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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 Casters: 6 diameter soft rubber running on a flat wood deck.
Wagon: 3000#
v: 3.5 ft/sec
a: 2 ft/sec2
First, find the Force required to move the wagon: Forcetotal = Faccel + Ffriction + Flift
Faccel = m a Faccel
m : mass =
weight 32.2ft/sec2
Frolling friction
N r = rc
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
Wagon: 3000#
v: 3.5 ft/sec
a: 2 ft/sec2
1hp =
"
cable : 1
"
Wagon: 3000#
v: 3.5 ft/sec
a: 2 ft/sec2
Size the Reducer & Sprockets: match desired top speed (3.5 ft/sec)
speed =
3.5ft 60 sec 1rev = 100.48 rev at drum min sec 1 min 2.09ft
Choose 15:1 reducer.
1750 motor rpm = 17.42 reduction needed 100.48 drum 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.
Wagon: 3000#
v: 3.5 ft/sec
a: 2 ft/sec2
hp =
rpm 5252
T: torque in ft lbs
> 346.3
Jon Lagerquist
Technical Director South Coast Repertory Theatre
Torque tamer (Dodge) with quick pins for disconnecting sprocket from shaft
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
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
-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
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
Shipping Crate Top is removed to attach directly to batten and lift out of box
Bill Meyer
Technical Director Cal State Fullerton
Basic 1 HP DC Winch with dolly and strap Frame design version 8ish Setup to be used in either direction
Top Easily removable for adjustment and inspections Gaps at both end for cable in / cable out
Old version with jack shaft with squared end for hand crank
New version without hand crank option but holes punched if necessary (And they werent necessary)
Complete pillow block, drum, sprocket and shaft assembly for ease in changing between endless cable and drum setups
A list of winch prices for a 1 1/2 HP DC winch 180 v DC 1 1/2 HP motor Grainger 4Z379 $480.00 Gear reducer w/ base Grainger 1L426 $360.00 Dynaper Series R45 Encoder # R4500602222 $285.00 Furnas Rotary limit switch 72:1 54EB23FC $360.00 Chain & Sprockets Grainger $125.00 1 1/4 shafts, pillow blocks, $125.00 10 d grooved drum x 11 long Est. $550.00 6 sheaves for Tension assembly @ $50.00 each 3 Groove Sheave w/ hub for Turntable drive $150.00 Misc Hardware, bolts, all thread etc $75.00 Misc Electrical $48.00 Steel for frame $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
Drive Line Reactors Brake Resistor E-Stop Relay Amp Enable Relay Disconnect Embedded Controller
Dan Eslinger
Seattle Rep Standard 5HP Winch
Slick Features:
Cable Tensioning Drive Chain Tensioning Overtravel Limits & Encoder Built-in
Specs
Baldor 5HP 3-phase AC, 1725 rpm, 184 TC Grove Gear 20:1, dual shaft right angle 25-tooth on reducer, 30-tooth on drum, #60 chain #60 + connecting links, etc. McKissick 6-1-B, 1 1/4" bore bushing, 6" dia. 1 1/4" cold rolled steel 3/4-10, 36" drum: Browning VPS 228 sheave shaft: Browning 1A116 VF2S 100 series Albrect #589W switch assemblies 12F9766 10K Potentiometer (being replaced) NEMA 1 enclosure spur gears & belt 2"x2"x3/16" angle, 1/4" x 4" strap Bolts, nuts, etc $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ Total $ 12" Sch.80 pipe, 9" wide, grooved for 1/4" cable $
Cost
255.00 560.00 1,250.00 65.00 30.00 65.00 9.00 9.00 38.00 23.00 295.00 95.00 26.00 4.00 40.00 40.00 12.00 2,816.00
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
www.fishertechnical.com
FTSI flying winch for the film Spiderman 2 300 lbs @ 43 fps (2580 fpm, ~30mph)
www.fishertechnical.com
Design
2006 Fisher Technical Services, Inc.
Details
Parts List:
www.fishertechnical.com
SEW Servo Gearmotor 16 Diameter Drum Dual coil holding brake Custom Control Enclosure
www.fishertechnical.com
www.fishertechnical.com
Controls
On location in NYC
www.fishertechnical.com
On location in NYC
www.fishertechnical.com
On location in NYC
www.fishertechnical.com
Winches on Truss
www.fishertechnical.com
www.fishertechnical.com
& Spiderman 2
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 info@creativeconners.com. Phone 401.862.2980 Mail Creative Conners, Inc. 48 Wabun Ave. Providence, RI 02908