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Development of an Active Rope Guide to Generate Zero-Degree Drum Angles for True Vertical Lift Hoists

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Abstract

In the crane industry, the sizing of hoisting machinery is based on several factors, including the weight of the load being lifted, the frequency of the duty cycles, the speed at which the lifting is done, and the method of rope reeving. Industrial cranes, such as those used in the Paper, Automotive, Steel, and Power industries, often utilize hoists with a true vertical lift rope reeving method that employs both left-handed and right-handed ropes. The rope drum is a key component that plays a crucial role in determining the size of the hoisting gear. International design standards, such as FEM, EN, and CMAA, govern the dimensioning of the rope drum. These design standards not only confirm the strength of the drum tube but also provide guidance on the maximum permissible fleet angle for ropes leaving the drum. This paper presents the development of an active rope guide that aims to create zero-degree drum angles, thus activating the area of use that is typically forbidden by crane standards. To test this concept, a prototype was built.

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Abbreviations

ARG:

Active rope guide

C :

Distance between guiding sheaves in ARG and hook block sheaves (mm)

d :

Rope diameter (mm)

D :

Rope drum pitch diameter (mm)

EOT:

Electric overhead traveling

H:

Distance between guiding sheaves and top of hook block (mm)

HOL:

Height of lift (mm)

P :

Drum groove pitch (mm)

PLC:

Programmable Logic Controller

SWL:

Safe working load (ton)

T:

Rope travel on drum (mm)

TVL:

True vertical lift

\(\eta_{reev}\) :

Reeving efficiency

i rope :

Reeving ratio or mechanical advantage

T drum :

Drum torque (kN m)

F h :

Guiding force (N)

α :

Angle of the grooves on the drum (°)

\(\beta_{L}\) and \(\beta_{R}\), ϕ, ν :

Fleet angles on the pulley (°)

\(\beta_{L} + \alpha\) and \(\beta_{R} - \alpha\) :

Fleet angles on the drum (°)

P_angle:

Pitch angle of groove (°)

F_angle:

Fleet angle (°)

R_angle:

Rope angle (°)

X_up:

Rope distance in up position (mm)

X_low:

Rope distance in lower position (mm)

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Acknowledgments

The authors would like to acknowledge Konecranes Finland for the funding, test facilities and resources to carry out this prototype test. A special thanks to Mr. Jari Kaiturinmäki and Mr. Jari Jalkanen for their guidance and support during the project.

Funding

This work was funded by Konecranes Finland.

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Authors and Affiliations

  1. AISSMS College of Engineering, Pune, Maharashtra, India

    Dinesh Y. Dhande & Vinit Ahluwalia

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  1. Dinesh Y. Dhande
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  2. Vinit Ahluwalia
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Correspondence to Dinesh Y. Dhande.

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Dhande, D.Y., Ahluwalia, V. Development of an Active Rope Guide to Generate Zero-Degree Drum Angles for True Vertical Lift Hoists. J Fail. Anal. and Preven. 23, 1001–1025 (2023). https://doi.org/10.1007/s11668-023-01639-2

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