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
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
Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
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
Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
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.
Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
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
Technical DirectorTechnical Director
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
Technical DirectorTechnical Director
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.
www.fishertechnical.com
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)
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
DesignDesign
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.
Parts List:•SEW Servo Gearmotor•16” Diameter Drum•Dual coil holding brake•Custom Control Enclosure
DetailsDetails www.fishertechnical.com
Assembled Drive TrainAssembled Drive Train
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
ControlsControls
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
On location in NYCOn location in NYC
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.
On location in NYCOn location in NYCwww.fishertechnical.com
© 2006 Fisher Technical Services, Inc.
On location in NYCOn location in NYCwww.fishertechnical.com
Winches on Winches on TrussTruss
© 2006 Fisher Technical Services, Inc.
www.fishertechnical.com
SpidermanSpiderman®® 22
&&
www.fishertechnical.com
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