4- steps in hoist design
TRANSCRIPT
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1
Steps in Design of a Hoisting System
©Dr. B. C. Paul 1999 major revision 2012
With Credit to Dr. H. Sevim for Oriinal Boo!
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2
Steps in Design of Hoisting
System Determine the "erforman#e re$uirements
% &suall' means "rodu#tion
% #an also involve fiurin a##e"ta(le sto""in
distan#es ) num(er of levels to (e served under
*hat #onditions
Sele#t hoist t'"e to meet #onstraints
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+
Once Upon a Mine
Dar! Bla#! #oal mine *ill "rodu#e + million
tons of #oal from a sinle level. ,he hoistin
distan#e from loadin "o#!et to dum" (in is1000 ft. ,he mine o"erates 2-0 da's "er 'ear
+ "rodu#tion shifts "er da' *ith hours of
o"eration ea#h "rodu#tion shift. ,he "ea! "rodu#tion *ill (e a(out -000 tons "er shift.
,he averae "rodu#tion is /000 tons "er shift.
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Your Mission Jim, Should you
decide to accept it Desin a hoistin s'stem for the Dar! Bla#! Coal
ine.
irst Ste" is to esta(lish the "erforman#ere$uirement.
,he fundamental Ca"a#it' $uation is
% 3 4 P 5 ,
% 3 is re$uirement in ,ons Per Hour
% P is Produ#tion "er shift
% , is the averae shift "rodu#tion time
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Which Production Numer Do
We Use! 6#tual "rodu#tion is a distri(ution ) not an
averae num(er
7f *e desin on averae then all the num(ers
a(ove the mean *ill o "ast #a"a#it' ) *e8ll
loose our hih values and not meet
"rodu#tion 7f *e desin on a "ea! that is seldom
a#hieved *e8ll "a' (i (u#!s
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Decision "riteria
7f "ea! a""roa#hes 2 times averae ) need to
#onsider #ost of *or! sto""ae vs. ta!e *or!
sto""aes 7f "ea! is some*hat #lose to averae then
desin for the "ea!
7n e:am"le the "ea! is 12-; of the averae<*hi#h is not #onsidered a sinifi#ant
deviation. Desin for the Pea!=
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What if #ife had not een so
$ind! Cal#ulate the #ost of a "rodu#tion sto""ae
% a' (e #ost of lost "rodu#tion
% a' in#lude "enalties on #ontra#ts% a' in#lude idle la(or #ost
Cal#ulate the amorti>ed #ost of the ne:t
in#rement of "rodu#tion #a"a#it' Che#! multi"le "oints and o for minimum
total #ost.
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?
Pic% production capacity 6""l' formula
% 1/ t"h 4 -000 t5shift 5 hours "rod time
Other desin de#isions need to (e made
% 7s this a @eo"e or a Drum HoistA
% One evel so @eo"e *on8t (e too tri#!'
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&nput My Hoist Distance and
Production 'ate (arget
9
' S"readsheet is
O"ti)Hoist.
e:t ets loo! at some fi:ed
C'#le time elements
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)lements
Ho* on *ill it ta!e for the ore "o#!et doors to
o"en and dro" a load into the s!i"A
On#e the S!i" is in "osition ho* lon *ill it ta!eto de"osit the load into the dum" "oint #huteA
% 6(out ? se#onds to load
% 10 se#onds to dum" is reasona(le
% our load and unload times ma' de"end on other
desin elements of the s'stem.
10
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"reep (ime
Hoists and levators slo* to near
sto" as the' line u" *ith a set level
% Pull a*a' fromthe loadin "oint% Or line u" *ith dum" "oint
% Will &suall' ta!e a (it more time to
line u" *ith the unload "oint
% 2 se#onds to "ull a*a' from load and
/ to line u" *ith dum" is reasona(le.
116 fo*l Beast
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No* We Need to Pic% a Pea%
Speed and a 'ate of S%ip +cceleration
12
,he ma:imum s"eed *e lift at is safet' related. or men there are reulations.
or materials there are uidelines Esho*n in "in!F
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"onsiderations
,his is a @eo"e Hoist
% ,he ro"e is just sittin over a fri#tion *heel
% 7f 7 G"eel out and the ro"e starts to sli" 7 have
a major hoistin a##ident
Hih s"eed and hih a##eleration in#rease
"rodu#tion% But the' also #ause a (i in#rease in motor si>e
and ener' (ill.
1+
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&m going to go for modest speed
and particularly modestacceleration
1/
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-eometry "onsiderations
1-
,*o S!i"s S!i" and Counter)*eiht
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Stopping "onsiderations
1
7f m' #ontrols miss
Sto""in the s!i" at
,he dum" "oint I ho*
ar do 7 have for an
meren#' sto" (efore
,he over)*iend turns
7nto a disasterA
Dum"
Chute
oadin #hute
Shaft Bottom
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-etting Our .irst )stimate
1
&sin a ord(er a""ro:imation of the #'#le time the "roram estimates the si>e
Of s!i" that *ill (e needed to a#hieve the "rodu#tion taret usin the distan#e<
S"eed and a##eleration #onditions s"e#ified.
E,his "art of the s"readsheet is inde"endent of *hether the hoist *as a @eo"e or
6 drum hoistF.
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Our Ne/t (as% is to -et Our
)/act "ycle (ime
1?
,he onl' missin
Pie#e of information
Was *hat is the
Cree" s"eed E2 ft5se#
7s reasona(leF.
E7 *ant8s 'ou mone' for m' fa!e
Jlo(al *armin initiativeF
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Ne/t We Must 0alance S%ip Si1e,
Weight, 'ope Diameters andWheel Si1es
19
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.irst We Need to Pic% + S%ip Si1e
20
We have alread' (een iven a first uess s!i" si>e. We tr' a(out that si>e
6nd then #he#! the a#tual hourl' "rodu#tion a#hieva(le in the red (o: E*e
o* have fiured the e:a#t #'#le time tooF.
6s #an (e seen a 1 ton s!i" *ill et me m' 20 tons5hour.
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Ne/t &ll -o for S%ip Weight
21
7n eneral a s!i" heav' enouh to handle the (anin of ore loadin and
&nloadin *ill *eiht a(out -; of the load *eiht.
O"ti)Hoist estimates this for us (ut leaves us a 'ello* (lan! to #hoose theWeiht. 6 hiher *eiht usuall' means *e are just addin *eihts to our
S!i".
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Ne/t We -o .or 'ope Si1ing
22
@eo"e hoists usuall' have multi"le ro"es in even num(ers< 2< /< < and ? (einCommon. Where that 12 #ame from is unsure.
We need to #onsider (oth hoistin ro"es and tail ro"es. Sometimes tail ro"es
6re used and *orn)out hoist ro"es *hi#h #an #ause tail ro"es to (e the same
6s hoist ro"es.
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My .irst -uess is 2 ropes
3(his is a relati4ely modest depth5
2+
,he red (o: estimates that 7 *ill need a 1.0/ in#h ro"e to rea#h needed
Safet' fa#tors for this de"th.
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.rom Here & Need to -o +nd
)nter My 'ope Properties
2/
7 enter m' ro"e si>e< it8s *eiht and it8s strenth. E7 have the advantae of Havin an estimate of *hat si>e ro"e to tr'F.
,he s"readsheet then #om"ares the a#hieved fa#tor of safet' to *hat is re$uired
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Where Do & -et (hese 'ope
Properties
2-
,he s"readsheet has a
Ko"e "ro"erties ta(le
Kiht (elo* for me to
oo! thins u" on.
78m loo!in for 1.0/
lattened strand
7 o for 1.12-
Weiht 2.2? l(s5ft
Strenth -.9 tons
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)nter My 'ope and "hec% My
.actor of Safety
2
6 fa#tor of safet' #learl' meets a .-
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& Wonder &f & "ould -et +*ay
*ith a 6 inch rope
2
eee I one in#h ro"e is a no"e.
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What if & Use High Strength
Steal!
2?
Oh so #lose (ut still no"e to the ro"e
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With Hoist 'ope Selected & can
no* pic% the Wheel for My Hoist .rame
29
7 need a .- ft *heel Esee "i#! re#ommendationF to avoid (endin m' ro"e to
Shar". Eou #an see *h' 7 *anted a smaller ro"e I it *ould have allo*ed me
,o use a smaller lo*er inertia *heelF.
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No* & Need to Deal *ith (ail
'ope Sim"le #ase is to et used ro"e
6lso easiest to have just one tail ro"e so
have less s*inin and tanlin.
um(er of tail ro"es is #ommonl' less than
num(er of hoist ro"es.
+0
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&m going to try straight across
Using my *orn7out hoist ropes for tail ropes8
+1
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No* &ll "hec% "onditions at My
$eope Wheel
+2
,1 is the *eiht of the heav' loaded side. ,2 is the *eiht of the lihter em"t'
Side.
Kemem(er I onl' fri#tion sto"s the ro"e from sli""in. ,he ratio of ,1 to ,2
ust therefor not (e more than 1.-
Of #ourse 1.9- is reater than 1.- so life is su#!in riht no*.
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+nother Parameter is (read
Pressure
++
@eo"e *heels are normall' lined *ith a leather li!e fri#tional material. Sin#e *eDon8t *ant the ro"es to #ut the material to "ie#es *e need to limit the load to
6(out +00 "si or less.
Well at least one thin *or!ed.
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So What Do & Do No*
ither ,1 is to (i or ,2 is too little
7 #ould loo! at ro"e *eiht (ut the ro"e *eiht
shifts (a#! and forth from ,1 to ,2 de"endin on*here *e are
% ,he ,1 and ,2 ratios are "i#!ed (' the s"readsheet to (e
*orst #ase
7 #ould ma!e m' s!i" lihter % But a liht dut' s!i" #ould et (eat to "ie#es
% 6nd a lihter s!i" *ould also redu#e ,2
+/
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&dea
7f m' s!i"s *ere heavier then the s!i"s *ould
a##ount for a hiher "er#entae of the *eiht.
Sin#e s!i"s are the for ,1 and ,2 ma!in it alarer "ro"ortion *ill even the ratio
E7 #ould ma!e a similar arument for "i#!in
heavier ro"es (ut ro"es are e:"ensive and (iro"es for larer hiher inertia *heelsF.
+-
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Putting 9 tons of Dead Weight on
My s%ips made it more e4en
+
Of #ourse 78m still not there 'et.
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O% : +dding 6;8; dead *eight
tons to the s%ip did it
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So What "an & Do With My (read
Pressure 7 #an8t #hane m' ,1 and ,2
But 7 #an s"read the load over a reater area
% ,hat unfortunatel' *ould mean ettin a (ier
@eo"e *heel
+?
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(here : + 6= ft Wheel Spreads
the #oad
+97 !no* I the inertia situation su#!s.
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"ome to (hin% +out &t : (he
.actor of Safety Suc%s (oo
/0
Ho* "rofound I 7 "ut more *eiht on the ro"e *ithout strenthenin the ro"e
6nd 7 et into safet' fa#tor trou(le.
EWhere the
one' JoesF
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(a%e + #ittle Weight Off the S%ip
and Put + #ittle More On the 'ope
/1
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(ime to Pic% Out Our Motor
/2
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/+
#oo%ing at Hoist Duty "ycle
Hoist doesn8t al*a's run at a sinle s"eed
7nitial a##eleration ) time it starts to move )
(ut its (' the loadin "o#!et so *e don8tGfloor it
Cree" 1 ) #arefull' #ree"s "ast the loadin
area to avoid tearin somethin u" ain a##eleration ) after #lear of loadin area
) hit it u" to full s"eed
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//
Hoist Duty "ycle
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/-
Duty "ycle "ontinued
Kun at ull S"eed ) until 'ou et #lose
enouh to the to" that 'ou8d (etter slo* do*n
or 'ouLll "ut the s!i" u" some"la#e interestin ain De#eleration ) slo* do*n to #ree"
s"eed (efore 'ou ta!e out the dum" (in
Cree" 2 ) move slo*l' into dum" "osition inal De#eleration ) sto" to dum"
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/
What Si1e Motor!
Ke$uired horse"o*er for motor varies
reatl' throuh hoistin #'#le
6djustments are made (' #al#ulatin theKoot ean S$uared EKSF Horse"o*er
re$uirements
,his re$uires ta!in horse"o*er duties atmulti"le "oints throuh the hoistin #'#le
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(he Spreadsheet Does Your
"alculations
/
,he otor Si>in is
6 fun#tion of somethin
Called W I *hat is
that.A
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/?
(he Mystery of the ))W (erm
W stands for e$uivalent effe#tive *eiht Hoist #ontains motors< ears< and lare
*heels that #ontri(ute inertia to the s'stem
durin a##eleration Could o throuh lon hand and #al#ulate
inertia of ever'thin Eif 'ou8re sadisti#
enouhF
6lternative is to use manufa#tures ta(les that
redu#e inertia to an e$uivalent load on a ro"e.
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/9
Norderg )>ui4alent )ffecti4e
Weight "hart
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'eading the "hart
-0
We !no* it is
6 @eo"e hoist
So 7 *ill use
,he @eo"e line
7 !no* 7 have
6 10ft *heel
So 7 start at
10 and read u"
,o the @eo"e
ine
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& (hen 'ead O4er to the
)>ui4alent )ffecti4e Weight
-1
78ll (e #onservative
7n m' readin and
Call it +
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)nter the Numer and -et Motor
Si1ing
-2
Of #ourse understandin
What all these HP1< HP6
6nd ,S stuff is *ould
6dd a lot of understandin
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@eo"e Hoist -+
(he Horsepo*er Demand of a
$eope Hoist O4er (ime #oo%s #i%e (his
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-/
Understanding $eope Duty
"ycles3 ) Wh' is there a stead' flat line for Horse"o*er re$uired in a @eo"eHoist Dut' C'#le
6 ) Horse"o*er is an ener' out"ut "er unit time. 7t ta!es ener' tolift the s!i" load u" the shaft as it travels at full stead' s"eed.
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--
$eope Duty "ycles3 ) Wh' is there a slo"ed line leadin u"*ard from *hen the hoist starts
6 ) When the hoist is o"eratin at less than full s"eed the load is
trans"orted a lesser distan#e "er unit time and thus the ener' out"ut "er
unit time is less. ,he line has a linear slo"e (e#ause the a##eleration rate is
a #onstant.
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-
(he $eope Duty "ycle3 ) Wh' is there a "ea! that dro"s shar"l' to the flat line forHorse"o*er to run the @eo"e
6 ) ou must add additional for#e to a##elerate the load. 6t the end
of the a##eleration "eriod the additional for#e is no loner needed.
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-
$eope Duty "ycles3 ) Wh' is there a (i dro" in horse"o*er at the end of the full s"eed runfor the hoist
6 ) When the hoist de#elerates< the momentum of the load "rovides "art of
the ener' to !ee" the load movin u" the shaft.
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-?
$eope "ycles3 ) Wh' does the line slo"e do*n at the end of the Hoist
C'#le
6 ) ,he load is slo*in do*n and a##umulatin less "otential
ener' "er unit of time.
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-9
$eope "ycles3) Wh' the funn' dashed lines that sho* more "o*er
(ein used at the start and less (ein re#overed at the end.
6 ) ri#tional losses
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@eo"e Hoist 0
+pproach to +ttac%ing the 'MS
Horsepo*er 'e>uirements We *ill #al#ulate #om"onents of Horse"o*er
re$uirements% HP
1 *ill (e the horse"o*er to a##elerate the load
% HP+ *ill (e the horse"o*er to move the load at full s"eed u"
the shaft
% HP2 *ill (e the horse"o*er re#overed from momentum *hen
the load is de#elerated
% HP *ill (e the horse"o*er still re$uired to lift the load after
de#eleration starts
% HP/ and HP- *ill #over fri#tional losses
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You "an See (hose Horsepo*ers
"alculated8
1
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@eo"e Hoist 2
Horsepo*er ?6 3.or $eope
Hoists5 HP1 4 ,S M N2 5 E--0 M M ,aF
% Where ,S is the ,otal Sus"ended oad
% N is the Nelo#it'% is the a##eleration of ravit'
% ,a is the a##eleration time to et the hoist to full
s"eed and in#ludes time to a##elerate to #ree" s"eed
Einitial a##eleration t1F and then to a##elerate to fulls"eed Et+F
% ,a 4 t1 t+
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@eo"e Hoist +
(otal Suspended #oad
,S 4 W 2000 M S 2ME2000MSWF Ko"e Weiht E(oth sidesF
% S and SW are the s!i" *eiht and load in tons
% K is the ro"e *eiht% Be#ause of tail ro"e there is a full lenth of ro"e on (oth s!i" sides
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@eo"e Hoist /
Horsepo*er ?@ 7 Po*er to #ift a
#oaded S%ip at .ull Speed HP+ 4 N M 2000 M S 5 --0
% ote that the s!i" *eiht term is missin
% 7 have a s!i" oin do*n to (alan#e a s!i"#omin u"
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@eo"e Hoist -
Horsepo*er ?A 7 Negati4e
Horsepo*er from Momentum During Deceleration HP2 4 ) ,S M N2 5 E--0 M M ,r F
% Where ,r is time durin de#eleration
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@eo"e Hoist
Horsepo*er ?2 7 #osses in -ears
and Dri4es Derived em"iri#all' rather than (' "h'si#s
fundamentals
HP/ 4 0.111 M E2000 M S M N 5 --0F
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@eo"e Hoist
+pproach to 'MS Horsepo*er
"ontinued We *ill add the different fundamental #om"onents
of horse"o*er to et the horse"o*er needs at
various #ardinal "oints durin the lift
We *ill la(el these #ardinal "oints 6 throuh
% :am"le D is the "ea! "o*er re$uired at the heiht of
the a##eleration "hase
We *ill "ut the horse"o*er values at the #ardinal "oints into the KS horse"o*er e$uation and use
that to si>e the motor.
"alculate Horsepo*er at @
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@eo"e Hoist ?
"alculate Horsepo*er at @
"ardinal Points Point 6 ) Pea! of the 6##eleration Phase HP6 4 HP1 HP+ HP/
Point B ) Durin ull S"eed Kun
HPB 4 HP+ HP/
Point C ) 6t 7nitiation of De#eleration
HPC 4 HP2 HP+ HP/
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Yip : (here are the 4alues
9
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@eo"e Hoist 0
One More Monster Po*er Sin%
,hese Bi otors have an 6rmature to Sin!
a Battleshi"= ) ta!es a lot of inertia to s"in
the thin u" or do*n HP- Eto s"in it u"F 4 0.- M HP6 M 1.2 5 ,a
HP9 Eto s"in do*nF 4 )0.- M HP6 M 1.2 5 ,r
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(hose "alculations are Done (oo
1
" ti " di l P i t f
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@eo"e Hoist 2
"orrecting "ardinal Points for
+rmature +cceleration Point D is the revision of 6 "ea! of
a##eleration
HPD 4 HP6 HP-
Point is revision of C initiation of
De#eleration
HP 4 HPC HP9
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+nd the "alculations +re (here
+
'MS )>uations Depend on
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@eo"e Hoist /
'MS )>uations Depend on
Motor (ype or 6C otor
HPrms 4 E HPD2 M ,a HPB2M ,fs HP2M ,r F5
E 0.- M ,a ,sf 0.- M ,r 0.2- M tr F Q0.-
% Where% ,a is a##eleration time
% ,sf is full s"eed time
% ,r is de#eleration time
% tr is the rest time
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-
'MS Horsepo*er for D" Motors
umerator is the same as 6C
Denominator is #haned to
E 0.- M ,a ,sf 0.- M ,r 0.- Mtr F
KS HP DC 4 umerator5
DenominatorQ0.-
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#oo%s #i%e & Need +out 6A==
HP
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(ime to Pic% the Motors
7 need to #hoose the num(er and si>e of motor and the inertia of the rotor
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"onsider Pic%s
?
78d rather o 6C *ith fre$uen#' #ontrol. 78d li!e to do 2 00 h" motors (ut
With a 10 ft diameter @eo"e *heel 78ll still need ear redu#tion so 7 *ould
Onl' et a(out 9/; transmission I ' "i#! a 12-0 t*o "ole 6C
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Plug7&n My Motor Parameters
and -ear 'eduction )fficiency
9
O! I ,hat seems to *or!
Eote that there are limits to ho* mu#h 'ou #an turn do*n the s"eed of 6 motor *ith varia(le fre$uen#' drivesF
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Our #ast (as% is to Si1e the 0ra%e
?0
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We Want (*o (hings .rom Our
0ra%e Hold the ma:imum "ossi(le u(alan#ed load
*ith a 1.- fa#tor of safet'
7f a full s"eed load "asses the ore dum"s"eed it must "erform an emeren#' sto"
(efore the s!i" #rashes into the to" of the
headframe.
?1
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?2
Ne/t Step is to Design the
0ra%ing System Durin Clut#hin O"erations the Bra!e must hold the
load so it doesnLt o to the shaft (ottom
Desin "ra#ti#e is to rate the (ra!e and #lut#h to hold
the ma:imum load "lus -0;
BK 4 CK 4 ED52F M E 2000MS 2000MSW H M Wr M
nF M E1.-F R&nits are ft)l(s
% D is drum or *heel diameter
% BK and CK are Bra!e and Clut#h Katins in ftMl(s tor$ue
% ote this is the load on one side of a drum hoist if the other is
#lut#hed
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(he Spreadsheet 'uns the
"alculation
?+
7 need to set m' (ra!e ratin to at least this si>e.
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& .ill &n the Numers
?/
Bra!e ratin #omes from the re#ommendation
ass of the rotor #ame from the motor s"e#ifi#ation list
,he ear ratio and s"eed *ere *or!ed to et a *or!a(leKatio and a motor s"eed that *as *ithin the turn)do*n
imit for the motor.
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?-
+nother .actor is 0ra%e
Performance During an )mergency Stop Desin is done on *orst #ase s#enario
% ma:imum un(alan#ed load travelin at full s"eed
% dis#overed *ith a minimum toleran#e distan#e
(efore 'ou ride into the head frame or #rash into the
(ottom
ust either desin for a toleran#e distan#e 'our (ra!e #an sto" in or si>e u" the (ra!e for the
toleran#e 'ou have.
D i " t
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?
Design "oncept
6ssume the Bra!e must fiht aainst thema:imum un(alan#ed load
% Su(tra#t un(alan#ed load from (ra!e #a"a#it'
% ,his leaves the net for#e availa(le for the emeren#'
sto"
&se e*tons Se#ond a*
% @no* the net for#e availa(le
% @no* total mass in motion% Solve for the de#eleration rate
Cal#ulate the time and distan#e to sto"
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?
.ormula
oo! at a:imum differential load
% W 4 E,1 ) ,2F M 2000
% ,1 4 a: load 4 S SW EH M Wr M n52000F% ,2 4 in Balan#in oad 4 SW
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(he Spreadsheet +pplies the
.ormula to -et the DifferentialWeight8
??
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?9
(he Mass that must e Stopped
,o use e*tonLs a* to et or#e Ke$uirements
the load must (e in mass% eans *e must use slus ) some ho* a s'stem made (' @ins usin slus
sounds *ron
4 E W M K 2 WK 2m M JK 2F 5 K 2 ,1 M2000
,2 M 2000 Q 5 +2.2% Where K is the Drum or Wheel Kadius D52
% WK 2m is the inertia of the motor rotor in ft 2
% JK is the ear ratio of the motor to the drive
% ote that the K 2 terms are needed to #onvert rotatin inertia to e$uivalent
mass
Sol4ing for the Deceleration 'ate
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90
Sol4ing for the Deceleration 'ate DK 4 E B ) W F 5
% DK 4 De#eleration Kate
% 4 ass to (e sto""ed
% W 4 et un(alan#ed load E,1 ) ,2F M 2000
% B 4 Bra!e Katin in l(s linear for#e
% Jet B 4 BK 5 K I BK is the Bra!e Katin in tMl(s
6""l'in the De#eleration Kate% ,ime to Sto" 4 , 4 N 5 DK
% Bra!in Distan#e 4 S 4 EN52F M ,
Che#! Bra!in Distan#e 6ainst 6vaila(le or ma!e
sure 'ou have the distan#e
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@eo"e Hoist 91
(he -ear 'atio Prolem
JK 4 N 5 ND
% N is r"m of motor at rated travel s"eed
% ND is r"m of Drum ND 4 N 5 E"i M D F R remem(er 7 need r"m
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Sol4ing for the Mass to e
Stopped
@eo"e Hoist 92
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"hec% Out Our Stopping
Distance
u" I We 6""ear to Be O@