Transcript Friction Drive Winch

Stage Winch Design
Techniques
Motor Winch
Physics
Dan Eslinger
Assistant Technical Director
Seattle Repertory Theatre
Sample Winch Design
Application:
Wagon: 3000#
Rules of thumb:
Velocity: 3 ft/sec standard top speed
4 ft/sec for fast applications
Acceleration: 1 ft/sec2 – 4 ft/sec2
Decide how long for it to reach
top speed.
Max velocity: 3.5 ft/sec
Acceleration: 2 ft/sec2
Casters: 6” diameter soft
rubber running on a flat
wood deck.
Wagon: 3000#
v: 3.5 ft/sec
a: 2 ft/sec2
6” diameter soft rubber casters
First, find the Force required to move the wagon:
Forcetotal = Faccel + Ffriction + Flift
m : mass 
Faccel  m  a
weight
32.2ft/sec2
3000#
2
#
Faccel 

2
ft
/
sec

186
.
3
32.2 ft / sec2
N  r
Frolling friction 
rc
3000#  0.08"
Ff 
 80#
3"
N: normal force, perpendicular to motion,
here: the load
µr: caster’s coefficient of rolling friction
hard rubber on wood: 0.003”
soft rubber on wood: 0.008”
rc: radius of caster
Ftotal  186.3#  2  80#  346.3#
Double the friction to be safe.
Wagon: 3000#
v: 3.5 ft/sec
a: 2 ft/sec2
6” diameter soft rubber casters
Force to move wagon: 346.3#
Size the Motor (hp):
1hp 
Power
550lb  ft / sec
Power  F  v  346.3#  3.5 ft / sec  1212lb  ft / sec
hp 
1212lb  ft / sec
 2.20hp
550lb  ft / sec
Round up to 3 hp motor.
sample: 1750 rpm
Size the Drum: at least 30 times the cable diameter.
1
"
"
cable : 1  30  7.5" min. drum diameter
4
4
circumfere nce    d    8"  25.13"  2.09'
Choose 8” diameter drum.
Wagon: 3000#
v: 3.5 ft/sec
Force to move wagon: 346.3#
a: 2 ft/sec2
6” diameter soft rubber casters
3 hp motor 1750 rpm
2.09’ per drum rev.
Size the Reducer & Sprockets: match desired top speed (3.5 ft/sec)
speed 
3.5ft
60 sec 1re v
 100.48 rev
at drum


min
sec
1 min 2.09ft
1750motorrpm
 17.42 reductionneeded
100.48drum rpm
17 .42
 1.161 reduction needed in sprockets
15
Drum sprocket teeth = 1.161 x reducer sprocket teeth.
e.g. 12 teeth on reducer & 14 teeth on drum.
Choose 15:1 reducer.
Wagon: 3000#
v: 3.5 ft/sec
Force to move wagon: 346.3#
a: 2 ft/sec2
6” diameter soft rubber casters
3 hp motor 1750 rpm
2.09’ per drum rev.
15:1 Reducer 12 teeth – 14 teeth sprockets
Verify Amount of Torque:
hp 
  rpm
5252
  1750
3
5252
T: torque in ft lbs
   9.0 ft  lbs
drum  motor  gear reduction effeciency sprocket reduction
15
14 teeth
 126 ft  lbs  1512 in  lbs at drum
 9.0 ft  lbs   80% 
1
12 teeth
drum  Fcable  rdrum
1512in  lbs  Fcable  4"  Fcable  378#
 346.3
#
Force is great enough
to move wagon!
Compact Manual Winch
Loren Schreiber
Technical Director
San Diego State University
Compact Manual Winch Price List
Less Gears: $380
Item
Vendor
Part Number
Cost
Drive Pulley
Martin Sprocket
3 3V 1060TB
$92.01
Drive Gear
Martin Sprocket
C16160
$80.82
Drive Gear
Martin Sprocket
S1664
$36.76
Bushing 5/8"
Martin Sprocket
2517-5
$17.83
Shafting
McMaster-Carr
1497K41
$26.94
Acme Nuts (2)
McMaster-Carr
94815A118
$9.28
Acme Coupling Nut
McMaster-Carr
93023A680
$16.30
Acme 1 X 10 Screw
McMaster-Carr
98935A866
$19.00
Thrust Bearing
McMaster-Carr
60715K15
$15.28
Bearings (4)
McMaster-Carr
6361K21
$118.20
Tension Pulley (2)
McMaster-Carr
9466T89
$25.88
In-feed Sheaves (2)
McMaster-Carr
9466T83
$17.04
Shoulder Bolt
McMaster-Carr
91264A798
$4.70
Shoulder Washers
McMaster-Carr
91140A266
$7.75
Shaft Collar
McMaster-Carr
6166K29
$0.97
Keyless Bushing
McMaster-Carr
5926K18
$32.76
Misc. Steel
NA
NA
$25.00
Misc. Hardware
NA
NA
$10.00
Total:
$556.72
Jon Lagerquist
Technical Director
South Coast Repertory Theatre
Hand crank winch with
pneumatic disc brake
Disc brake detail
Square shaft end for removable crank
Winch for chain driven
turntable
Cable tension device with welded end
Torque tamer (Dodge) with
quick pins for disconnecting
sprocket from shaft
Winch farm on midrail
Design for new winch yet
to be built
Friction Drive Winch
Chris Fretts
Technical Director
Indiana Repertory Theatre
Friction Drive Winch
Motorized or manual operation
Does not use a Grooved Drum
Uses a keyed four groove Multi-sheave above and five idler sheaves below
Cable is either an endless loop or both ends terminate at wagon
Drive: 2HP Motor with 25:1 Gear Reducer
Motor Output:
1750 RPM
Gear Reducer Output: 70RPM
Top Cable Speed:
3ft./sec.
Shafts: 13/16” Roller Chain: #50
Operation of the winch can be changed from motorized to manual by shifting the
roller chain from the sprocket on the Gear Reducer to the idler sprocket on the
motor mount. By pulling the lower pins on the mount and pivoting the motor
mount on the upper bolts, the roller chain can be shifted to the idler.
A handle for manual operation can be attached to either end of the two shafts
on the top of the winch unit.
In its current configuration, we have installed a additional 1.5:1 output
reduction with the installation of a 20 tooth and 30 tooth sprocket on the two
top shafts. This allows some choice of mechanical advantage if the winch is
operated manually. This additional reduction decreases the motorized top cable
output to 2ft./sec.
Proper tension on the drive
cable is controlled by drawing
back the idler sheave assembly
on the two threaded rods. This
is done by using an impact
wrench on the welded nuts on
back end of each threaded rod.
A rotary encoder is attached with #25 roller chain and
sprockets to the drive sheave to enable positioning
control with our PLC system. This can be interchanged
with a mechanical counter if needed for manual operation
Major Parts List
Baldor #
2HP Motor
#VM3558T
ebay “Buy it now” price $120
25:1 Gear Reducer
#GF2532BG
ebay “Buy it now” price $199
Grainger #
Pillow Blocks (4)
#5X685
Multi-sheave 11.25”OD
#2L371
Sheave 7”OD (5)
#3X923
#50 Roller Chain 10’
#2W095
15 Tooth #50 Sprocket (3)
Varies with Bore
30 Tooth #50 Sprocket
# 6G021
www.surpluscenter.com
Friction Drive Winch
Indiana Repertory Theatre
Peter Pan
Winch
Developed and designed by
Stephen Henson at California
State University Fullerton
with special thanks to Bill Meyer, Matthew McKinney and Scott Shiba for
various creative influences during the process of development
Prototype winch
-Form followed function purely
-Used with a sprocket instead of threegrooved sheave, for direct chain-drive
-Two plates punched to be bolted to the
gear box, welded to a cross member
punched for hangers
Version 2.0 winch
-Rotated motor 90 degrees
-Added two vertical angle irons for pushing
motor away from batten
-Allowing for three-grooved sheave with a
double sheave hung above directly from
batten (not shown)
-Crudely mounted mule blocks for directing
cables along batten to scenery
-Rotary Limit Switch and Junction box
mounted to motor mount plate
View of completed winch frame
-Top plate is designed to facilitate standard Batten hangers, as
well as suspend a swivel double sheave
-Slotted flat bars accommodate multiple positions for head
blocks as well as twisting into alignment with three-grooved
sheave
-Center plates are punched accordingly for mounting gear box
with encoder and motor suspended from gearbox
-Bottom of frame has additional steel structure for mounting
rotary limit switch and junction box containing RJ45 connectors.
-Head block assembly is punched with extra holes to allow for
flexibility with parts
CAD MODEL IMAGES
Matthew McKinney
Graduate Student
San Diego State University
Frankenwinch






Traveler winch
Built from equipment on
hand
2HP AC Vector Motor
Drive Mounted to winch
Massively over powered
(Opera Capable)
Cost: Priceless
Winch hanging from batten
Shipping Crate
Top is removed to attach
directly to batten and lift out
of box
Bill Meyer
Technical Director
Cal State Fullerton
•Basic 1 ½ HP DC Winch with dolly
and strap
•Frame design version 8ish
•Setup to be used in either direction
•Winch box/case with
carpet sound
profingish
•Built as a Parallel
•Top Easily removable
for adjustment and
inspections
•Gaps at both end for
cable in / cable out
Breaks down for easy storage
•Old version with jack shaft
with squared end for hand crank
New version without hand crank option but holes punched if necessary
(And they weren’t necessary)
Set Screw for adjustment of chain tension
Cable clamp
½” x 1 ½” bolt with 7/32” hole
Cable tensioning device
½” All-thread
and removable guides
Complete pillow block, drum,
sprocket and shaft assembly for
ease in changing between
endless cable and drum setups
Endless cable turntable winch
Easy access limit switch location
Good location and labeling for limit and encoder connections
A list of winch prices for a 1 1/2 HP DC winch
180 v DC 1 1/2 HP motor Grainger 4Z379
Gear reducer w/ base
Grainger 1L426
Dynaper Series R45 Encoder # R4500602222
Furnas Rotary limit switch 72:1 54EB23FC
Chain & Sprockets Grainger
1 1/4” shafts, pillow blocks,
10” d grooved drum x 11” long Est.
6” sheaves for Tension assembly @ $50.00 each
3 Groove Sheave w/ hub for Turntable drive
Misc Hardware, bolts, all thread etc
Misc
Electrical
Steel for frame
$480.00
$360.00
$285.00
$360.00
$125.00
$125.00
$550.00
$150.00
$75.00
$48.00
$30.00
TOTAL $2464.00
Variations on a Theme



San Diego State University Stock Winch
5HP AC Vector Drive
Drive Mounted on Winch
Shorter Encoder Cables
 Shorter Limit Cables



Creative Conner’s Control System
MCued Servo System







Drive
Line Reactors
Brake Resistor
E-Stop Relay
Amp Enable
Relay
Disconnect
Embedded
Controller
Dan Eslinger
Seattle Rep Standard 5HP Winch
Seattle Rep’s 5HP Winch
Slick Features:
Cable Tensioning
Drive Chain Tensioning
Overtravel Limits & Encoder Built-in
Seattle Rep’s 5HP Winch
Equipment
Specs
Cost
Motor
Baldor 5HP 3-phase AC, 1725 rpm, 184 TC
$
255.00
Reducer
Grove Gear 20:1, dual shaft right angle
$
560.00
Drum
12" Sch.80 pipe, 9" wide, grooved for 1/4" cable $
1,250.00
Sprockets
25-tooth on reducer, 30-tooth on drum, #60 chain
$
65.00
Chain
#60 + connecting links, etc.
$
30.00
Sheaves
McKissick 6-1-B, 1 1/4" bore bushing, 6" dia.
$
65.00
Sheave Shaft
1 1/4" cold rolled steel
$
9.00
Threaded Rod
3/4-10, 36"
$
9.00
Pillow Blocks
drum: Browning VPS 228
$
38.00
sheave shaft: Browning 1A116 VF2S 100 series
$
23.00
Rotary Limits
Albrect #589W switch assemblies
$
295.00
Encoder
12F9766 10K Potentiometer (being replaced)
$
95.00
Limit Enclosure
NEMA 1 enclosure
$
26.00
Limit & Enc.Plugs 3-pin & 4-pin XLR
$
4.00
Limit Gearing
spur gears & belt
$
40.00
Steel Frame
2"x2"x3/16" angle, 1/4" x 4" strap
$
40.00
Hardware
Bolts, nuts, etc
$
Total $
12.00
2,816.00
Seattle Rep’s 5HP Winch
Stirling Shelton
Technical Director
Cincinnati playhouse in the park
www.fishertechnical.com
&
®
Spiderman
2
Joseph Champelli
Professor of Entertainment
Technology
University of Tennessee
www.fishertechnical.com

Typical FTSI flying winch
rated for 500 lbs @ 15 fps (4.5 meters per second - 900 feet/minute)
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com

FTSI flying winch for the film Spiderman® 2
300 lbs @ 43 fps (2580 fpm, ~30mph)
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
Design
© 2006 Fisher Technical Services, Inc.
Details
www.fishertechnical.com
Parts List:
•SEW Servo Gearmotor
•16” Diameter Drum
•Dual coil holding brake
•Custom Control Enclosure
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
Assembled Drive Train
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
Controls
© 2006 Fisher Technical Services, Inc.
On location in NYC
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
On location in NYC
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
On location in NYC
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
www.fishertechnical.com
Winches on Truss
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
&
®
Spiderman
2
Standards for Winch Design and Fabrication
ESTA: E1.6-1 watch for public review in 2006
German:
www.esta.org
BGV C1
www.vplt.org/en/index.html
BS 7905-1:2001
http://www.ihs.com.au/standards/bsi
Website
www.creativeconners.com
Email
[email protected].
Phone
401.862.2980
Mail
Creative Conners, Inc.
48 Wabun Ave.
Providence, RI 02908