross pattern to release
the locking device.
Parameters
𝑴𝒕 The transmissible torque stated in table (N.m)
𝑴𝒔 Screws tightening torque
𝑵 Radial force on the shaft and hub contact surfaces
𝝁 The coefficient of friction
𝑷𝒗 Axial force
𝒅 Shaft diameter (mm)
𝑴𝒕𝒂𝒎 Permissible torque (N.m)
𝑭𝑨𝑿𝑹 Required axial force (N)
∆𝑷𝒏 additional pressure on hub (N/mm²)
𝑭𝒓 radial force applied (N)
𝑫 external diameter of the locking device (mm)
𝑯 locking device outer ring width (mm)
𝑫𝒎𝒊𝒏 minimum hub diameter
𝑲 application coefficient
𝝈𝟎,𝟐 hub material elastic limit in (N/mm²)
𝑿 factor depending on hub shape and width
𝑷𝒏 surface pressure on the hub
𝑭𝒂𝒙 Transmissible axial force
𝑷𝒘 Pressure on shaft
32
Shaft Elements Design
Dimensions [mm] Clamping screws DIN 912 12.9 Values with tolerances for shaft h8/hub H8
Ms Mt Fax Pw Pn
dxD H H0 H1 H2 Number Type
[Nm] [Nm] [kN] [N/mm²] [N/mm²]
18 x 40 12 15 20 24 6 M4 5 218 24 297 135
19 x 41 12 15 20 24 6 M4 5 230 24 282 130
A X =1 3,74 2,49 2,17 1,97 1,78 1,69 1,59 1,48 1.40 1,35 1,30 1,25
130
B X=0,8 2,35 1,93 1,78 1,67 1,56 1,50 1,44 1,36 1,30 1,27 1,24 1,19
C X=0,6 1,78 1,59 1,51 1,45 1,38 1,35 1,30 1,25 1,22 1,19 1,17 1,14
𝑑 2
𝑀𝑡𝑎𝑚 = √𝑀𝑡2 + (𝐹𝐴𝑋𝑅 ∗ )
2000
𝐹𝑟
∆𝑃𝑛 =
𝐷∗𝐻
𝐷𝑚𝑖𝑛 ≥ 𝐷 ∗ 𝐾
𝜎 +(𝑋∗𝑃 ) 390+(1∗130)
𝐾 = √𝜎0,2 −(𝑋∗𝑃𝑛) 𝐾 = √390−(1∗130) = 1.4 (𝑎𝑠 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒𝑠)
0,2 𝑛
References
33
Shaft Elements Design
6.4. Coupling
Assumptions for the rigid flange coupling
780∗103
𝜏= 𝜋 754 −504
=11.73 Mpa
∗{ }
16 75
34
Shaft Elements Design
𝜏 𝑎𝑙𝑙 = 85𝑚𝑝𝑎
85
𝑛. 𝑠 = 3.53 = 24
780 ∗ 103
𝜏 𝑏𝑜𝑙𝑡 = = 62𝑚𝑝𝑎
𝜋 2 125
(4) ∗ 8 ∗ 2
𝜏 𝑎𝑙𝑙 85
𝑛. 𝑠 = = = 1.37
𝜏 𝑏𝑜𝑙𝑡 62
35
Further Design Analysis
1. Manual Hoists:
Operated by hand, these hoists are lever-actuated or hand-
operated lifting devices. They use a hand chain or lever to control
lifting .
Pros of Manual Hoists:
Versatility: Manual hoists are versatile and can be used in
various applications, including construction, maintenance,
and industrial settings
Portability: They are often lightweight and portable,
making them suitable for use in remote locations or areas
with limited access Figure 1:manual hoists
Simple Operation: Manual hoists are easy to operate and
require minimal training, allowing for quick setup and use .
Cost-Effective: They tend to have lower initial costs compared to powered hoists,
making them a cost-effective option for certain lifting needs .
Cons of Manual Hoists:
Limited Capacity: Manual hoists typically have limited lifting capacities compared to
powered hoists, restricting their use for heavier loads
Physical Effort Required: Operating manual hoists involves physical effort from the
operator, which can be tiring and may not be suitable for prolonged use or heavy
loads
Use Cases:
Manual hoists are commonly used in scenarios where:
Lifting requirements are relatively light to moderate.
Portability and ease of setup are essential, such as in construction sites or
maintenance tasks.
36
Further Design Analysis
37
Further Design Analysis
Safety Features: Mobile hoists are designed with multiple safety mechanisms to
prevent accidents and injuries, ensuring patient safety during transfers
Cons
Space Requirements: They require floor space for maneuvering, which can be a
limitation in smaller environments
Battery Maintenance: For battery-powered models, regular charging is necessary to
maintain functionality, and forgetting to charge can lead to operational issues
Storage Needs: Storage space is required when the hoist is not in use, which may
pose challenges in crowded settings
Use Cases
Mobile hoists are commonly used in:
Homecare settings where transferring individuals between rooms or areas is
required
Care facilities such as nursing homes and hospitals for patient transfers and mobility
assistance
Emergency situations where quick and efficient lifting of individuals is necessary
4. Ceiling Hoists:
Installed on ceilings, these hoists utilize tracks or rails to
facilitate lifting and transferring individuals, offering a space-
saving and efficient solution
Pros:
Space-saving: Ceiling hoists maximize floor space,
making them ideal for environments with limited
room for maneuverability
Permanent installation: Once installed, ceiling hoists
provide a fixed transfer solution, eliminating the need
for repetitive setup and dismantling Figure 4:Ceiling Hoists
Safety: They reduce the risk of falls associated with
manual transfers, enhancing patient safety
Convenience: Ceiling hoists facilitate efficient transfers, reducing strain on
caregivers and promoting ease of use
Cons:
Installation time: Ceiling hoists require time-consuming installation compared to
mobile hoists, delaying immediate use
Limited portability: Once installed, ceiling hoists are fixed in place, limiting their
flexibility for use in different locations .
Cost: Initial setup costs for ceiling hoists may be higher compared to mobile hoists,
depending on the complexity of the installation
Applications:
Ceiling hoists are commonly used in healthcare facilities, rehabilitation centers, and
residential settings where a permanent and safe transfer solution is required. They are
particularly beneficial for transferring patients with limited mobility or those requiring
frequent transfers, such as elderly individuals or individuals with disabilities.
38
Further Design Analysis
5. Hydraulic Hoists:
These hoists use hydraulic power to lift heavy loads.
They are often used in industrial settings where precise
control and high lifting capacity are required
Pros:
Cost-effective: Hydraulic hoists are often
cheaper to install compared to other types of
hoists, making them a preferred choice for
budget-conscious projects
Space-saving: They require less space in a
building, typically occupying almost 10% less
Figure 5:Hydraulic Hoists
area than other elevator types, making them
suitable for installations where space is limited
Energy-efficient: Hydraulic lifts use less electricity compared to other lift types, as
the motor only operates during upward travel, contributing to lower operational
costs
Versatility: Hydraulic hoists can be used in various applications and environments
due to their wide range of capabilities and adaptability
Cons:
Maintenance: They may require more frequent maintenance compared to other
types of hoists due to the complexity of hydraulic systems
Potential leaks: Hydraulic systems are susceptible to oil leaks, which can lead to
environmental hazards and require prompt attention for repair
Limited travel height: Hydraulic hoists are typically limited in terms of travel height
compared to other lift types, which may restrict their use in taller buildings or
structures
Cases of Use:
Hydraulic hoists are commonly used in various industries, including automotive,
construction, and manufacturing, for lifting and moving heavy loads such as engines,
machinery, and materials
They are also utilized in building construction projects for temporary lifting
applications, such as installing beams and structural components
39
Further Design Analysis
https://www.researchgate.net/publication/294105466_Modeling_Power_Flow_in_a_Hoist_
Motor_of_a_Rubber-Tired_Gantry_Crane
https://iopscience.iop.org/article/10.1088/1742-6596/1605/1/012061/pdf
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6936941/
https://www.researchgate.net/publication/343334580_Bariatric_patients_and_the_use_of_
mobile_hoists_user_experiences_from_three_hospitals_in_South_Australia
https://www.researchgate.net/publication/26257745_Evaluation_of_ceiling_lifts_Transfer_t
ime_patient_comfort_and_staff_perceptions
https://www.researchgate.net/publication/285029694_Evaluation_of_Ceiling_Lifts_in_Healt
h_Care_Settings_Patient_Outcome_and_Perceptions
https://www.researchgate.net/publication/266651435_Study_on_Vibration_and_Noise_For
_the_Hydraulic_System_of_Hydraulic_hoist
https://www.researchgate.net/publication/328081866_Analytical_and_experimental_resea
rch_on_stability_of_large_slenderness_ratio_horizontal_hydraulic_hoist
40
Further Design Analysis
N28 Y-10.45
N29 Z-.85
N30 G01 Z-3.6 F73.273
N31 G03 X10.124 I10.124 J10.45 F293.091
N32 G01 X-10.124
N33 Y-8.05
N34 X-14.916
N35 G03 X14.916 I14.916 J8.05
N36 G01 X-10.124
N37 Y-5.65
N38 X-18.507
N39 G03 X18.507 I18.507 J5.65
N40 G01 X-10.124
N41 Y-3.25
N42 X-21.506
N43 G03 X21.506 I21.506 J3.25
N44 G01 X-10.124
N45 X-21.506
N46 G03 X21.506 I21.506 J3.25
N47 G01 X-10.124
N48 G00 Z.5
N49 Z25.
N51 X-21.506
N52 Z.5
N53 G01 Z-3.35 F73.273
N54 G03 X-20.363 Y-7.642 I21.506 J3.25 F293.091
N55 G02 X-17.321 Y-3.25 I3.043 J1.142
N56 G01 X-21.506
N57 G00 Z.5
N58 Z-.85
N59 G01 Z-3.6 F73.273
N60 G03 X-20.363 Y-7.642 I21.506 J3.25 F293.091
N61 G02 X-17.321 Y-3.25 I3.043 J1.142
N62 G01 X-21.506
N63 G00 Z.5
N64 X17.321
N65 G01 Z-3.35 F73.273
N66 G02 X20.363 Y-7.642 I0 J-3.25 F293.091
N67 G03 X21.506 Y-3.25 I-20.363 J7.642
N68 G01 X17.321
N69 G00 Z.5
N70 Z-.85
N71 G01 Z-3.6 F73.273
N72 G02 X20.363 Y-7.642 I0 J-3.25 F293.091
N73 G03 X21.506 Y-3.25 I-20.363 J7.642
N74 G01 X17.321
N75 G00 Z.5
N76 Z25.
N78 X3.23 Y-5.382
N79 Z1.
N80 G01 Z-3.6 F73.273
N81 G41 D21 X1.024 Y-3.176 F219.818
N82 G03 X.6 Y-3. I-.424 J-.424
N83 G01 X-21.794 F293.091
N84 G03 X21.794 I21.794 J3.
N85 G01 X-.6
N86 G03 X-1.024 Y-3.176 I0 J-.6
N87 G40 G01 X-3.23 Y-5.382
41
Further Design Analysis
42
Further Design Analysis
43
Further Design Analysis
44
Further Design Analysis
7.2.2. Key
The key will be made in two steps
1. Machining of the key parallelogram shape
2. Forging to obtain the fillets of the key
We made a study for the key as if it manufactured using only machining, and this is the cost
report in this case:
Costing Report for Key Manufacturing
45
Further Design Analysis
46
Further Design Analysis
47
Further Design Analysis
7.2.3. Flange
We will manufacture flange with casting method
Process of Manufacturing Flanges with Casting
1. Pattern Making: First, a template in the shape of the intended flange design is
created. Usually, this is done with wood.
2. Mold Preparation: The pattern is used to build a mold. The final flange's dimensions
and shape will be determined by this mold. Sand will be used to make the mold.
3. Metal Melting: steel a furnace is used to melt metal to the appropriate temperature.
4. Pouring: The prepared mold cavity is filled with molten metal. To prevent flaws in
the finished product and allow room for a bolt and nut, care must be taken to ensure
that the mold is properly filled.
5. Solidification and Cooling: The molten metal inside the mold begins to solidify and
cool after pouring, assuming the shape of the mold cavity. The complexity and size of
the flange will determine how long this operation takes.
6. Extracting the Casting: After the metal has set completely, the casting is taken out of
the mold.
7. Cleaning and Finishing: The casting is cleaned to get rid of any surface flaws and
leftover mold material. To obtain the flange's final size and surface polish, machining
procedures may be used.
8. Examination: To make sure the completed flanges fulfil quality requirements and
standards; a comprehensive examination is conducted. Dimensional checks, visual
examination, and non-destructive testing techniques might be examples of this.
After the casing process, the threads will be made in the flange with drilling methods.
48
Further Design Analysis
49
Further Design Analysis
50
Further Design Analysis
7.4.1. Advanced Load Analysis for the Wire Rope on the Drum
As the precise analysis of the load transmitted to the wire rope drum from the load
acting on the wire rope is very complex (actually some research papers are covering only
such analyses) we thought of preforming FEA analysis to study the load distribution more
accurate and in several cases and also with different loads.
This can be beneficial for the design of the drum, the shaft, and also the number of
pulleys to reach the maximum mechanical advantage per cost possible.
The body can have an actuator to move it horizontally which is important for many
use-cases
The body will be fixed with two supports to hold its weight and the weight lifted by
the system.
51