HOISTING EQUIPMENT

1
HOISTING EQUIPMENT
• Hoisting equipment are usually powered
equipment used for lifting and lowering
unit and varying loads intermittently.
• In certain equipment while lifting and
lowering, shifting of the load can also be
accomplished, within an area known as
the reach of the equipment.

2
 CONT’D
• The component parts and units of hoisting
equipment include:
o Flexible hoisting appliances;
o Pulleys and pulley systems;
o Sprockets and drums;
o Load handling attachments;
o Stopping and braking devices;
o Drivers (motors), Transmission components (axles,
shafts, bearings, clutches, etc.);
o Rails and travelling wheels;
o Machine structures (crane frames) and Control devices.3
 CONT’D
• There are three groups of hoisting equipment
having the following main distinctive features.
i. Hoisting machines: designed as self-lifting
gear and for hoisting and moving.
ii. Cranes: a combination of separate hoisting
mechanism with a frame for lifting and/or
moving loads.
iii. Elevators: a group of periodic action machine
intended for raising loads with guide- ways.

4
 CONT’D
• The main technical parameters are:
o Lifting capacity: the maximum safe load the
machine is designed to handle;
o Dead weight of the machine: the total weight of
the machine with out the load;
o Speed of various movements: hoisting speed,
the bridge travel speed and the trolley travel
speed;
o Lifting height: the height to which the load is
intended to be raised;
o Geometrical dimension of the machine. 5
 CONT’D
• Hoisting machines are periodic-action machines
and their hourly capacity can be determined
from:
Qhr n Q

• Where n = number of machine cycles per hour

Q = weight of live load [tons]

Qhr = hourly capacity [tons/h]

6
 CONT’D
• When handling bulk material, the weight of live
loads is:
Q = V  

• Where: V = capacity of bucket, grab etc [m3]

 = filling factor
 = specific weight [t/m3]

7
 CONT’D
• The total load lifting capacity of the machine will
be:
Qtot Q  G

• Where: Q = live load [tons]

G = weight of bucket, grab, etc. [tons]

8
 CONT’D
• The number of cycle per hour is:
3600
n
t
• Where:

operating time
starting time
constant speed time
retardation time
time lost in grappling and discharging the load
cycle time (in seconds)
9
 DUTY CHARACTERISTICS OF HANDLING
MECHANISMS
• Factors acting on the operating conditions are:
1. Load on the machine
2. Its annual and daily utilization
3. Relative duty factory (DF)
4. Ambient temperature
• Mean lifting capacity utilization:
Qm
K load 
Qn
Where: Q=
m mean value of load [tons]

Qn= nominal load [tons] 10

 CONT’D
• Yearly utilization factor:

Days in operations per year

K year 
365

• Daily utilization factor:

Hours in operations per day

K day 
24

11
 CONT’D
• Hourly utilization factor:
Time - on in an operationa l hour(min )
K hr 
60

• Mean utilization of the machine per working

cycle: t op
DF  100%
t op  tidle

• The total time-on, T, of a mechanism throughout

its life, h (in years)
DF
T 365K 24 K K  h
100
year day hr
12
 CONT’D

• Duties of Hoisting Machinery

Duty Mean Utilization of Mechanism
By Time Duty Factor Temperature
K load (DF) 0
C
K year K day %
Light L 0.5 0.25 0.33 15 25
Medium M 0.5 0.5 0.67 25 25
Heavy H 0.75 0.75 0.67 40 25
Very Heavy VH 1.0 1.0 1.0 40 45

13
FLEXIBLE HOISTING APPLIANCES
• Hoisting machineries use different flexible
hoisting appliances for handling materials some
of which are:
o Hemp ropes
o Welded load chains
o Roller chains
o Steel wire ropes

14
HEMP ROPES
• Hemp ropes have poor mechanical
properties (rapid abrasion, inadequate
strength, rapid damage from sharp
materials and atmospheric effects).
• They can be recommended only for
hand-operated hoisting machinery
(rope pulleys with diameters at least
10d).
15
 CONT’D

Cross-sections of Hemp
Ropes
• Load on the rope [kgf]
2
F =
d
 br
4
For white rope  br  100 kgf/cm2 and
For tarred rope  br  90 kgf/cm2.
16
WELDED LOAD CHAINS
• They are widely used in hoisting installations as
pliable members.

Where t - pitch
d - diameter
B - chain outside width
“A chain is no stronger than its weakest
link” 17
 CONT’D
• Depending on the ratio between the
pitch and the diameter
i. Short-link chains with t3d
ii. Long-link chains witht > 3 d
• Depending on manufacturing accuracy
t 0.03d B 0.05d
i. Calibrated with in and
t 0.1d B 0.1d
ii. Un-calibrated with in and
18
 CONT’D
• Welded chains are formed from oval steel links by a
number of methods.
i. Hammer (forge) welding: the chain bar is formed
by forging to chain shape, then the ends are forge
welded.
ii. Electric resistance welding: the link is made of
two butt-welded half links.

Sequence in the Manufacturing of Welded 19

 CONT’D
Applications
• Because of the shortcoming, welded chains are used in
some hand-operated mechanisms where () in some
power-driven operations where ().
• Preference is given to uncalibrated chains for their
contact is smoother while moving on pulleys or drums.

20
Disadvantages CONT’D
- Heavy weight
- Susceptibility to jerks and
overload
- Sudden failure
- Intensive wear at the link
joints and
- Low safe speed of
movement
Advantages
– Good flexibility in all directions
– Use small diameter pulleys & drums
– Simple design and manufacture
21
 CONT’D
Selection of welded chains
Fbr
Fs 
K
Where
Fbr = breaking load [kgf]
,
K = factor of safety (3 to 8)
Fs = Safe load [kgf]
• Therefore the welded chain is selected based on
the safe load ()
22
ROLLER CHAINS
• They are composed of plates hinge-jointed by pins
and rollers. For light loads, two plates are used;
for very heavy loads, the number of plates can be
increased up to 12.

Simple Roller Chain with Two 23

 CONT’D
• The plates can be secured on the pins by
several methods like retainer rings, pins,
etc

24
 CONT’D
• Roller chains are used for hand-operated hoists and
power-driven winches and hoisting mechanisms of high
load lifting capacity.
• Advantage of chains
 The reliability of operation is higher since the plates are solid.
 Roller chains have good flexibility and therefore they can be
used on small diameter sprockets.
 The friction in the joints is considerably less.
• However, they should not be allowed:
 To carry weight at an angle
 To be used in dusty premises
 To wind on a drum
25
 To a speed greater than 0.25m/s
DATA FOR THE SELECTION OF CHAINS
Chains Drive Factor of Ratio Minimum
Safety, K (D/d) Number
of Teeth
on
Sprocket
Welded calibrated and 3 20 5
uncelebrated Hand 6 30 5

Power
Welded calibrated on sprocket 4.5 20 -
sheaves Hand 8 30 -

Power
Welded uncalibrated (sling) 6 - -
passing around the load -

Welded uncalibrated (sling) 5 - - 26

STEEL WIRE ROPES
• They are extensively used in hoisting
machinery as flexible lifting appliances.
• Comparing to chains they have the following
advantages.
 Lighter weight
 Less exposure to damage from jerks
 Silent operation even at high speeds
 Greater reliability in operation

(a) (b) (c) 27

 CONT’D
Steel Wire Rope Construction
• Wire ropes are manufactured first
by twisting separate wires, cold
drawn and given heat treatment
between drawing stages, into
strands and then into a "round"
rope.
• Wire ropes consist of 6 or 8
strands and a core. Each strand
consists of 19 or 37 wires.

28
 CONT’D
The lays of the rope classifies the wire ropes into:

a. Parallel or long lay ropes: the direction of twist of

wire and strand is the same. They are more flexible and
resist wear better, but tend to spring and are used in
lift.

b. Cross-of regular lay ropes: the direction of the twist

of the wires in the strand is opposite to that of the
strands in the rope.

c. Composite or reverse laid ropes: the wires in two

adjacent stands are twisted in the opposite direction. 29
 CONT’D

Steel Wire Rope Lays

30
KINDS OF WIRE ROPES
1. General Purpose Steel Wire Ropes
a. Ordinary construction: the strands are twisted
of wires of the same diameter. The repeatedly
cross over of the inner wires create zones of
increased unit pressure, which shortens life.
b. Warrington type compound rope: is twisted of
strands with different wire diameters keeping the
proportional pitch of every layer, thus crossovers
are eliminated.

31
 CONT’D
2. Wire Ropes with Flattened Strands
They are usually made from five flattened
strands with a flattened wire core; the strands
are laid on the hemp core.
They experience more uniform pressure and
are used where the rope is subjected to
intensive abrasion and wear.

Ropes with Flattened Strands 32

 CONT’D
3.Locked-coil Steel Wire Ropes
A locked coil rope consists of an outer layer
formed of specially shaped wire and an inner
single lay spiral rope.
Locked-coil wire ropes are used in cable-ways and
cable cranes; they are never met within hoisting
machines.

Locked-coil Ropes 33
 CONT’D
• They have the advantage over the
other wire ropes because they have
specific features of smooth surface,
tightly packed wires and little wear.
• However, their shortcoming is due to
their little flexibility.

34
 CONT’D
Selecting Steel Wire Ropes
• Wires in a loaded rope experience complex stress
consisting of tension, bending, twisting and
compression.
• Thus the total stress can be determined analytically
only to a certain degree of approximation.
• Experiments have shown that life of a rope is
greatly affected by fatigue and can withstand only
a definite number of bends during service life

35
 CONT’D
• Investigations have shown that the rope life is
inversely proportional to the number of bends
where one bend equals the transition of the rope
from a straight position into a bent position or
vise versa.
• Reverse bending reduces the rope life
approximately double of the single bend.
• The number of bends is obtained by the number
of points where the rope runs on and off over a
pulley/ drum surface. 36
 CONT’D
• Depending on the number of bends, the
corresponding rope life can be found from
the ratios
Dmin / d and Dmin / 
D=
min minimumdiameter of pulley/drum
d = diameter of rope
 diameter of one wire
=

37
 CONT’D

No. of bends 1 2 3 4 5 6 7 8
Dmin /d 16 20 23 25 26.5 28 30 31
No. of bends 9 10 11 12 13 14 15 16
Dmin/d 32 33 34 35 36 37 37.5 38

Values of Dmin /d as a Function of Number of

Bends

38
PULLEY AND SHEAVE BLOCK
• A pulley is a wheel on an axle or shaft that is
designed to support movement and change
of direction of a cable or belt along its
circumference.
• Pulleys are used in a variety of ways to lift
loads, apply forces, and to transmit power.
• In nautical contexts, the assembly of wheel,
axle, and supporting shell is referred to as a
"block."
39
 CONT’D
• A pulley may also be called a sheave or
drum and may have a groove between two
flanges around its circumference.
• The drive element of a pulley system can be
a rope, cable, belt, or chain that runs over
the pulley inside the groove.
• The pulley and sheave blocks suitable for
lifting rough surface and heavy loads.
• For this purpose the chains and wire ropes
are used. 40
 CONT’D
• The alloy chains are best suited for
hoisting operation.
• The weakest component of this system is
the load hook.
• The hook fails by straightening.
• Once the hook gets elongated or
straightened, it should be replaced.
• A typical sheave and pulley block is
41
CONT’D

42
 CRANES
• Crane is a materials handling equipment for lifting
or lowering a load by a hook and moving it
horizontally, in which the hoisting mechanism is an
integral part of the equipment.
• A crane may be driven manually or by power and
may be fixed or mobile
• A crane essentially consists of
i. a steel structure,
ii. a hoisting mechanism or a winch mechanism
with its pulley and pulley system,
iii.suitable load handling attachment /s and
iv.drive and controls 43
 CONT’D
• The major classification of cranes is based
on whether they are stationary or mobile.
• Movements of components of these
stationary cranes may be linear, revolving or
combination of both.

44
 CONT’D
Types of cranes
• There are different types of cranes under
each classification, based on their
constructional features and specific uses.
A. Stationary Cranes
i. Jib crane
ii. Overhead Travelling crane (also called
Bridge crane)
iii. Gantry crane
45
 CONT’D
B. Stationary Revolving Cranes
i. Wharf crane
ii. Pillar crane
iii. Tower crane
C. Mobile Cranes
i. Truck/wagon mounted crane
ii. Crawler crane
iii. Railway/Locomotive crane
iv. Floating crane
46
 JIB CRANES
• It consisting of a vertical member (called
pillar or column) from which extends a
horizontal swinging arm called jib, carrying
a trolley hoist or other-hoisting mechanism.
• The jib is generally made from a standard I-
beam section, and can rotate in a horizontal
plane (i.e. no luffing motion) between 180°
up to 360°.
47
 CONT’D

A jib crane
48
 CONT’D
 Jib cranes are inexpensive and widely used
in manufacturing industries for:
• serving individual or a group of work
places in machine shops.
• loading and unloading of vehicles.
• handling ladle, casting and mould in a
foundry.
• moving loads across shop bays and thus
49
BRIDGE CRANES CONT’D

• These cranes essentially consists of

one or more hoisting devices mounted
on a bridge.
• It consists of one or two horizontal
girders, which are supported at each
end by trucks riding on elevated
runways installed at right angles to the
bridge.
50
 CONT’D
• Runways are installed on building columns,
overhead stresses or frames, much above
floor level.
• The hoisting device moves along the bridge
while the bridge moves along the runway.
• Depending on the lifting capacity of these
cranes, the hoisting device may be a hand
operated trolley type hoist, an electric hoist
or a drum-type crane trolley or crab.
51
 CONT’D
• The major advantage of overhead travelling bridge
crane is that it does not interfere with work on floor.

Overhead
Travelling
Cranes or
Bridge
Cranes

52
 CONT’D
• Its characteristics includes:
 It can reach the entire rectangular area bounded
by the bridge length and runway length.
 Runways can extend beyond the building,
supported by columns erected suitably.
 Capacities may vary from small value 1 ton to up
to 1000 tons.
 Bridge cranes are designed and built as per
requirement by specialist companies.
 Requires heavy frame work and are expensive.
 Requires trained operators. 53
 GANTRY CRANES
• Gantry cranes have a girder or bridge, on
which the hoisting device/s operate, similar
to an overhead travelling crane, except
that the bridge is rigidly supported on two
or more legs with wheels which run on
fixed rails or runways at the level of the
floor.
• The movement of the gantry crane may be
done manually or through motor. 54
 CONT’D

Gantry cranes 55
 CONT’D
• The characteristics of a gantry crane are :
 Can be used indoors or outdoors.
 Relatively easy to change its location.
 Simple operation.
 Long life and low maintenance.

56
 CONT’D
• These crane are used for loading and
unloading carriers, outdoor storage
operations, for handling unit or even bulk
materials where movement is short.
• These cranes serve purpose of a bridge crane
and are used where installation of a bridge
crane is not possible.
• Limitation of these cranes are their limited
movement and capacities up to a maximum
of 300 ton. 57
 CONT’D
• The characteristics of a gantry crane are :
 Can be used indoors or outdoors.
 Relatively easy to change its location.
 Simple operation.
 Long life and low maintenance.

58
 MOBILE CRANES
• Mobile crane is used in big construction
projects for lifting heavy loads.
• It is used for loading and unloading for
material in coal mines.
• Loading and unloading of ships.
• To take the load from ground level and
place it into the trucks.

59
CONT’D

60
CONT’D

61
 TOWER CRANES
• These are the crane of swing job type and are
mounted on high steel towers.
• The height of tower maybe 25 to 30 m and
these cranes are found to be suitable in the
construction of tall buildings in congested
areas.
• The ground area required for such cranes is
very small.

62
CONT’D

63
 CONT’D
• The power is supplied by a diesel engine or
by an electric motor.
• A typical derrick crane is illustrated in fig.
• This derrick can be constructed up to 200
tones capacity .
• In stiff leg type derricks, the guy wires are
replaced by trussed structure.
• This type of derricks are suitable for loads
from 10 to 50 tones. 64
 WINCH
• A winch is a mechanism in the shape of a
cylinder or drum, over which rope or chain
is wound.
• If a winch is used only for raising and
lowering, it is sometimes referred to as
hoist.
• The winches are of two types :
1. hand winches
2. power winches 65
CONT’D

66
ARRESTING GEAR AND BRAKES
• In hoisting equipment, use of arresting
gears or brakes is of paramount
importance to prevent the raised load
from getting lowered of its own weight,
when the raising effort is withdrawn.
• Arresting gear is used to hold the load
lifted by winches.

67
 CONT’D
• The common arresting gears are:
a) Pawl and ratchet mechanism(ratchet gearing)
b) Roller ratchet
a) Pawl and ratchet mechanism(ratchet
gearing)
• This comprises of ratchet wheel and a pawl.
• The ratchet teeth can be arranged external or
internal to the wheel.
68
 CONT’D
• The teeth are so designed that the ratchet
wheel runs free over the pawl when the
load is being raised, but the pawl gets
engaged with ratchet tooth when the
ratchet wheel tries to rotate in opposite
direction (lowering direction of load).
• During lowering of load, the pawl has to
be kept deliberately away from ratchet
path.
69
 CONT’D

Ratchet gearing
• Arresting gear is used to hold the being lifted without
interfering in the hoisting process but preventing the
load from coming down due to gravity
70
 CONT’D

Ratchets and pawls

71
 CONT’D
b) Roller ratchet
• It is used as an arresting gear in combination with a
brake.
• Brakes are used for dual purpose of holding the
suspended load at rest and for controlling the
speed of lowering of load.
• Some of these brakes are to be operated while some are
automatic.
• Operated brakes include shoe, band, cone, disk brakes
etc.
• Centrifugal brakes and brakes applied by weight of the
72
 CONT’D
• The ratchet is fitted with the shaft of the drive
and a pawl whose pivot receives support from a
fixed structural part.
• The ratchet teeth number is dependent up on
the purpose and design.
• The following values are some examples
Z=6 to 8 rack and pinion jacks
Z=12 to 20 for independent ratchet arresters
Z=16 to 25 and more for ratchet brakes
73
 CONT’D
• Actuation of the operated brakes may be through
pulling a handle or by pressing a pedal which are
termed as mechanical brakes.
• Actuation can be through energizing magnet by AC
or DC electricity (electromagnetic brakes) or may
be by hydraulic means (electro-hydraulic thrustor
brakes).
• The electromagnetic brakes and electro hydraulic
thrustor brakes can be used as controlled brakes.
Moreover, these brakes can also be used as fail safe
device. 74
 CONT’D
• Normally these are in open condition (brake is not
engaged), but actuates when the power fails.
 Points to observe during use
• The pawls are designed to
prevent reverse rotation.
• They are not suitable for use as
driving ratchets or driving
rotation.
• Ratchets can be manufactured
using a lost wax casting
method. 75
CONT’D

76
CONT’D

77
 BRAKES
• In hoisting machinery, brakes are employed for
controlling the speed of load lowering and
holding the suspended load at rest.
• Depending on the purpose, brakes can be
classified as
 Parking(holding)brakes
 Lowering brakes
 Combined type of both holding and
/lowering/controlling the speed. 78
 CONT’D
• From operational aspect they can be
classified as
• Operated brakes: includes shoe, band,
cone, disc and ratchet brakes with safety
handles.
• Automatic brakes: this includes
centrifugal brakes(to control speed) and
brakes applied by the weight of the load.
79
 Definition of brakes
• A brake is a device by means of which
artificial frictional resistance is applied to a
moving machine member, in order to retard or
stop the motion of a machine.
Characteristics of brakes
• In the process of performing this function, the
brake absorbs either kinetic energy of the
moving member or potential energy given up
by objects being lowered by hoists, elevators80
 CONT’D
• The energy absorbed by brakes is
dissipated in the form of heat.
• This heat is dissipated in the
surrounding air so that excessive
heating of the brake lining does not
take place.

81
Types of Brakes
• The brakes, according to the means used for
transforming the energy by the braking
element, are classified as:
1. Mechanical brakes
2. Hydraulic and pneumatic brakes
3. Electric brakes

82
 CONT’D
1. Mechanical brakes
• Mechanical brakes are operated by mechanical means
such as levers, springs and pedals.
• Depending upon the shape of the frictional material, the
mechanical brakes are classified as a block brake, internal
or external shoe brake, disk brake and band brake.
• Brakes are also classified into two groups according to
direction of the actuating force, namely, radial brakes and
axial brakes.
• Internal and external shoe brakes are radial brakes, while
disc brakes are axial brakes.

83
 CONT’D
2. Hydraulic and Pneumatic Brakes
• Hydraulic and pneumatic brakes are
operated by fluid pressure such as oil
pressure or air pressure.
3. Electric Brakes
• Electrical brakes are operated by magnetic
forces and include magnetic particle brakes,
hysteresis brakes and eddy current brakes.
84
 Energy Absorbed by a Brake

• The first step in the design of a mechanical brake is to

determine the braking-torque capacity for the given
application.
• The braking-torque depends upon the amount of energy
absorbed by the brake.
• The energy absorbed by a brake depends upon the type of
motion of the moving body.
• The motion of a body may be either pure translation or pure
rotation or a combination of both translation and rotation.
• The energy corresponding to these motions is kinetic
energy. Let us consider these motions as follows :
85
 CONT’D
1.When the motion of the body is pure
translation
• Consider a body of mass (m) moving with a velocity v 1

m / s.
• Let its velocity is reduced to v2 m / s by applying the brake.
Therefore, the change in kinetic energy of the translating body
or kinetic energy of translation,

• This energy must be absorbed by the brake.

• If the moving body is stopped after applying the brakes, then
v2 = 0, and
86
 CONT’D
2. When the motion of the body is pure rotation
• Consider a body of mass moment of inertia I (about a given
axis) is rotating about that axis with an angular velocity ω1
rad /s. Let its angular velocity is reduced to ω2 rad /s after
applying the brake. Therefore, the change in kinetic energy
of the rotating body or kinetic energy of rotation,

• This energy must be absorbed by the brake. If the rotating

body is stopped after applying the brakes, then ω2 = 0, and

87
 CONT’D
3. When the motion of the body is a
combination of translation and rotation
• Consider a body having both linear and
angular motions, e.g. in the locomotive
driving wheels and wheels of a moving car.
• In such cases, the total kinetic energy of the
body is equal to the sum of the kinetic
energies of translation and rotation.
• Total kinetic energy to be absorbed by the
brake, 88
 CONT’D
• Also the brake has to absorb the potential
energy given up by objects being lowered by
hoists, elevators etc.
• Consider a body of mass m is being lowered
from a height h1 to h2 by applying the brake.
Therefore the change in potential energy,
E3 = m.g (h1 – h2)

89
 CONT’D
• If v1 and v2 m / s are the velocities of the mass
before and after the brake is applied, then the
change in potential energy is given by

where:
v = Mean velocity = (v1+ v2)/2 , and
t = time of brake application

90
 CONT’D
• Thus, the total energy to be absorbed by the brake,
E = E1 + E2 + E3
• Let Ft = Tangential braking force or frictional force
acting tangentially at the contact surface of the brake
drum,
 d = Diameter of the brake drum,
 N1 = Speed of the brake drum before the brake is
applied,
 N2 = Speed of the brake drum after the brake is
applied, and
 N = Mean speed of the brake drum = (N1+N2)/2
91
 CONT’D
• It known that the work done by the braking or frictional
force in time t seconds;
= Ft × π d N × t
• Since the total energy to be absorbed by the brake must
be equal to the work done by the frictional force,
therefore
E = Ft × π d N × t or
• The magnitude of Ft depends upon the final velocity (v2)
and on the braking time (t).
• Its value is maximum when v2 = 0, i.e. when the load
comes to rest finally. 92
 CONT’D
• We know that the torque which must
be absorbed by the brake,
T = Ft x r = Ft x d/2
Where:
r = Radius of the brake drum
T = braking-torque (N-m)

93