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Rope Drive System Design Guide

The document provides a 12 step process for designing transmission rope drives based on data from the PSG Design Data Book: 1. Select a suitable wire rope based on application and standard designations. 2. Calculate the design load by assuming a safety factor, usually 15, of the expected load. 3. Select the wire rope diameter that meets the design load based on breaking strength tables. 4. Calculate sheave diameter based on rope speed ratios from tables. 5. Select the rope's useful cross sectional area from construction type tables. 6. Calculate wire diameter using strand and wire count relationships. 7. Obtain rope weight from tables based on diameter.

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67 views3 pages

Rope Drive System Design Guide

The document provides a 12 step process for designing transmission rope drives based on data from the PSG Design Data Book: 1. Select a suitable wire rope based on application and standard designations. 2. Calculate the design load by assuming a safety factor, usually 15, of the expected load. 3. Select the wire rope diameter that meets the design load based on breaking strength tables. 4. Calculate sheave diameter based on rope speed ratios from tables. 5. Select the rope's useful cross sectional area from construction type tables. 6. Calculate wire diameter using strand and wire count relationships. 7. Obtain rope weight from tables based on diameter.

Uploaded by

Rajmchz
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© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Design of Transmission System

Design of Rope Drives based on PSG Design Data Book

Step 1: Selection of suitable Wire Rope:


 Select a suitable wire rope based on application. Use the following table

Standard
[Link] Application
Designation
Used as haulage and guy rope in mines, tramways and power
1. 6 x 7 Rope
transmission.
Used as hoisting ropes in mines, quarries, cranes, derricks,
2. 6 x 19 Rope
dredges, elevators, tramways, well drilling etc.
Used as an extra flexible hoisting rope in steel mill ladles,
3. 6 x 37 Rope
cranes, high speed elevators.
4. 8 x 19 Rope Used as an extra flexible hoisting rope.

Step 2: Calculation of Design Load:


 Calculate the design load by assuming a larger FoS, say 15 (or find the design load by
assuming a FoS 2 to 2.5 times the factor of safety given in PSG DDB [Link] 9.1)
 Therefore
 Design Load = Load to be lifted x Assumed FoS

Step 3: Selection of Wire Rope Diameter (d):


 Select a wire rope diameter (d) taken from PSG DDB [Link] 9.5 & 9.6 by taking the
design load as the breaking strength.

Step 4: Calculation of Sheave Diameter (D):


 From PSG DDB [Link] 9.1, obtain the diameter of sheave (or drum). Always larger
sheave diameter is preferred.
 Ratio of 50 m/min of rope speeds – to be increased by 8% for each additional speed of
50m/min.

Step 5: Selection of the area of useful cross section of the rope (A)
 Consulting the following table, select the area of useful cross section of the rope.

[Link] Type of Construction Metallic area of rope A, mm2


1. 6x7 0.38 d2
2. 6 x 19 0.4 d2
3. 6 x 37 0.4 d2
Step 6: Calculation of Wire Diameter (dw):
 Calculate the diameter of wire using the relation

𝒅
dw =
𝟏.𝟓 𝒙 √𝒊

Where,

i = Number of wires in the rope

= Number of strands x Number of wires in each strand.

Step 7: Selection of weight of rope (Wt)


 Obtain the Weight of rope from the table given in PSG DDB [Link] 9.5 and 9.6.

Step 8: Calculation of various loads:


 Calculate the various Load using the following relations:
o Direct Load, Wd = W + Wr
𝑑𝑤
o Bending Load, Wb = 𝜎𝑏 𝑥 𝐴 = 𝐸𝑟 𝑥 𝑥𝐴
𝐷
o Acceleration load due to change in the speed of hoisting

𝑊+ 𝑊𝑒
Wa = ( ).𝑎
𝑔

𝑣2 − 𝑣1
Where, a = (When speed of the rope changes from v1 to v2 in t
𝑡
seconds)

 Starting or stopping load:


 When there is no slack in the rope:
 Starting load, Wst = [Link] = 2(W + Wr)
 When there is slack in the rope:
2.𝑎𝑠 .ℎ.𝐸𝑟
 Starting Load, Wst = 𝜎𝑠𝑡 𝑥 𝐴 = (𝑊 + 𝑊𝑟 ) (1 + √1 + )
𝜎𝑑 .𝑙.𝑔

Step 9: Calculation of Effective Loads:


 Effective Load on the rope during normal working, Wen = Wd + Wb
 Effective Load on the rope during acceleration of the load, Wea = Wd + Wb + Wa
 Effective Load on the rope during starting, West = Wb + Wst
Step 10: Calculation of working (or actual) Factor of Safety (FSW):
 Working Factor of Safety, FS w =

𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑 𝑓𝑟𝑜𝑚 𝑃𝑆𝐺 𝑃𝑔. 𝑁𝑜 9.5 𝑎𝑛𝑑 9.6 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑠𝑒𝑙𝑐𝑡𝑒𝑑 𝑟𝑜𝑝𝑒
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑙𝑜𝑎𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 (𝑊𝑒𝑎 )

 Generally effective load during starting (West) is not used for calculating the working
factor of safety. It is used to calculate the induced stress.

Step 11: Check for Safe Design:

 Obtain the recommended factor of safety (FSR) from the table given in PSG DDB
[Link] 9.1
 Check whether FSW >FSR, then the design is safe and satisfactory
 If FSW < FSR, then the design is not safe and satisfactory. So choose some other
rope with greater breaking strength or increase the number of ropes.

Step 12: Calculation of No of Ropes:


𝑅𝑒𝑐𝑜𝑚𝑚𝑒𝑛𝑑𝑒𝑑 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 𝐅𝐒𝐑
 Number of ropes = =
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 𝐅𝐒𝐖

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