# Stage Winch Design Techniques

## Presentation on theme: "Stage Winch Design Techniques"— Presentation transcript:

Stage Winch Design Techniques

Dan Eslinger Assistant Technical Director Seattle Repertory Theatre
Motor Winch Physics Dan Eslinger Assistant Technical Director Seattle Repertory Theatre

Sample Winch Design Application:
Wagon: 3000# Max velocity: 3.5 ft/sec Acceleration: 2 ft/sec2 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. Casters: 6” diameter soft rubber running on a flat wood deck.

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: Forcetotal = Faccel + Ffriction + Flift 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 Double the friction to be safe.

Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
Force to move wagon: 346.3# Size the Motor (hp): Round up to 3 hp motor. sample: 1750 rpm Size the Drum: at least 30 times the cable diameter. Choose 8” diameter drum.

Wagon: 3000# v: 3.5 ft/sec a: 2 ft/sec2 6” diameter soft rubber casters
Force to move wagon: 346.3# 3 hp motor rpm ’ per drum rev. Size the Reducer & Sprockets: match desired top speed (3.5 ft/sec) Choose 15:1 reducer. reduction needed in sprockets Drum sprocket teeth = 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 6” diameter soft rubber casters
Force to move wagon: 346.3# 3 hp motor rpm ’ per drum rev. 15:1 Reducer 12 teeth – 14 teeth sprockets Verify Amount of Torque: T: torque in ft lbs Force is great enough to move wagon!

Compact Manual Winch Loren Schreiber Technical Director San 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 C16160 \$80.82 S1664 \$36.76 Bushing 5/8" 2517-5 \$17.83 Shafting McMaster-Carr 1497K41 \$26.94 Acme Nuts (2) 94815A118 \$9.28 Acme Coupling Nut 93023A680 \$16.30 Acme 1 X 10 Screw 98935A866 \$19.00 Thrust Bearing 60715K15 \$15.28 Bearings (4) 6361K21 \$118.20 Tension Pulley (2) 9466T89 \$25.88 In-feed Sheaves (2) 9466T83 \$17.04 Shoulder Bolt 91264A798 \$4.70 Shoulder Washers 91140A266 \$7.75 Shaft Collar 6166K29 \$0.97 Keyless Bushing 5926K18 \$32.76 Misc. Steel NA \$25.00 Misc. Hardware \$10.00 Total: \$556.72

Technical Director South Coast Repertory Theatre
Jon Lagerquist Technical Director South Coast Repertory Theatre

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

Chris Fretts Technical Director Indiana Repertory Theatre
Friction Drive Winch Chris Fretts Technical Director Indiana Repertory Theatre

Friction Drive Winch Motorized or manual operation
Does 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 Reducer Motor Output: 1750 RPM
Gear Reducer Output: 70RPM Top Cable Speed: ft./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

www.surpluscenter.com Friction Drive Winch Major Parts List
Baldor # 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 11.25”OD #2L371 Sheave 7”OD (5) #3X923 #50 Roller Chain 10’ #2W095 15 Tooth #50 Sprocket (3) Varies with Bore 30 Tooth #50 Sprocket # 6G021 Friction Drive Winch Indiana Repertory Theatre

Peter Pan Winch Developed and designed by Stephen Henson at California State University Fullerton 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

Graduate Student San Diego State University
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

Winch hanging from batten

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

Technical Director Cal State Fullerton
Bill Meyer Technical Director Cal 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

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 4Z \$480.00 Gear reducer w/ base Grainger 1L \$360.00 Dynaper Series R45 Encoder # R \$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 @ \$ 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 \$

Variations on a Theme San Diego State University Stock Winch
5HP AC Vector Drive Drive Mounted on Winch Shorter Encoder Cables Shorter Limit Cables Creative Conner’s Control System MCued Servo System

Drive Line Reactors Brake Resistor E-Stop Relay Amp Enable Relay Disconnect Embedded Controller

Seattle Rep Standard 5HP Winch
Dan Eslinger Seattle Rep Standard 5HP Winch

Seattle Rep’s 5HP Winch Slick Features: Cable Tensioning
Drive Chain Tensioning Overtravel Limits & Encoder Built-in

Seattle Rep’s 5HP Winch

Seattle Rep’s 5HP Winch

Technical Director Cincinnati playhouse in the park
Stirling Shelton Technical Director Cincinnati playhouse in the park

& Spiderman® 2 Joseph Champelli Professor of Entertainment Technology
& Spiderman® 2 Joseph Champelli Professor of Entertainment Technology University of Tennessee

Typical FTSI flying winch rated for fps (4.5 meters per second feet/minute) © 2006 Fisher Technical Services, Inc.

FTSI flying winch for the film Spiderman® fps (2580 fpm, ~30mph) © 2006 Fisher Technical Services, Inc.

Design © 2006 Fisher Technical Services, Inc.

Details Parts List: SEW Servo Gearmotor 16” Diameter Drum
Parts List: SEW Servo Gearmotor 16” Diameter Drum Dual coil holding brake Custom Control Enclosure © 2006 Fisher Technical Services, Inc.

Assembled Drive Train www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.

Controls www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.

On location in NYC www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.

On location in NYC www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.

On location in NYC www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.

Winches on Truss www.fishertechnical.com
© 2006 Fisher Technical Services, Inc.

& Spiderman® 2

Standards for Winch Design and Fabrication
ESTA: E watch for public review in 2006 German: BGV C1 BS :2001

Website www.creativeconners.com
Phone Mail Creative Conners, Inc. 48 Wabun Ave. Providence, RI 02908