Stage Winch Design Techniques. Motor Winch Physics Dan Eslinger Assistant Technical Director Seattle...

Stage Winch Stage Winch Design Design

TechniquesTechniques

Motor Winch Motor Winch PhysicsPhysics

Motor Winch Motor Winch PhysicsPhysics

Dan EslingerDan EslingerAssistant Technical DirectorAssistant Technical Director

Seattle Repertory TheatreSeattle Repertory Theatre

Dan EslingerDan EslingerAssistant Technical DirectorAssistant Technical Director

Seattle Repertory TheatreSeattle Repertory Theatre

Casters: 6” diameter soft rubber running on a flat wood deck.

Casters: 6” diameter soft rubber running on a flat wood deck.

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.

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.

Wagon: 3000#

Max velocity: 3.5 ft/sec

Acceleration: 2 ft/sec2

Wagon: 3000#

Max velocity: 3.5 ft/sec

Acceleration: 2 ft/sec2

Sample Winch Design Application:

Sample Winch Design Application:

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:First, find the Force required to move the wagon:

Forcetotal = Faccel + Ffriction + FliftForcetotal = Faccel + Ffriction + Flift

232.2ft/sec

weightmass:m 232.2ft/sec

weightmass:m

22

#

sec/2sec/2.32

3000F ft

ftaccel 2

2

#

sec/2sec/2.32

3000F ft

ftaccel

c

rfrictionrolling r

NF

c

rfrictionrolling r

NF

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

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"3

"08.03000# fF "3

"08.03000# fF

amaccel F amaccel F

#3.346#3.346

#3.186#3.186

#80#80

## 8023.186 totalF## 8023.186 totalF Double the friction to be safe.Double the friction to be safe.

Force to move wagon: 346.3#Force to move wagon: 346.3#

Size the Motor (hp):Size the Motor (hp):secftlb

hp/550

Power1

secftlb

hp/550

Power1

vFP ower vFP ower

secftlb

secftlb

/550

/2121hp

secftlb

secftlb

/550

/2121hp

Round up to 3 hp motor.Round up to 3 hp motor.

Size the Drum: at least 30 times the cable diameter.Size the Drum: at least 30 times the cable diameter.

diameter drum min. "5.7 diameter drum min. "5.7Choose 8” diameter drum.Choose 8” diameter drum.

dncecircumfere dncecircumfere

secftlbsecft /1212/5.33.346 # secftlbsecft /1212/5.33.346 #

sample: 1750 rpmsample: 1750 rpmhp20.2 hp20.2



3041:cable4

1 ""304

1:cable41 ""

'09.2"13.25"8 '09.2"13.25"8

Force to move wagon: 346.3# 3 hp motor 1750 rpm 2.09’ per drum rev.Force to move wagon: 346.3# 3 hp motor 1750 rpm 2.09’ per drum rev.

Size the Reducer & Sprockets: match desired top speed (3.5 ft/sec)Size the Reducer & Sprockets: match desired top speed (3.5 ft/sec)

sec

ft5.3speed sec

ft5.3speed

neededreduction 42.17rpm drum 100.48

rpmmotor 1750 neededreduction 42.17

rpm drum 100.48

rpmmotor 1750 Choose 15:1 reducer.Choose 15:1 reducer.

Drum sprocket teeth = 1.161 x reducer sprocket teeth.e.g. 12 teeth on reducer & 14 teeth on drum.Drum sprocket teeth = 1.161 x reducer sprocket teeth.e.g. 12 teeth on reducer & 14 teeth on drum.

161.115

42.17 161.1

15

42.17 reduction needed in sprocketsreduction needed in sprockets

drumat minrev 48.100 drumat min

rev 48.100



ft09.2

re1

min1

sec60 v ft09.2

re1

min1

sec60 v

15:1 Reducer 12 teeth – 14 teeth sprockets15:1 Reducer 12 teeth – 14 teeth sprockets

Verify Amount of Torque:Verify Amount of Torque:

5252

rpmhp

5252

rpmhp

T: torque in ft lbsT: torque in ft lbs

5252

17503

5252

17503

reductionsprocket effeciencyreductiongear motordrumreductionsprocket effeciencyreductiongear motordrum

teeth12

teeth14%80

1

150.9 lbsft teeth12

teeth14%80

1

150.9 lbsft

drumcabledrum rF drumcabledrum rF

"4lbsin 1512 cableF "4lbsin 1512 cableF #346.3 #346.3 Force is great enough

to move wagon!

Force is great enough to move wagon!

lbsft 0.9 lbsft 0.9

drumat lbsin 1512lbsft 126 drumat lbsin 1512lbsft 126

#cable 378 F

#cable 378 F

Force to move wagon: 346.3# 3 hp motor 1750 rpm 2.09’ per drum rev.Force to move wagon: 346.3# 3 hp motor 1750 rpm 2.09’ per drum rev.



Compact Manual Compact Manual WinchWinch

Loren SchreiberLoren SchreiberTechnical DirectorTechnical Director

San Diego State UniversitySan 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 LagerquistJon Lagerquist

Technical DirectorTechnical Director

South Coast Repertory South Coast Repertory TheatreTheatre

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 Friction Drive WinchWinch

Chris FrettsChris Fretts

Technical DirectorTechnical DirectorIndiana Repertory TheatreIndiana Repertory Theatre

Friction Drive WinchMotorized or manual operationDoes 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 ReducerMotor Output: 1750 RPMGear Reducer Output: 70RPMTop 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

Friction Drive WinchIndiana Repertory Theatre

Major Parts List Baldor #2HP Motor #VM3558T

ebay “Buy it now” price $12025:1 Gear Reducer #GF2532BG

ebay “Buy it now” price $199 Grainger #Pillow Blocks (4) #5X685Multi-sheave 11.25”OD #2L371Sheave 7”OD (5) #3X923#50 Roller Chain 10’ #2W09515 Tooth #50 Sprocket (3) Varies with Bore30 Tooth #50 Sprocket # 6G021

www.surpluscenter.com

Peter Pan Peter Pan WinchWinch

Developed and Developed and designed by Stephen designed by Stephen Henson at California Henson at California

State University State University FullertonFullerton

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 three-grooved 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 Matthew McKinneyMcKinney

Graduate StudentGraduate Student

San Diego State UniversitySan Diego State University

FrankenwinchFrankenwinch

Traveler winchTraveler winch Built from equipment Built from equipment

on handon hand 2HP AC Vector Motor2HP AC Vector Motor Drive Mounted to Drive Mounted to

winchwinch Massively over Massively over

powered (Opera powered (Opera Capable)Capable)

Cost: PricelessCost: Priceless

Winch hanging from batten

Shipping Crate

Top is removed to attach directly to batten and lift out of box

Bill MeyerBill Meyer


Cal State FullertonCal 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 $480.00Gear reducer w/ base Grainger 1L426 $360.00Dynaper Series R45 Encoder # R4500602222 $285.00Furnas Rotary limit switch 72:1 54EB23FC $360.00Chain & Sprockets Grainger $125.001 1/4” shafts, pillow blocks, $125.0010” d grooved drum x 11” long Est. $550.006” sheaves for Tension assembly @ $50.00 each3 Groove Sheave w/ hub for Turntable drive

$150.00Misc Hardware, bolts, all thread etc $75.00Misc Electrical $48.00 Steel for frame $30.00

TOTAL $2464.00

Variations on a ThemeVariations on a Theme

San Diego State University Stock San Diego State University Stock WinchWinch

5HP AC Vector Drive5HP AC Vector Drive Drive Mounted on WinchDrive Mounted on Winch

Shorter Encoder CablesShorter Encoder Cables Shorter Limit CablesShorter Limit Cables

Creative Conner’s Control System Creative Conner’s Control System MCued Servo SystemMCued Servo System

DriveDrive Line Line

ReactorsReactors Brake Brake

ResistorResistor E-Stop E-Stop

RelayRelay Amp Amp

Enable Enable RelayRelay

DisconnectDisconnect Embedded Embedded

ControllerController

Dan EslingerDan Eslinger

Seattle Rep Standard 5HP Seattle Rep Standard 5HP WinchWinch

Seattle Rep’s 5HP WinchSeattle Rep’s 5HP Winch

Slick Features:Slick Features:Cable Tensioning

Drive Chain Tensioning

Overtravel Limits & Encoder Built-in

Cable Tensioning

Drive Chain Tensioning

Overtravel Limits & Encoder Built-in

Seattle Rep’s 5HP WinchSeattle Rep’s 5HP WinchEquipment 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 12.00$

Total 2,816.00$

Seattle Rep’s 5HP WinchSeattle Rep’s 5HP Winch

Stirling SheltonStirling Shelton


Cincinnati playhouse in the Cincinnati playhouse in the parkpark

SpidermanSpiderman®® 22

&&

www.fishertechnical.com

Joseph Champelli

Professor of Entertainment

Technology

University of Tennessee

Typical FTSI flying winchTypical FTSI flying winchrated for 500 lbs @ 15 fps rated for 500 lbs @ 15 fps (4.5 meters per second - 900 (4.5 meters per second - 900 feet/minute)feet/minute)

© 2006 Fisher Technical Services, Inc.


FTSI flying winch for the film SpidermanFTSI flying winch for the film Spiderman® ® 22

300 lbs @ 43 fps (2580 fpm, ~30mph) 300 lbs @ 43 fps (2580 fpm, ~30mph)



DesignDesign




Parts List:•SEW Servo Gearmotor•16” Diameter Drum•Dual coil holding brake•Custom Control Enclosure

DetailsDetails www.fishertechnical.com

Assembled Drive TrainAssembled Drive Train



ControlsControls



On location in NYCOn location in NYC




On location in NYCOn location in NYCwww.fishertechnical.com

Winches on Winches on TrussTruss



SpidermanSpiderman®® 22

&&


BGV C1

Standards for Winch Design and Fabrication

ESTA: E1.6-1 watch for public review in 2006

German:

www.esta.org

www.vplt.org/en/index.html

http://www.ihs.com.au/standards/bsi

BS 7905-1:2001

Website www.creativeconners.com

[email protected]. Phone 401.862.2980 Mail Creative Conners, Inc.

48 Wabun Ave.Providence, RI 02908

Stage Winch Design Techniques. Motor Winch Physics Dan Eslinger Assistant Technical Director Seattle...

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