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Stage Winch Design Techniques. Motor Winch Physics Dan Eslinger Assistant Technical Director Seattle Repertory Theatre Dan Eslinger Assistant Technical.

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Presentation on theme: "Stage Winch Design Techniques. Motor Winch Physics Dan Eslinger Assistant Technical Director Seattle Repertory Theatre Dan Eslinger Assistant Technical."— Presentation transcript:

1 Stage Winch Design Techniques

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

3 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/sec 2 – 4 ft/sec 2 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/sec 2 – 4 ft/sec 2 Decide how long for it to reach top speed. Wagon: 3000# Max velocity: 3.5 ft/sec Acceleration: 2 ft/sec 2 Wagon: 3000# Max velocity: 3.5 ft/sec Acceleration: 2 ft/sec 2 Sample Winch Design Application:

4 Wagon: 3000#v: 3.5 ft/sec a: 2 ft/sec 2 6” diameter soft rubber casters First, find the Force required to move the wagon: Force total = F accel + F friction + F lift N: normal force, perpendicular to motion, here: the load µ r : caster’s coefficient of rolling friction hard rubber on wood: 0.003” soft rubber on wood: 0.008” r c : radius of caster Double the friction to be safe.

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

6 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) 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. reduction needed in sprockets Wagon: 3000#v: 3.5 ft/sec a: 2 ft/sec 2 6” diameter soft rubber casters

7 15:1 Reducer 12 teeth – 14 teeth sprockets Verify Amount of Torque: T: torque in ft lbs Force is great enough to move wagon! 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/sec 2 6” diameter soft rubber casters

8 Compact Manual Winch Loren Schreiber Technical Director San Diego State University

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12 Compact Manual Winch Price List Less Gears: $380 ItemVendorPart NumberCost Drive PulleyMartin Sprocket3 3V 1060TB$92.01 Drive GearMartin SprocketC16160$80.82 Drive GearMartin SprocketS1664$36.76 Bushing 5/8"Martin Sprocket2517-5$17.83 ShaftingMcMaster-Carr1497K41$26.94 Acme Nuts (2)McMaster-Carr94815A118$9.28 Acme Coupling NutMcMaster-Carr93023A680$16.30 Acme 1 X 10 ScrewMcMaster-Carr98935A866$19.00 Thrust BearingMcMaster-Carr60715K15$15.28 Bearings (4)McMaster-Carr6361K21$118.20 Tension Pulley (2)McMaster-Carr9466T89$25.88 In-feed Sheaves (2)McMaster-Carr9466T83$17.04 Shoulder BoltMcMaster-Carr91264A798$4.70 Shoulder WashersMcMaster-Carr91140A266$7.75 Shaft CollarMcMaster-Carr6166K29$0.97 Keyless BushingMcMaster-Carr5926K18$32.76 Misc. SteelNA $25.00 Misc. HardwareNA $10.00 Total:$556.72

13 Jon Lagerquist Technical Director South Coast Repertory Theatre

14 Hand crank winch with pneumatic disc brake

15 Disc brake detail

16 Square shaft end for removable crank

17 Winch for chain driven turntable

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19 Cable tension device with welded end

20 Torque tamer (Dodge) with quick pins for disconnecting sprocket from shaft

21 Winch farm on midrail

22 Design for new winch yet to be built

23 Friction Drive Winch Chris Fretts Technical Director Indiana Repertory Theatre

24 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

25 Drive: 2HP Motor with 25:1 Gear Reducer Motor Output: 1750 RPM Gear Reducer Output: 70RPM Top Cable Speed: 3ft./sec. Shafts: 1 3 / 16 ” Roller Chain: #50

26 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.

27 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.

28 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.

29 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

30 Friction Drive Winch Indiana Repertory Theatre 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 www.surpluscenter.com

31 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

32 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

33 View of completed winch frame

34 -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

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40 CAD MODEL IMAGES

41 Matthew McKinney Graduate Student San Diego State University

42 Frankenwinch Traveler winch Traveler winch Built from equipment on hand Built from equipment on hand 2HP AC Vector Motor 2HP AC Vector Motor Drive Mounted to winch Drive Mounted to winch Massively over powered (Opera Capable) Massively over powered (Opera Capable) Cost: Priceless Cost: Priceless

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44 Winch hanging from batten

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

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49 Bill Meyer Technical Director Cal State Fullerton

50 Basic 1 ½ HP DC Winch with dolly and strap Frame design version 8ish Setup to be used in either direction

51 Winch box/case with carpet sound profingish Built as a Parallel

52 Top Easily removable for adjustment and inspections Gaps at both end for cable in / cable out

53 Breaks down for easy storage

54 Old version with jack shaft with squared end for hand crank

55 New version without hand crank option but holes punched if necessary (And they weren’t necessary)

56 Set Screw for adjustment of chain tension

57 Cable clamp ½” x 1 ½” bolt with 7/32” hole

58 Cable tensioning device ½” All-thread and removable guides

59 Complete pillow block, drum, sprocket and shaft assembly for ease in changing between endless cable and drum setups

60 Endless cable turntable winch

61 Easy access limit switch location

62 Good location and labeling for limit and encoder connections

63 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

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

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

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69 Dan Eslinger Seattle Rep Standard 5HP Winch

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

71 Seattle Rep’s 5HP Winch

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73 Stirling Shelton Technical Director Cincinnati playhouse in the park

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89 Spiderman ® 2 & www.fishertechnical.com Joseph Champelli Professor of Entertainment Technology University of Tennessee

90 Typical FTSI flying winch rated for 500 lbs @ 15 fps (4.5 meters per second - 900 feet/minute) Typical FTSI flying winch rated for 500 lbs @ 15 fps (4.5 meters per second - 900 feet/minute) © 2006 Fisher Technical Services, Inc. www.fishertechnical.com

91 FTSI flying winch for the film Spiderman ® 2 300 lbs @ 43 fps (2580 fpm, ~30mph) FTSI flying winch for the film Spiderman ® 2 300 lbs @ 43 fps (2580 fpm, ~30mph) © 2006 Fisher Technical Services, Inc. www.fishertechnical.com

92 Design © 2006 Fisher Technical Services, Inc. www.fishertechnical.com

93 © 2006 Fisher Technical Services, Inc. Parts List: SEW Servo Gearmotor 16” Diameter Drum Dual coil holding brake Custom Control EnclosureDetails www.fishertechnical.com

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

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

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

97 © 2006 Fisher Technical Services, Inc. On location in NYC www.fishertechnical.com

98 © 2006 Fisher Technical Services, Inc. On location in NYC www.fishertechnical.com

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

100 Spiderman ® 2 & www.fishertechnical.com

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103 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

104 Websitewww.creativeconners.com Emailinfo@creativeconners.com.info@creativeconners.com Phone 401.862.2980 MailCreative Conners, Inc. 48 Wabun Ave. Providence, RI 02908


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