CLUMP WINCH ANALYSIS

Design Criteria: ABS Rules for Building and Classing Underwater Vehicles, Systems and Hyperbaric Facilities

IMCA D 024 Diving Equipment Systems Inspection Guidance Note for Saturation Diving
Systems (Bell)

Winch Specification:
LPR := 10000.0lbf Rated Line Pull at Full Drum
LSR := 250.0fpm Rated Line Speed at Full Drum
LPD := 20000.0lbf Design Line Pull at Full Drum
PD B := 1.2292ft Bare Drum Pitch Diameter
PD B1 := 1.3013ft Second Layer Pitch Diameter
PD F2 := 2.2395ft Second Layer Below Full Drum Pitch Diameter
PD F1 := 2.3117ft First Layer Below Full Drum Pitch Diameter
PD F := 2.3838ft Full Drum Pitch Diameter

PD F
TR := LPR⋅ = 11919.0 ⋅ ft⋅ lbf Rated Drum Torque
2
LSR
n R := = 33.38 ⋅ rpm Rated Drum Speed
π⋅ PD F

PD F
TD := LPD⋅ = 23838.0 ⋅ ft⋅ lbf Design Drum Torque
2

Planetary: Fairfield S10 A1 4470, 1.00 x 4.25 Key

TPC := 10417.0ft⋅ lbf Planetary Continuous Output Torque
TPI := 20833.0ft⋅ lbf Planetary Intermittent Output Torque
TPP := 25000.0ft⋅ lbf Planetary Peak Output Torque
n PI := 2400.0rpm Planetary Maximum Input Speed
FPR := 30000.0lbf Planetary Allowable Radial Bearing Load
FPT := 10530.0 ⋅ lbf Planetary Allowable Thrust Bearing Load
mPR := 70.70 Planetary Reduction Ratio

Hydraulic Motor: Linde HMF 105-02 2556

3
in
DMV := 6.407 Motor Displacement
rev
n MM := 3500.0rpm Motor Maximum Operating Speed
PMC := 3625.9psi Motor Continuous Operating Pressure
PMM := 6091.6psi Motor Maximum Operating Pressure
TMC := 308.30ft⋅ lbf Motor Continuous Output Torque
TMM := 517.77ft⋅ lbf Motor Maximum Output Torque

1/5 Clump Winch Analysis 12/29/2010

 Primary Brake: Ausco Disc Brake 76929
TBP := 750.0ft⋅ lbf Primary Brake Torque Rating, Spring Set Hydraulic Release

Secondary Brake: Hagglunds MDA 14

TBS := 49200.0ft⋅ lbf Secondary Brake Torq Rating, Spring Set Hydraulic Release
FBR := 44800.0lbf Secondary Brake Allowable Bearing Radial Load

Figure 1: Clump Winch, Pedestal Support

Verify Planetary Size:
TR is slightly greater than TPC but less than TPI
TD is less than TPP
n PIr := n R⋅ mPR = 2360.2⋅ rpm nPIr is less than nPI

PBRp := LPD⋅ ⎛⎜
19.99 ⎞
⎟ = 17012.8 lbf PBRp is less than FPR
⎝23.50 ⎠

PBAp := LPD⋅ sin⎛⎜ ⎞⎟ = 698.0 lbf

π
PBAp is less than FPT
90⎝ ⎠
Key Size and Hub Interface:
b := 1.00⋅ in
t := 1.00⋅ in
L := 4.25⋅ in
r := 2.25⋅ in
Fy := 50000psi AISI 1045

TD
fv := = 49857.3 psi
b ⋅ L⋅ r⋅ .6
2 ⋅ TD
fc := = 49857.3 psi
t⋅ L⋅ r⋅ 1.2
fv
= 0.997
Fy

2/5 Clump Winch Analysis 12/29/2010

 fc
= 0.997
Fy

Verify Motor Size:

TR
TM R := = 168.6 ⋅ ft⋅ lbf TMR is less than TMC
mPR

TD
TM D := = 337.2 ⋅ ft⋅ lbf TMD is less than TMM
mPR

TM R
PR := 2π⋅ = 1983.9 psi PR is less than PMC
DMV

TM D
PD := 2π⋅ = 3967.9 psi PD is less than PMM
DMV

n RQ := n R⋅ mPR = 2360.2⋅ rpm nRQ is less than nMM

DMV
Q := n RQ⋅ = 65.5⋅ gpm required flow rate for maximum rated line speed
231

Verify Primary Brake Size:

1.10TD
TB P := = 370.9 ⋅ ft⋅ lbf TBP is less than TBP
mPR

Verify Secondary Brake Size:

TB S := 1.10⋅ TD = 26221.8 ⋅ ft⋅ lbf TBS is less than TBS

PBRb := LPD⋅ ⎛⎜
19.99 ⎞
⎟ = 17012.8 lbf PBRb is less than FBR
23.50 ⎝ ⎠
Verify Drum Size:
Flange Design:
t := 1.00⋅ in
Fy := 36000psi ASTM A36

2LPD ⎡⎛ PDB ⎞ 3 ⎛ 1 PD F ⎞ ⎤
M b := ⋅ ⎢⎜ 1 − ⎟+ ⎜ + ⎟ ( PDF2 − PDB)⎥ = 4990.8 lbf
3 tan⎛⎜
π⎞
⎟ ⎢⎝ ⎠ 16 ⎜⎝ PDF PDF12 ⎟⎠
PD F ⎥
⎝3⎠ ⎣ ⎦
6⋅ Mb
fb := = 29944.6 psi
2
t
fb
= 0.832
Fy

3/5 Clump Winch Analysis 12/29/2010

Barrel Design:
w := .50⋅ in wire rope diameter
E := 29000000psi
ν := .30
r := 6.938 ⋅ in
t := 1.00⋅ in
L := 19.00 ⋅ in
4
2 3 2
E⋅ t ⎛ 1 ⎞ t = 72341.2 psi
q := 0.807 ⋅ ⋅ Roark's Table 35, case 19b
L⋅ r ⎜ 2⎟ 2
⎝1 − ν ⎠ r
q a := .4⋅ q = 28936.5 psi

4TD
p b := ⎛⎜ 3 + 1 ⎞⎟ = 13329.0 psi
w ⎜ 8PDB2 PDB12 ⎟
⎝ ⎠
pb
= 0.461
qa

Shaft Fastener Design:

3/4 - 10 UNC SAE Grade 8
d := .75⋅ in
d bc := .6458ft
2
Abt := .334⋅ in
2
Abs := .302⋅ in

Fu := 150000psi

Fat := .455⋅ Fu = 68250 psi

Fas := .42⋅ Fu = 63000 psi

n := 12

1 ⎡ −2 ⋅ TD π ⎤
− LPD⋅ ⎛⎜
19.99 ⎞
Fx := ⋅ ⎢ ⎟ ⋅ cos⎛⎜ ⎞⎟⎥ = −7484.3 lbf
n
⎣
d bc ⎝ 23.50 ⎠ ⎝ 9 ⎠ ⎦
1 ⎡ 2 ⋅ TD π ⎤
+ LPD⋅ ⎛⎜
19.99 ⎞
Fy := ⋅ ⎢ ⎟ ⋅ sin⎛⎜ ⎞⎟⎥ = 6637.0 lbf
n d bc
⎣ ⎝ 23.50 ⎠ ⎝ 9 ⎠ ⎦
Fx
fvx := = 24782.4 psi
Abs

Fy
fvy := = 21976.7 psi
Abs

4/5 Clump Winch Analysis 12/29/2010

 fvx
= 0.393
Fas

fvy
= 0.349
Fas

Winch Spooling Capacity:

Drum Data
Flange Diameter: 33.000 in
Drum Diameter: 14.250 in
Drum Length: 17.000 in

Rope Data
Rope Diameter: 0.500 in
Oversize Factor: 1.000
Oversize Diameter: 0.500 in

Number of Turns: 34.000

Effective Drum
Length: 17.000 in

Drum Spooling Capacity

Drum Pitch Outside Layer Spooling
Layer Diameter Diameter Capacity Capacity
Number (in) (in) (ft) (ft)
1 14.750 15.250 129.4 129.4
2 15.616 16.116 134.9 264.3
3 16.482 16.982 144.6 408.8
4 17.348 17.848 149.9 558.7
5 18.214 18.714 159.7 718.4
6 19.080 19.580 164.8 883.3
7 19.946 20.446 174.9 1,058.2
8 20.812 21.312 179.8 1,238.0
9 21.678 22.178 190.1 1,428.1
10 22.544 23.044 194.8 1,622.9
11 23.410 23.910 205.3 1,828.2
12 24.276 24.776 209.7 2,038.0
13 25.142 25.642 220.5 2,258.5
14 26.008 26.508 224.7 2,483.2
15 26.874 27.374 235.7 2,718.9
16 27.740 28.240 239.7 2,958.5
17 28.606 29.106 250.9 3,209.4

The above calculations show that the winch is adequately designed for the rating specified.

5/5 Clump Winch Analysis 12/29/2010