Sizing Calculation of Swl 25t Ah5t Lift 9.3m Span 9.75m Lt 91m Crane (3299.1). (1)

8/3/2019 Sizing Calculation of Swl 25t Ah5t Lift 9.3m Span 9.75m Lt 91m Crane (3299.1). (1)

1/15


2/15

DATE - 24/10/2011 CON. 3299.1/CAL/R0CAP 25T /5T

MAIN HOIST MOTOR POWER CALCULATION

As per IS3177:1999

Safe Working Load (T) swl 25:= T

Weight of attachments (T) wt_att 0.7:= T

Specified Speed (mpm) V_hoist 3:= mpm

Duty factor for specified class of duty Cdf_hoist 1.5:= (For M5 IS- 3177 Refer Table-2, Page no.-7)

Gear Efficiency Eg 0.985:= (For Hardaned profile ground and oilsplashed lubrication as per IS- 3177

Annex -C,C-1, Page no. 52)

Number of Gears pairs M_mhoist 4:=

Sheave Efficiency Es_hoist 0.99:= (For antifriction deep groove bearing as perIS- 3177 Annex -C,C-1, Page no. 52)

Number of rotating Sheaves n_mhoist 6:=

Service Factor for AC motors Cv_hoist 0.67:= (IS- 3177 Annex -C,C-1, Page no. 53)

Ambient temperature Deration Factor Der_fac 0.95:= (IS- 3177 Annex -C,C-1, Page no. 53)

Motor_kw_hoist_MHswl wt_att+( ) V_hoist Cv_hoist Cdf_hoist

6.12 EgM_mhoist

Es_hoistn_mhoist

Der_fac:=

Motor_kw_hoist_MH 15.038= kw

Considering 10% as margin Motor KW required is

Motor_kw_req Motor_kw_hoist_MH 1.10:=

Motor_kw_req 16.542= kw

Selected Motor 18.5 kw

TEFC, Sq cage, 4 pole, 40%CDF, S4 duty, with temp. rise limited to class B insulation, IP-55, 150

ST/HR, ambient temp 45C,suitable derated for 50C 415v10% & 50hz5% and variation

Frame Size : 180L

FOR REVA INDUSTRIES LTD.

Authorised Signatory

PAGE - 2 - 15


3/15


MAIN HOIST BRAKE TORQUE CALCULATION

as per IS3177:1999

Main Hoist Motor RPM MH_mot_rpm 1440:=

Main Hoist Motor Required KW Motor_kw_hoist_MH 15.038=

Input_Torque_MH975 Motor_kw_hoist_MH

MH_mot_rpm:=

Input_Torque_MH 10.18= KgM.

Brake torque service factor=1.5

Required Braking Torque

Braking_Torque_MH 1.5 Input_Torque_MH:=

Braking_Torque_MH 15.27= KgM.

Selected Brake

2 No. AC EHT Size 200 -18 with minimum rated torque 20 KgM.



PAGE - 3 - 15


4/15


AUXILARY HOIST MOTOR POWER CALCULATION

As per IS3177:1999

Safe Working Load (T) swl_ah 5:= T

Weight of attachments (T) wt_att_ah 0.1:= T

Specified Speed (mpm) V_hoist_ah 6:= mpm

Duty factor for specified class of duty Cdf_hoist 1.5= (For M5 IS- 3177 Refer Table-2, Page no.-7)

Gear Efficiency Eg 0.985:= (For Hardaned profile ground and oilsplashed lubrication as per IS- 3177

Annex -C,C-1, Page no. 52)Number of Gears pairs A_hoist 3:=

Sheave Efficiency Es_hoist 0.99= (For antifriction deep groove bearing as perIS- 3177 Annex -C,C-1, Page no. 52)

Number of rotating Sheaves n_hoist 3:=

Service Factor for AC motors Cv_hoist 0.67= (IS- 3177 Annex -C,C-1, Page no. 53)

Ambient temperature Deration Factor Der_fac 0.95= (IS- 3177 Annex -C,C-1, Page no. 53)

Motor_kw_hoist_ahswl_ah wt_att_ah+( ) V_hoist_ah Cv_hoist Cdf_hoist

6.12 EgA_hoist

Es_hoistn_hoist

Der_fac:=

Motor_kw_hoist_ah 5.704= kw

Considering 10% as margin Motor KW required is

Motor_kw_req_ah Motor_kw_hoist_ah 1.10:=

Motor_kw_req_ah 6.275= kw

Selected Motor 7.5 kw


ST/HR, ambient temp 45C, suitable derated for 50C 415v10% & 50hz5% and variation

Frame Size : 132 M (IS:325)



PAGE - 4 - 15


5/15


AUXILARY HOIST BRAKE TORQUE CALCULATION

as per IS3177:1999

Aux Hoist Motor RPM ah_motor_rpm 1440:=

Aux Hoist Motor Required KW Motor_kw_hoist_ah 5.704=

Input_Torque_ah975 Motor_kw_hoist_ah

ah_motor_rpm:=

Input_Torque_ah 3.86= KgM.



Braking_Torque_ah 1.5 Input_Torque_ah:=

Braking_Torque_ah 5.79= KgM.

Selected Brake

2 Nos. AC EHT Size 100 -18 with minimum rated torque 6 KgM.



PAGE - 5 - 15


6/15


CROSS TRAVEL MOTOR POWER CALCULATION as per IS3177:1999

Safe Working Load (T) swl 25= T

Weight of crab (T) wt_crab 5:= T

Specified Speed (Mpm) V_trolley 15:= MPM

Duty factor for specified class of duty Cdf_trolley 1.25:= (For M5 IS- 3177 Refer Table-2, Page no.-7)

(For Hardaned profile ground and oil

splashed lubrication as per IS- 3177


Gear Efficiency Eg 0.985=

Number of Gears pairs M_ct 3:=

Overall Friction Factor F 8:= (IS- 3177 Annex -C,C-2.2, Page no. 54)Average linear acceleration a_ct 8:= (IS- 3177 Annex -C,C-2.2, Page no. 54)

Torque Factor T 1.7:= (IS- 3177 Annex -C,C-2.2, Page no. 54)

Der_fac 0.95= (IS- 3177 Annex -C,C-1, Page no. 53)

Service Factor for Trolley S_ct 1.06:= (IS- 3177 Annex -C,C-1, Page no. 54)

Number of drives n_ct 1:=

Motor_kw_ctswl wt_crab+( ) V_trolley S_ct Cdf_trolley

6117 T( ) n_ct( ) Der_facF

1100 a_ct

981 EgM_ct

+

:=

Motor_kw_ct 1.049= KW

Considering 10% margin Motor KW required is

Motor_kw_req_ct Motor_kw_ct 1.10:=

Motor_kw_req_ct 1.154= KW

Selected Motor 1.5 KW


ST/HR, ambient temp 45C, suitable derated for 50C 415v10% & 50hz5% and variation

Frame Size : 90S



PAGE - 6 - 15


7/15


CROSS TRAVEL BRAKE TORQUE CALCULATION

as per IS3177:1999

Cross Travel Motor RPM ct_mot_rpm 1440:=

Cross Travel Motor Required KW Motor_kw_ct 1.049=

Input_Torque_ct975 Motor_kw_ct

ct_mot_rpm:=

Input_Torque_ct 0.711= KgM.



Braking_Torque_ct 1.25 Input_Torque_ct:=

Braking_Torque_ct 0.888= KgM.

Selected Brake

1. No. of EM DC DISC Brake 10 with minimum rated torque 1.6 KgM.



PAGE - 7 - 15


8/15


LONG TRAVEL MOTOR POWER CALCULATION

as per IS3177:1999

Safe Working Load (T) swl 25= T

Weight of Crane (T) wt_crane 15:= T

Specified Speed (mpm) V_lt 23:= mpm

Duty factor for specified class of duty Cdf_lt 1.25:= (For M5 IS- 3177 Refer Table-2, Page no.-7)

Gear Efficiency Eg 0.985= (For Hardaned profile ground and oilsplashed lubrication as per IS- 3177


Number of Gears pairs M_lt 3:= (IS- 3177 Annex -C,C-2.2, Page no. 54)

Overall Friction Factor F 8= (IS- 3177 Annex -C,C-2.2, Page no. 54)

Average linear acceleration a_lt 10:= (IS- 3177 Annex -C,C-2.2, Page no. 54)

Torque Factor T 1.7= (IS- 3177 Annex -C,C-2, Page no. 53)

Ambient temperature Deration Factor Der_fac 0.95= (IS- 3177 Annex -C,C-2, Page no. 54)

Service Factor for Bridge S_lt 1:=

Number of drives n_lt 2:=

Motor_kw_ltswl wt_crane+( ) V_lt S_lt Cdf_lt

6117 T( ) n_lt( ) Der_facF

1100 a_lt

981 EgM_lt

+

:=

Motor_kw_lt 1.149= KW

Considering 10% margin Motor kw required is

Motor_kw_req_lt Motor_kw_lt 1.10:=

Motor_kw_req_lt 1.263= KW

Selected Motor 1.5 KW

TEFC, Sq cage, 4 pole, 40%CDF, S4 duty, with temp. rise limited to class B insulation, IP-55, 150ST/HR, ambient temp 45C,suitable derated for 50C 415v10% & 50hz5% and variation

Frame Size : 90S



PAGE - 8 - 15


9/15


LONG TRAVEL BRAKE TORQUE CALCULATION

as per IS3177:1999

Long Travel Motor RPM lt_mot_rpm 1440:=

Long Travel Motor Required KW Motor_kw_lt 1.149=

Torque at Motor Stage

Input_Torque_lt975 Motor_kw_lt

lt_mot_rpm:=

Input_Torque_lt 0.778= KgM.



Braking_Torque_lt 1.25 Input_Torque_lt:=

Braking_Torque_lt 0.972= KgM.

Selected Brake

2. No. of EM DC DISC Brake 10 with minimum rated torque 1.6 KgM.



PAGE - 9 - 15


10/15


MAIN HOIST WIRE ROPE CALCULATION

as per IS3177:1999

Safe Working Load (T.) swl 25=

No of falls No_falls 8:=

Weight of attachments (T.) wt_att 0.7=

Load per fall of Rope (T.) load_fall_MHswl wt_att+

No_falls:=

load_fall_MH 3.212=

Minimum Practical Co-efficient of utilization Zp 3.5:=IS 3177:1999 AMENDMENTNO. 2 JULY 2003. Page 10,clause 8,3.2 (Second Revision)

Duty Factor for Hoisting Cdf_hoist 1.5=

Required Breaking Strength of Rope

F0_MH load_fall_MH Zp Cdf_hoist:=

F0_MH 16.866= T

Type of core/cons = STEEL CORE / 6x36

Tensile Strength = 180 Kg/mm2 (1770N/mm2)

Wire Rope Dia Selected = 18 mm.

Minimum Breaking Strength = mbs 20.79:= T (IS : 2266)

Factor of Safety Achived = fosmbs Zp Cdf_hoist

F0_MH:=

fos 6.472=

Hence Selection of wire rope is O.K.



PAGE - 10 - 15


11/15


AUXILARY HOIST WIRE ROPE CALCULATION

as per IS3177:1999

Safe Working Load (T.) swl_ah 5=

No of falls No_falls_ah 4:=

Weight of attachments (T.) wt_att_ah 0.1=

Load per fall of Rope (T.) load_fall_AHswl_ah wt_att_ah+

No_falls_ah:=

load_fall_AH 1.275=

Minimum Practical Co-efficient of utilization Zp 3.5= IS 3177:1999 AMENDMENTNO. 2 JULY 2003. Page 10,clause 8,3.2 (Second Revision)

Duty Factor for Hoisting Cdf_hoist 1.5= (For M5 IS- 3177 Refer Table-2, Page no.-7)

Required Breaking Strength of Rope

F0_AH load_fall_AH Zp Cdf_hoist:=

F0_AH 6.694= T

Type of core/cons = STEEL CORE / 6x36

Tensile Strength = 180 Kg/mm2 (1770N/mm2)

Wire Rope Dia Selected = 11 mm.

Minimum Breaking Strength AH = mbs_a 7.74:= T (IS : 2266)

Factor of Safety Achived = fos_ambs_a Zp Cdf_hoist

F0_AH:=

fos_a 6.071=

Hence Selection of wire rope is O.K.



PAGE - 11 - 15


12/15


CROSS TRAVEL WHEEL LOAD AND DIA CALCULATION

as per IS3177:1999

Safe Working Load swl 25= T

Span of the crane span 9.75:= M

Crane weight wt_crane 15= T

Crab weight wt_crab 5= T

centroid of load wrt CT wheel cent_load 1.07:=

No CT Wheels no_wheels_ct 4:=

Crab Wheel Base (mm) Wheel_base_ct 2500:=

MAX WHEEL LOAD (CT)

max_wh_load_ctwt_crab

no_wheels_ct

swl

no_wheels_ct

2

Wheel_base_ct( ) cent_load 1000(

Wheel_base_ct+:=

max_wh_load_ct 8.4= T

MIN WHEEL LOAD (CT)

min_wh_load_ctwt_crab

no_wheels_ct

swl

no_wheels_ct2

cent_load 1000

Wheel_base_ct

+:=

min_wh_load_ct 6.6= T

WHEEL HARDNESS

BHw = Brinnel Hardness of Wheel Rim

BHr = Brinnel Hardness of the Rail/Rectangular bar BHr 170:=



PAGE - 12 - 15


13/15


Cl 1.0:= (IS- 3177 Annex -C,C-1, Page no. 13)

Cz 1.0:= (IS- 3177 Annex -C,C-1, Page no. 13)

Cd 1.09:= (IS- 3177 Annex -C,C-1, Page no. 13)

BHw1.3 BHr Cl

Cz Cd:=

BHw 202.752=

MEAN LOAD ACTING ON THE WHEELS

Pmean2 max_wh_load_ct min_wh_load_ct+

3:=

Pmean 7.8= T

Pmean Pmean 10000:= N

WHEEL DIAMETER

duty factor Cdf 1.25:= (For M5 IS- 3177 Refer Table-2, Page no.-7)

Hardness factor for wheel material Cbh 4.05:=

safety factor depending on the material used Csf 1:=

Co-efficient depending on the speed of rotation of the wheel Csp 1.06:= (O/P RPM = 19.09)

Head width for 63x32 rec bar rail B 63:= mm

Usefull width of rail a 63:= mm

Diameter of Wheel D_wheel_ctPmean Cdf Csf

1.5 a Cbh Csp:=

D_wheel_ct 240.332= mm

Diameter of wheel Selected = 250 mm



PAGE - 13 - 15


14/15


LONG TRAVEL WHEEL LOAD AND DIA CALCULATION

as per IS3177:1999

Safe Working Load swl 25= T

Span span 9.75= M

crane weight wt_crane 15= T

Crab weight wt_crab 5= T

Minimum Hook Approach min_hook_app 1.0:= M

NO of Wheels For Long Travel no_wheels_lt 8:=

MAX WHEEL LOAD (LT)

max_wh_load_ltwt_crane wt_crab( )

no_wheels_lt

swl wt_crab+

no_wheels_lt

2

span min_hook_app

span+:=

max_wh_load_lt 7.981= T

MIN WHEEL LOAD (LT)

min_wh_load_ltwt_crane wt_crab( )

no_wheels_lt

swl wt_crab+

no_wheels_lt2

min_hook_app

span+:=

min_wh_load_lt 2.019= T

WHEEL HARDNESS

BHw_lt = Brinnel Hardness of Wheel Rim for LT

BHr_lt = Brinnel Hardness of the Rail for LT ( 90 LBS ) BHr_lt 200:=

Cl_lt 1.29:= (IS- 3177 Annex -C,C-1, Page no. 13)

Cz_lt 1.08:= (IS- 3177 Annex -C,C-1, Page no. 13)

Cd_lt 1.03:= (IS- 3177 Annex -C,C-1, Page no. 13)



PAGE - 14 - 15


15/15


BHw_lt 1.3 BHr_lt Cl_ltCz_lt Cd_lt

:=

BHw_lt 301.51= BHN

Pmean_lt2 max_wh_load_lt min_wh_load_lt+

3:=

Pmean_lt 5.99359= T

Pmean_lt Pmean_lt 10000:= N

WHEEL DIAMETER for Long Travel

class duty factor Cdf 1.25= (For M5 IS- 3177 Refer Table-2, Page no.-7)

hardness factor for wheel material Cbh_lt 8.65:=

safety factor depending on the material used Csf 1=

Co-efficient depending on the speed of rotation of the wheel Csp_lt 0.99:= (Out Put RPM=36.6)

Head width for R52 (105lbs rail) B_lt 61.9:= mm

corner radius r 9.5:= mm

Usefull width of rail lt_a B_lt 4.r

3:= mm

lt_a 49.233=

Diameter of Wheel D_wheel_ltPmean_lt Cdf_lt Csf

1.5 lt_a Cbh_lt Csp_lt:=

D_wheel_lt 118.466= mm

Diameter of wheel Selected = 200 mm



PAGE - 15 - 15

Documents

Sizing Calculation of Swl 25t Ah5t Lift 9.3m Span 9.75m Lt 91m Crane (3299.1). (1)