118916295 USITT 2006 Winch Session Com

7/27/2019 118916295 USITT 2006 Winch Session Com

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Stage WinchStage Winch

DesignDesignTechniquesTechniques


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Motor WinchMotor Winch

PhysicsPhysics

Motor WinchMotor Winch

PhysicsPhysicsDan EslingerDan Eslinger

Assistant Technical DirectorAssistant Technical DirectorSeattle Repertory TheatreSeattle Repertory Theatre

Dan EslingerDan Eslinger

Assistant Technical DirectorAssistant Technical DirectorSeattle Repertory TheatreSeattle Repertory Theatre


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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/secAcceleration: 2 ft/sec2

Wagon: 3000#

Max velocity: 3.5 ft/secAcceleration: 2 ft/sec2

Sample Winch DesignApplication:Sample Winch DesignApplication:


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Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6 diameter soft rubber castersWagon: 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 =

2

2

#

sec/2sec/2.32

3000F ft

ftaccel =

c

rfrictionrolling

r

NF

=

N: normal force, perpendicular to motion,

here: the load

r: casters 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

r: casters coefficient of rolling friction

hard rubber on wood: 0.003

soft rubber on wood: 0.008rc: radius of caster"3

"08.03000 # =fF

amaccel =F

#3.346=

#3.186=

#80=

## 8023.186 +=total

F Double the friction to be safe.Double the friction to be safe.


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

Size the Motor (hp):Size the Motor (hp): secftlbhp

/550

Power1

=

vFP =ower

secftlb

secftlb

/550

/2121

hp

=

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.

diameterdrummin."5.7=Choose 8 diameter drum.Choose 8 diameter drum.

d= ncecircumfere

secftlbsecft /1212/5.33.346 # ==

sample: 1750 rpmsample: 1750 rpmhp20.2=


304

1:cable4

1 ""

'09.2"13.25"8 ===


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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 =

neededreduction42.17rpmdrum100.48rpmmotor1750 = 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= reduction needed in sprocketsreduction needed in sprockets

drumatmin

rev48.100=


ft09.2

re1

min1

sec60 v


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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

= T: torque in ft lbsT: torque in ft lbs

525217503 =

reductionsprocketeffeciencyreductiongear = motordrum

teeth12

teeth14

%801

15

0.9=

lbsft

drumcabledrum rF =

"4lbsin1512 = cableF#

346.3>Force is great enough

to move wagon!

Force is great enough

to move wagon!

lbsft= 0.9

drumatlbsin1512lbsft126 ==

#

cable 378F =

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.



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Compact ManualCompact ManualWinchWinch

Loren SchreiberLoren Schreiber

Technical DirectorTechnical Director

San Diego State UniversitySan Diego State University


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ompact Manual Winch Price List

ess Gears: $380Item 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


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Jon LagerquistJon Lagerquist


South Coast RepertorySouth Coast RepertoryTheatreTheatre


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Hand crank winchwith pneumatic discbrake


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Disc brake detail


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Square shaft end for removable crank


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Winch for chaindriven turntable


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Cable tension device with welded end


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Torque tamer (Dodge)with quick pins fordisconnecting sprocket

from shaft


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Winch farm on midrail


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Design for new

winch yet to be built


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Friction DriveFriction DriveWinchWinch

Chris FrettsChris Fretts

Technical DirectorTechnical DirectorIndiana Repertory TheatreIndiana Repertory Theatre


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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


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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.


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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.


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A rotary encoder is attached with #25 roller chain andsprockets 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


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Friction Drive Winch

Indiana Repertory Theatre

Major Parts ListBaldor #

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 11.25OD #2L371

Sheave 7OD (5) #3X923#50 Roller Chain 10 #2W095

15 Tooth #50 Sprocket (3) Varies with Bore

30 Tooth #50 Sprocket # 6G021

www.surpluscenter.com


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Peter PanPeter PanWinchWinch

Developed andDeveloped and

designed by Stephendesigned by Stephen

Henson at CaliforniaHenson at CaliforniaState UniversityState University

FullertonFullertonwith special thanks to Bill Meyer, Matthew McKinney and

Scott Shiba for various creative influences during the processof development


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Prototype winch-Form followed function purely-Used with a sprocket instead of

three-grooved sheave, for directchain-drive-Two plates punched to be boltedto the gear box, welded to a crossmember punched for hangers

Version 2.0 winch-Rotated motor 90 degrees-Added two vertical angle irons forpushing motor away from batten-Allowing for three-groovedsheave with a double sheave hungabove directly from batten (notshown)-Crudely mounted mule blocks fordirecting cables along batten toscenery

-Rotary Limit Switch and Junctionbox mounted to motor mount


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View of completed winchframe


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-Top plate is designed to facilitate standard Battenhangers, as well as suspend a swivel doublesheave

-Slotted flat bars accommodate multiple positionsfor head blocks as well as twisting into alignmentwith three-grooved sheave

-Center plates are punched accordingly formounting gear box with encoder and motorsuspended from gearbox

-Bottom of frame has additional steel structure formounting rotary limit switch and junction boxcontaining RJ45 connectors.

-Head block assembly is punched with extra holes

to allow for flexibility with parts


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CAD MODEL IMAGES


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MatthewMatthew

McKinneyMcKinneyGraduate StudentGraduate Student

San Diego State UniversitySan Diego State University


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FrankenwinchFrankenwinch

Traveler winchTraveler winch

Built fromBuilt from

equipment on handequipment on hand

2HP AC Vector2HP AC VectorMotorMotor

Drive Mounted toDrive Mounted to

winchwinch Massively overMassively over

powered (Operapowered (Opera

Capable)Capable)

Cost: PricelessCost: Priceless


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Winch hanging from


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Shipping CrateTop is removed to

attach directly tobatten and lift out of

box


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Bill MeyerBill Meyer


Cal State FullertonCal State Fullerton


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Basic 1 HP DC Winch withdolly and strap

Frame design version 8ish

Setup to be used in eitherdirection


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Winch box/casewith carpetsound profingishBuilt as a

Parallel


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Top Easilyremovable foradjustment andinspections

Gaps at bothend for cable in /cable out


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Breaks down for easy storage


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Old version with jackshaft with squared endfor hand crank


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New version without hand crank option but holespunched if necessary

(And they werent necessary)


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Set Screw for adjustment of chain tension


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Cable clamp

x 1 bolt with 7/32 hole


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Cable tensioning

device

All-thread

and removable guides


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Complete pillow block,

drum, sprocket and shaftassembly for ease inchanging between

endless cable and drum

setups


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Endless cable turntable winch


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Easy access limit switch location


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Good location and labeling for limit and

encoder connections


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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 $75.00

Misc Electrical $48.00Steel for frame $30.00

TOTAL $2464.00


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Variations on a ThemeVariations on a Theme

San Diego State University StockSan 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 Conners Control SystemCreative Conners Control System

MCued Servo SystemMCued Servo System


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DriveDrive

LineLineReactorsReactors

BrakeBrake

ResistorResistor

E-StopE-StopRelayRelay

AmpAmp

EnableEnable

RelayRelay

DisconnectDisconnect

EmbeddedEmbedded

ControllerController


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Dan EslingerDan Eslinger

Seattle Rep Standard 5HPSeattle Rep Standard 5HP

WinchWinch

Seattle Reps 5HP WinchSeattle Reps 5HP Winch


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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



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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 12.00$

Total 2,816.00$



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Stirling SheltonStirling Shelton


Cincinnati playhouse in theCincinnati playhouse in theparkpark


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www.fishertechnical.com


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SpidermanSpiderman

22

&

Joseph Champelli

Professor of

EntertainmentTechnology

University ofTennessee

Typical FTSI flying winchTypical FTSI flying winch



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

2006 Fisher Technical Services, Inc.

FTSI flying winch for the film SpidermanFTSI flying winch for the film Spiderman 22www.fishertechnical.com


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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)




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DesignDesign


DetailsDetailswww.fishertechnical.com


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Parts List:SEW Servo Gearmotor16 Diameter Drum

Dual coil holding brakeCustom Control Enclosure

Assembled Drive TrainAssembled Drive Train



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Assembled Drive TrainAssembled Drive Train


ControlsControlswww.fishertechnical.com


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ControlsControls


On location in NYCOn location in NYC



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On location in NYCwww.fishertechnical.com


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On location in NYCwww.fishertechnical.com


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Winches onWinches on



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TrussTruss



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Standards for Winch Design and Fabrication


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BGV C1

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


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Website www.creativeconners.com

[email protected].

Phone 401.862.2980Mail Creative Conners, Inc.

48 W b A
mailto:[email protected]:[email protected]

Documents

118916295 USITT 2006 Winch Session Com