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Belt Conveyor

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Submitted By karimsalah
Words 2147
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Cairo University Faculty of Engineering Credit hours system Mechanical Design Engineering

Special Topics in mechanical engineering Overhead crane
Submitted To: DR. Tarek Osman Eng. Ahmed Hamed

Submitted By: Abdelrahman HeshamAbdalla Ahmed Mohamed Emad 1105014 1095348

Karim Mohamed Salah EL-Din 1092177

Table of Contents
M otor selection ................................................................................................................................................................................... 3 Gearbox selection ............................................................................................................................................................................... 4 Hook design......................................................................................................................................................................................... 5 Hoist Selection .................................................................................................................................................................................... 5 Cri teria for selection ...................................................................................................................................................................... 6 Design selection for rope ............................................................................................................................................................... 6 Components of a chain hoist ......................................................................................................................................................... 6 Ins tallation........................................................................................................................................................................................... 8 Sta nda rd Pa rts..................................................................................................................................................................................... 9 Chai n selection .................................................................................................................................................................................. 10 Bra kes................................................................................................................................................................................................ 11 Hoist bra kes tes ting ..................................................................................................................................................................... 11 Control bra kes .............................................................................................................................................................................. 11 Hoist bra kes.................................................................................................................................................................................. 11 According OSHA 1910.179 Overhead & Gantry Cranes Regula tions........................................................................................... 11 Types of brakes ............................................................................................................................................................................ 11 Bra kes for hoists ...................................................................................................................................................................... 11 Holding brakes ......................................................................................................................................................................... 11 Bra kes selection ................................................................................................................................................................................ 12 Adva ntages .............................................................................................................................................................................. 12 Power Transmission .......................................................................................................................................................................... 13 Cons truction...................................................................................................................................................................................... 14 Shaft Design ...................................................................................................................................................................................... 15 Cos t es tima tion of pa rts.................................................................................................................................................................... 16 Dra wings Solidworks ......................................................................................................................................................................... 17 Hook ............................................................................................................................................................................................. 17 Shaft ............................................................................................................................................................................................. 18 Gears ................................................................................................................................................................................................. 21 ...................................................................................................................................................................................................... 23 Assembl y ...................................................................................................................................................................................... 24 Fi nite element anal ysis...................................................................................................................................................................... 25 OUTPUT SHAFT............................................................................................................................................................................. 25 References......................................................................................................................................................................................... 36

2

Motor selection
Given
Load: 5ton D= 425 mm Lifting height: 5m N= 1400 rpm lifting Speed (assumed) =2.8 m/min

Equations
P=Txω T= Force x R ω= (2πN/ 60) V= (πDN)

Calculations
Torque= (0.2125)x 50000= 10625N.m Velocity = 2.8 = (π D N) then , N= 2 rpm P= (10625).( 2πN/ 60)= 2.22 KW
Model Capacity HSY TON Lifting Height M Lifting Speed M/MIN Power KW Lifting motor Rotation Voltage Frequency al Speed V HZ/S R/MIN 1440 1440 1440 1440 1440 380/220 380/220 380/220 380/220 380/220 50/60 50/60 50/60 50/60 50/60 Power KW 0.4 0.4 0.75 0.75 0.75 Drive motor Rotation Running al Speed speed R/MIN 1440 1440 1440 1440 1440 M/MIN 11/21 11/21 11/21 11/21 11/21 3 3 3 3 3 380/220 380/220 380/220 380/220 380/220 50/60 50/60 50/60 50/60 50/60 Voltage Phase V Frequen cy HZ/S

01-01 02-02 2.5-01 03-02 05-02

1 2 2.5 3 5

3/9 3/9 3/9 3/9 3/9

6.8 3.4 6.8 5.8 2.8

1.5 1.5 3 3 3

3

Selected Motor for lifting t he load, its specifications are Power: 3KW= 4 HP Speed: 1440 rpm Lifting Speed: 2.8 m/min

Gearbox selection
Helical gearing system is selected for its advantages long life (3times that of a spur gear) Smooth and quiet operation Only 2 gear reductions are required (load capacity is less than 30 ton) High efficiency (0.985 for helical reduction)

Calculations
Motor calculations:  Load(W): 5000kg = 11023 Pound  Hoisting speed(V): 2.8 m/min = 9.18 ft/min  Gear efficiency(E): 0.985 ������ ∗ ������ 33000 ∗ ������

������������ = Needed Power =3.2 hp Selected Motor is of 4 HP

4

Hook design
For cranes of 5 to 50 ton capacity, hooks are usually forged from carbon or alloy steel. Single Hooks would be sufficient for the needed capacity.

Hoist Selection
The two most common hoist types are wire hosts and chain hosts. The main differences, advantages and disadvantages will be discussed to reach the optimum selection. First Wire hoists Advantages: - Heavier loads (from 2 to 30 tons on average) - Long working hours. - Works in intense (harsh) environments. - Can operate safely in elevated temperature. Disadvantages: - Stationary (cannot be torn down easily) - Heavy (heavier than chain hoists) - Expensive - Larger and more complicated - Requires much room

5

Second Chain hoists Advantages: - Less permanent (easier to move around) - Cheaper - Ease of use - Light weight Disadvantages: - Smaller capacity (1/8 ton to 5 ton) - Can’t handle elevated temperature or harsh environment - Can’t handle high rated hoist capacity under prolonged periods of time

Criteria for selection
Application Capacity Duty cycle Investment cost Maintenance

Design selection for rope
Fmax = 5tons Assume rope material Alloy steel Su= 1500 Mpa Operating conditions Medium K= 5.5 , e= 25 C= 4917 MPa for 6 x 15 d= root (0.38* 537 )= 14.28 Drum d= 16 mm D= 425 mm for Steel 6x 15

For selecting such a hoist the cost would be significantly larger than chain hoist. Taking into consideration the application (workshop), therefore a chain hoist would be more appropriate.

Components of a chain hoist
Chain drive o Includes self-lubrication chain guide o Chain sprocket o Gray cast iron casing Driving Motor Brakes Control

-

6

-

Chain o Surface hardened o Galvanized steel Chain box

-

7

Installation

8

Standard Parts
1. Chain sprocket For steel chains it must be ensured that at least three chain links are engaged with a positive fit. This reference is from the standard DIN 56950 “Entertainment Technology - Machinery Installations”

2. Bearings In the gearbox, there are three shafts:  Input  Counter  Output Loading varies from one shaft to another, yet and by taking into consideration the type of loading and its quantity proper selection was done. Input shaft Bearing type: Tapered Designation: 32006 Mounting: Face to Face Counter shaft Bearing type: Tapered Designation: 30210 Mounting: Face to Face Output shaft Bearing type: Tapered Designation: 32021 Mounting: Face to Face

9

Chain selection from the standard DIN 56950 stated before Grade 100 alloy chains: Alloy chain is extremely strong and made from a special composite alloy steel making it ideal for recovery applications or overhead lifting Size: 5/8 “ Needed is 5 m lift. Equivalent to 17 feet Get 20 feet long chains Estimated cost around 100$ for 20 feet of 5/8 Chain.

10

Brakes
Hoist brakes testing
The operator shall test the brakes each time a load approaching the rated load is handled. The brakes shall be tested by raising the load a few inches and applying the brakes.

Control brakes
Control braking exists to prevent the load from accelerating in the lowering direction. If the load is very high and a mechanical load control brake fails when you attempt to stop during load lowering

Hoist brakes
Hoist brakes are an essential safety feature of overhead cranes. Designed to hold a load w hen the hoist motor is not running, these brakes reduce the risk of falling loads that could result in injury and property damage.

According OSHA 1910.179 Overhead & Gantry Cranes Regulations Types of brakes
Brakes for hoists
1. 2. Each independent hoisting unit of a crane shall be equipped with at least one self-setting brake, hereafter referred to as a holding brake, applied directly to the motor shaft or some part of the gear train. Each independent hoisting unit of a crane, except worm-geared hoists, the angle of whose worm is such as to prevent the load from accelerating in the lowering direction shall, in addition to a holding brake, be equipped with control braking means to prevent over speeding.

Holding brakes.
1. Holding brakes for hoist motors shall have not less than the following percentage of the full load hoisting torque at the point where the brake is applied.  125 percent when used with a control braking means other than mechanical.  100 percent when used in conjunction with a mechanical control braking means.  100 percent each if two holding brakes are provided. 2. Holding brakes on hoists shall have ample thermal capacity for the frequency of operation Required by the service. 3. Holding brakes on hoists shall be applied automatically when power is removed. 4. Where necessary holding brakes shall be provided with adjustment means to compensate for wear. 5. The wearing surface of all holding-brake drums or discs shall be smooth. 6. Each independent hoisting unit of a crane handling hot metal and having power control braking means shall be equipped with at least two holding brakes. 11

Brakes selection
Mondel Motor Mounted Brakes
Magnetek’s new motor mounted crane brakes feature the brake already mounted on the opposite drive end (ODE) of the motor, which saves time and eliminates brake mounting labor. Crane builders often buy brake shoes , wheels and motors as separate items, then integrate them into their designs by building separate mounting bases for the motor and the brake. The motor and brake then need to be carefully aligned (usually with shims) to work properly. Obtaining the motor with a brake package factory mounted simplifies crane design and saves shop time. With the brake mounted, the motor simply needs to be bolted in place and its shaft coupled to the gearbox input shaft. To use this approach, motors with a C-Face and tapered shaft on the ODE are supplied. This allows the brake support to be bolted to the motor’s machined flange, ensuring precise location of the brake. Normally, brakes mounted to the motor will be in the 4- to 13-inch wheel diameter size range.

Advantages
Eliminates brake pedestal Eliminates alignment issues Purchased as a pre-assembled “package” Installs as a complete brake assembly Saves time and labour costs

12

Power Transmission
- Step 1: Inverter reduce speed to 108 rpm Inverters are electrical devices that control the frequency of any motor. In our case, the AC motor is controlled by the inverter. The problem with the inverter, however, is that as we approach lower rpm the temperature of the motor significantly increases. That’s why we resort to a gearbox to do the reduction in the next step. - Step 2: Two stages gearbox for speed reduction to 3 rpm As mentioned before, the selected gearing system is helical. The advantages of using such system are significant such as:     Quite sound during operation Allows smaller number of teeth for pinion Longer life Higher mechanical efficiency

We first reduce the speed from 108 rpm to 18 rpm then from 18 to 3. Design considerations: - Min. no of teeth (pinion) Zmin=(2/sin2α). cos 3 β α: pressure angle => 25 deg β: Helix angle We selected Z=13 teeth for pinion. - Face width Common design practices recommend that the face of both gear and pinion wouldn’t exceed the diameter of the pinion gear.

13

Construction

14

Shaft Design

15

According to DIN 748

Cost estimation of parts
300$ 100$ 300$ 110$ Motor (HSY model) Chain (Grade 100 alloy chain) Brakes (Mondel Motor) hook (Capacity of 5 tons )

Total price of overhead crane= 810 $

16

Drawings Solidworks
Hook

17

Shaft

input shaft

18

Shaft no.2

19

Output shaft

20

Gears

21

22

23

Assembly

24

Finite element analysis
OUTPUT SHAFT
Inputs:

- Gear Calculation • • • • • Power= 5 kw Speed= 3 rpm Torque= 9437 Nm ������������ = 20697 N ������������ = 17825 ������

- Material selected • • • • • St42 ������������������������ = 420 ������������������ Density: 7.8 ������������/������3 Poisson’s ratio: 0.3 Young’s Modulus: 200 GPa

25

Proposed Design:

Section 2 Section 1

Section 4

Section 3

Sections: Section 1 - ������������ = 105 ������������

Section 2 - ������������ = 115 ������������

Section 3 - ������������ = 111 ������������

Section 4 - ������������ = 105 ������������

26

Boundary Conditions:

Boundary 1

Boundary 2

Boundary Condition at 1 U2=0 U3=0 UR1=0

Boundary Condition at 2 U1=0 U2=0 U3=0

27

Stress concentration factors 1 :

1. For key ways:

Assuming key is in place. End-mill key seat (r/d=0.02): ������������������ = 3.0

2. For Snap rings:

Retaining ring groove: ������������������ = 3.0

1

Estimates for use in iterations, not based on actual dimensions. Budynas, Richard G., J. Keith Nisbett, and Joseph Edward Shigley. Shigley's mechanical engineering design. 9th ed. New York: McGraw-Hill, 2011.

28

Check for Critical Speed: 1st resonance:

������ = 10√10 ∗ 68.42 ∗ 60 ������ = 130,000 ������������������
Natural frequency is reached, when the shaft rotates by n=130,000 rpm

Design is safe.

29

Design Criteria: For Material St42 :

������������ = 420 ������������������ ������������ = 0.7 ∗ 420 = 294 ������������������
Strength:

,

n1 =

������������ /2 ������12

=

147 4.15������ − 2

= 3525

30

Fatigue :

n2 =

������������ ������������������ ������11 ∗ ������������

������������ ������������������ = ������������ ������ℎ������������ ∗ (������������ ∗ ������������ ∗ ������������ ∗ … ) ������������ ������������������ = n2 = ������������������������ 2 ∗ 0.8 = 210 ∗ 0.8 = 168 ������������������ = 168 5.86 ∗ 3 = 9.55

������������ ������������������ ������11 ∗ ������������

Total Factor of Safety

31

1 ������ ������������������������������ 1 ������ ������������������������������

= =

1 ������ 1 1

+

1 ������ 2 + 1 3525

9.55

������������������������������������ = ������. ������
Design for Rigidity: ������������������������������������ 100

- ������ ≤

- ������������������������������������ = 5
������ ≤ 0.05 (AT GEAR SEAT)

- ������ ≤

������ 3000

������������������ ������ = 142 ������������ (������������������������������������������ ������������������������������������������������)

������ ≤ 0.047 (AT rest of shaft)

32

δ = 0.0015 (At Gear Seat)
Factor of service = 33

δ = 0.0015 (At rest of shaft)
Factor of service = 3

Final Mass of Shaft = 2.6 kg

33

Similarly the input shaft

Maximum stress=41 Mpa Maximum deflection=0.02 mm First resonance at 100,000 rpm
Factor of safety=1.5

Therefore its safe

34

Similarly for the Counter Shaft First Resonance Max deflection S11 max S12 max Factor of safety 101,000 rpm 0.032 mm 43.6 Mpa 4.81e-2 Mpa 1.28

35

References http://www.loadhook.com/client_images/catalog19869/pages/files/chainhoistvswirerope.pdf http://hoistdepot.com/2014/01/22/hoist-decisions-wire-vs-chain/ https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=9830 http://www.konecranesusa.com/crane-safety-0/hoist-brakes-or-holding-brakes http://www.dukebrakes.com/dc-mill-motors-brakes/magnetek/mondel-mill-duty.html

36

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