Chapter 3

Project on Hydraulic elevator

3.1. Short summary of the project
This project is on designing hydraulic elevator. Hydraulic elevator systems lift a car using a hydraulic
ram, a fluid-driven piston mounted inside a cylinder. Hydraulic lifts work by the action of a pumped fluid,
normally oil. Within a cylinder driving a piston which-is attached to the lift car.

The hydraulic lift is used in applications where the maximum travel distance is about 20m.
The maximum traveling speed of commercially available hydraulic lifts is limited to about
0.75m/s.
This type of lift is suited to low intensity usage and is limited to around a maximum of 50
starts per hour.
The hydraulic lift has the advantage of lower capital cost when compared with a traction lift

3.2. Problem statement and justification

In place where lower capital cost is required, it is much applicable to use hydraulic elevators. For
building having not more than six floors, it is cheap to use hydraulic lifts rather than the electric traction
elevator. Since Hydraulic elevator systems lift a car using a hydraulic ram, a fluid-driven piston mounted
inside a cylinder, it is much safe to use it in terms of as one of the cable is loosen or breakdown as in
electric traction elevator.

3.3. Objective of the project

The project is aimed to solve the problem in terms of safety concern. This project is tried to solve both in
terms of safety When the cables are broken in the electric traction pipes and in terms of capital cost that is
spend when the floor level is not greater than six floors, so its capital cost is lower compared to the
electric traction system.
3.4 METHODOLOGY
In this chapter we have followed the procedure of creative engineering design. The following steps
have been followed
Definition of the problem.
Need analysis description.
Development of customer requirements.
Carryout detailed design based on the selected concept in all the design details and the
manufacturing drawing are given in the chapters to follow.

3.4.1 DEFINITION OF THE PROBLEM

We are going to design an elevator that is working with hydraulic, easier and less expensive to
manufacture. It also provides smooth drive and torque characteristics from starting to the designed peak
condition.
3.4.2 NEED ANALYSIS
The advent of highrise buildings in modern cities requires highspeed elevator systems to provide quick
access within buildings. There is a great demand of elevator by the society in todays world of
growing technology. it offers many advantages like
1. It is very useful in minimizing time in big building.
2. Elevators are used to lift pedestrian in mass for people with disablities

3.4.2 CUSTOMER REQUIREMENTS

1. Power consumption should be minimum.

2 Escalator running should be smoothly.
3. Handrail should be given for the support of passenger.
4. Surface of steps should not be slippery.
5. The size should be smallest possible so that it should occupy minimum amount of space.
6. angle of inclination should be 30 to 35 degree
7. The functioning of escalator should be easy to perform without much fatigue
8. It should be economical..

3.4.3 Design process

3.4.3.1 DETAIL DESIGN
In design of a gear drive, the following data is usually given:

Designing of elevator
DESIGN DATA AND FORMULAS (AMERICAN PRACTICE) ASME FORMULAE
MODIFIED S.I. UNITS BASED ON IMechE, LONDON
2.5.1 Introduction to basic formulas
For the purpose of structural design, the rated load shall be considered to be not less than:
(Imperial Units), ASME
Structural rated load (lb) = 4.6(W + 8)A (2.25)
(SI Units), IMechE
Structural rated load (kg) = 0.27(W + 203)A (2.26)
where
A = length of the horizontal projection of the entire truss measured along its centreline, ft (m)
W = width of the escalator, in. (mm).
Machinery
(1) For the purpose of driving machine and power transmission calculations, the rated load for all
single driving machines shall be considered to be not less than:
(Imperial Units), ASME
Machinery rated load (lb) = 3.5(W + 8)B1 (2.27)
(SI Units), IMechE
Machinery rated load (kg) = 0.21(W + 203)B1 (2.28)
(2) The rated load per module for two or more modular driving machines shall be considered to
be not less than:
(Imperial Units), ASME
Machinery rated load (lb) = 3.5(W + 8)B2 (2.29)
Limits of speed
The rated speed shall be not more than 125 ft/min (0.64 m/s), measured along the centreline of the
steps in the direction of travel.
Minimum rated load, passenger elevators
The following formulas shall be used for determining the minimum rated load of passenger elevators
(see also Rule 207.1 from the code).
(a) For an elevator having an inside net platform area of not more than 50 ft2 (4.65 m2)
(Imperial Units), ASME
W = 0.667A2 + 66.7A (2.30)
(SI Units), IMechE
W = 35.05A2 + 325.7A (2.31)
Specifications for the design of lifts or elevators
(b) For an elevator having an inside net platform area of more than 50 ft2 (4.65 m2)
(Imperial Units), ASME
W = 0.0467A2 + 125A 1367 (2.32)
(SI Units), IMechE
W = 2.454A2 + 610.3A 620.1 (2.33)
Car frame plank (buffer engagement)
The following formula shall be used to determine the stress resulting from buffer engagement:
(Imperial Units), ASME
Stress (psi) = D(C + W)/ 2Z (2.34)
(SI Units), IMechE
Stress (kPa) = 0.009807D(C + W) /2Z (2.35)
Where more than one oil buffer is used, the formula shall be modified to suit the location of the
buffers.
Car frame uprights (stiles)
The total stress in each car frame upright due to tension and bending, and the slenderness ratio of each
upright and its moment of inertia, shall be determined in accordance with the following formulas:
(a) Stresses due to bending and tension
(Imperial Units), ASME
Total stress (psi) = KL /4HZu + G/ 2A (2.36)
(SI Units), IMechE
Total stress (kPa) = 0.009807 (KL /4HZu + G /2 A ) (2.37)
Where KL/4HZu is the bending stress in each upright in the plane of the frame due to live load
W on the platform for the class of loading A, B or C for which the elevator is to be used (see
Rule 207.2b), G/2A is the tensile strength in each upright and K is determined by the following
formulas [see Fig. 2.11]:
(1) For Class A freight loading or passenger loading
(Imperial Units), ASME
K = WE / 8 (2.38)
(SI Units), IMechE
K = 9.807 ( WE/ 8 ) (2.39)
(2) For Class B freight loading
(Imperial Units), ASME
K = W( E/ 2 48 ) or K = WE / 8 (2.40)
Whichever is greater
(SI Units), IMechE
K = 9.807W ( E/ 2 1.219) or K = 9.807 WE / 8 (2.41)
Whichever the greater
fig

Fig turning moment based on class

(3) For Class C freight loading
(Imperial Units), ASME
K =WE/4 (2.42)
(SI Units), IMechE
K = 9.807 (WE /4 ) (2.43)
(b) Slenderness ratio
The slenderness ratio L/R for uprights subject to compressions other than those resulting
from safety and buffer action shall not exceed 120. Where the upper side-brace connections passenger
elevator car frame uprights are located at a point less than 2/3 of L from the bottom, (top fastening in car
frame plank) a slenderness ratio of L/R not exceeding 160 is permissible.
(c) Moment of inertia
The moment of inertia of each upright shall be not less than determined by the following
formula:
(Imperial Units), ASME
I = KL3 / 18EH (2.44)
(SI Units), IMechE
I = KL3 / 457.2EH (2.45)
where
A = net area of section, in.2 (m2)
C = net weight of complete elevator car, lb (kg)
D = distance between guide rails, in. (m)
E = inside clear width of car, in. (m), except for formulas in Rules 1301.5(c) and
1303.1d(4) where E = modulus of elasticity [psi (kPa)] of the material used
G = load supported by crosshead with the maximum load for the class of
loading in car at rest a top terminal landing, lb (kg)
H = vertical centre distance between upper and lower guide shoes (or rollers), in. (m)
I = moment of inertia of member, gross section, in.4 (m4)
K = turning moment as determined by class of loading, lbf.in. (Nm)
L = free length of uprights (distance from lowest fastening in plank), in. (m)
R = least radius of gyration of section, in. (m)
W = rated load, lb (kg)
Z = combined section moduli of plank members, gross section, in.3 (m3)
Zu = section modulus of one upright, gross section, in.3 (m3).
Freight elevator platform
The calculation for stresses in the platform members of freight elevators shall be based on the
following concentrated loads assumed to occupy the position which will produce the maximum
stress:
(a) For Class A loading
25% on the rated load;
(b) For Class B loading
75% on the rated load or 34,000 lb (15.422 kg), whichever is less, divided into two equal parts
5 ft (1.52 m) apart;
(c) For Class C1 loading with a loading rating of 20,000 lb (9062 kg) or less
80% of the rated load divided into two equal parts, 30 in. (762 mm) apart;
(d) For Class C2 loading with a loading rating of 20,000 lb (9062 kg) or less
80% of the rated load or of the loaded truck weight, whichever is greater, divided into two
equal parts 5 ft (1.52 m) apart;
(e) For Class C1 loading with a rated load in excess of 20,000 lb (9062 kg)
80% of the 20,000 lb (9062 kg) or of the maximum loaded truck weight, whichever is greater,
divided into two equal parts 5 ft (1.52 m) apart;
(f) For Class C3 loading.
Determined on the bases of the actual loading conditions but not less than that required for
Class A loading.
3.4.4 Hydraulic machines and piping
Plunger design
Plungers shall be designed and constructed in accordance with one of the following formulas:
(a) Plungers not subject to eccentric loading
(1) Where slenderness ratio of plunger is less than 120
(Imperial units)
W/ A = 13, 600 0.485(L/R)2 (2.46)
(SI Units)
W/ A = 9.773 107 3.344 103(L/R)2 (2.47)
(2) Where slenderness ratio of plunger is greater than 120
(Imperial Units)
W/ A = 95, 000, 000 / ((L/R)2 (2.48)
(SI Units)
W/ A = 6.552 1011 / ((L/R)2 ) (2.49)
where
A = net area of plunger (area of metal), in. 2 (m2)
L = maximum free length of plunger, in. (mm). Where a plunger-follower
guide is used, L shall be taken as one-half the amount that the free length
would be if no follower guide was provided.
R = radius of gyration of plunger section, in. (m)
W = allowable gross weight to be sustained by plunger, lbf (N). Where a
counterweight plus the unbalanced weight of the counterweight ropes
may be deducted in determining W, one-half of the weight of the plunger
shall be included except where a plunger-follower guide is used, in
which case, 3/4 of the plunger weight shall be included.
W/A = maximum allowable fiber stress.
(3) The plunger is 4 in. (102 mm) nominal pipe size or larger.
(4) Pipe not lighter than schedule 40 is used and not more than 1/16 in. (1.6 mm) of metal has
been removed from the wall thickness in machining.
(b) Plungers with varying cross section
For plungers with varying cross section, the stress shall be calculated for a factor of safety of
at least 3 using accepted methods for elastic stability.
s
(c) Plungers subject to eccentric loading
For plungers subject to bending, the stresses due to bending as determined by the following
formula shall be subtracted from the stresses W/A as determined by the applicable formula.
(Imperial Units), ASME
S (psi) = Wb e /Z (2.50)
(SI Units), IMechE
S (kPa) = 0.009807 Wb e /Z (2.51)
where
e = eccentricity of Wb, in. (mm)
Wb = maximum eccentricity load, lb (kg). Where any or all of this load is caused by
moving wheel loads imposed on the edge of the platform, the total of such loads shall be doubled for
impact (see Rule 1301.6).
S = stress due to bending
Z = section modulus of plunger section, in.3 (mm3)
(d) Plungers subjected to external pressure
For plungers subjected to external pressure, the working pressure shall be not more than that
indicated by the following formulas:
(1) Where the ratio of t/d is less than 0.023
(Imperial Units), ASME
1
2
p=333 1-1600( t/d) ] (2.52 )

(SI Units), IMechE

p = 2296[ 1 1 1600 ( t/d) 2 ] (2.53)
2) Where the ratio of t/d is greater than 0.023
(Imperial Units), ASME
p = 28, 890 t/ d 462 (2.54)
(SI Units), IMechE
p = 199200 t /d 3185 (2.55)
where
d = external finished diameter, in. (mm)
p = working pressure, psi (kPa)
t = finished wall thickness, in. (mm).
Cylinder Design
Cylinders shall be designed and constructed in accordance with the following formula:
t = pd / 2S (2.56)
where
d = internal diameter, in. (mm)
p = working pressure, psi (kPa)
S = design stress, psi (kPa)
t = minimum thickness of wall, in. (mm).
Cylinder and Plunger Heads
Heads of cylinders and heads of plungers subject to fluid pressure shall be designed and constructed
in accordance with one of the following applicable formulas:
(a) Flat unreinforced heads
t = d p/ S (2.57
(b) Dished seamless hemispherical heads, concave to pressure
t = 5pr / 6S (2.58)
(c) Dished seamless ellipsoidal heads, concave to pressure (ellipsoidal heads in which 1/2 of the
minor axis equals 1/4 the inside diameter of skirt),
t = 5pD / 6S (2.59)
where
d = diameter of head between supporting edges, in. (mm)
D = inside diameter of skirt, in. (mm)
p = working pressure, psi (kPa)
r = radius to which head is dished, measured on concave side
(not greater than d), in. (mm)
S = design stress, psi (kPa) (Rule 1302.5b)
t = minimum thickness of head, in. (mm).
Pipe design
The minimum wall thickness of pipe shall be detected by the following formula:
t = pD / 2S + C (2.60)

Or t C = pD / 2S (2.61)
where
C = 0.05 for threaded pipe up to 3/8 in. (9.5 mm) pipe size
= depth of thread for threaded pipe over 3/8 in. (9.5 mm) pipe size
= depth of groove for grooved pipe, in. (mm) 0.000 for other pipe of
unreduced thickness
D = outside diameter of pipe, in. (mm)
p = working pressure, psi (kPa)
S = allowable stress, psi (kPa) (Rule 1302.5b)
t = minimum wall thickness, in. (mm).
Safety factor
The minimum factor of safety for components subject to fluid pressure shall be as follows:
F = 5.04 / E 2.8 + 2.7 (2.62)
where
E = percent elongation in 2 in. (50 mm) gauge length as per ASTM
Standard E8 expressed as a whole number (e.g., 20% = 20 and 5% = 5).
The minimum allowable E shall be 5.
F = minimum factor of safety based on 0.2% proof stress yield
point. The minimum allowable F shall be 3.
Lifts, Elevators, Escalators and Moving Walkways/Travelators
where
fa = actual axial compressive unit stress based on gross section
fb = actual bending unit stress
Fa = allowable axial compressive unit stress [not exceeding
17,000 0.485(L/R)2 in Customary Units and 117 200 3.344(L/R)2
in SI Units]
Fb = allowable bending unit stress [16,500 psi (113 700 kPa) if area of basis is gross
section or 19,800 psi (134 400 kPa) if area of basis is net section]
L = free length of uprights (distance from lowest fastening in crosshead
to top fastening in plank), in. (mm)
R = least radius of gyration of section, in. (mm).
Car frame uprights (stiles)
The stresses in each car frame upright due to compression and bending and the slenderness ratio
of each upright and each moment of inertia shall be determined in accordance with the following
formulas:
(1) Stresses due to bending
fb =KL /4HZu (2.63)
where
fb = the bending stress in each upright in the plane of the frame due to the live load W on the platform for
the class of loading A, B, or Cfor which the elevator is to be used
K = turning moment in lbf.in. (Nm) as determined by the class of
loading by the following formulas:
(a) For Class A freight loading or passenger loading
(Imperial Units)
K = WE /8 (2.64)
(SI Units)
K = 9.807 (WE/ 8) (2.65)
(b) For Class B freight loading
(Imperial Units)
K = W( E/ 2 48) or K = WE/ 8 (2.66)
(SI Units)
K = 9.807W( E/ 2 1.219) or K = 9.807 WE/ 8 (2.67)
Whichever the greater
(c) For Class C freight loading
(Imperial Units)
 K =WE / 4 (2.68)
(SI Units)
K = 9.807( WE/ 4) (2.69)

Specifications for the design of lifts or elevators

(2) Stresses due to compression
fa = compressive stress in each upright
(3) Slenderness ratio
The slenderness ratio L/R for uprights subject to compressions other than those resulting
from safety and buffer action shall not exceed 120. Where the upper side-brace connections
passenger elevator car frame uprights are located at a point less than 2/3 of L from the bottom,
(top fastening in car frame plank) a slenderness ratio of L/R not exceeding 160 is permissible.
(4) Moment of inertia
The moment of inertia of each upright shall be not less than determined by the following
formula:
(Imperial Units), ASME
I = KL3/18EH (2.70)
(SI Units), IMechE
I = KL3 / 457.2EH (2.71)
Maximum stresses in car frame uprights
The maximum stresses in car frame uprights which are normally subject to compression shall be
such that the quantity [(fa/Fa) + (fb/Fb)] does not exceed unity.
2.5.3 Gravity stopping distances
The following formula gives the value of the stopping distance based on gravity retardation from
any initial velocity.
(Imperial Units)
S = V 2 / 19,320 (2.72)
(SI Units)
S =V 2/ 0.01963 (2.73)
where
S = free fall (gravity stopping distance), in. (mm)
V = initial velocity, ft/min (m/s).
Stopping distances for car and counterweight safeties
The following formulas shall be used to determine the maximum and minimum stopping distances
for Type B car and counterweight safeties:
(Imperial Units), ASME
S = V 2/ 81,144 + 0.84 (2.74)
S = V 2 / 231,840 (2.75)
(SI Units), IMechE
S = V 2/ 6.870 + 0.2560 (2.76)
S1 = V 2 /1 9.63 (2.77)
where
S = maximum stopping distance, ft (m)
S = minimum stopping distance, ft (m)
V = governor tripping speed, ft/min (m/s).
2.5.4 Factors of safety for suspension wire ropes for power elevators
2.5.4.1 Impact on buffer supports
Buffer reaction and impact for oil buffer supports
The following formulas give the buffer reaction and the impact of the supports of car and
counterweight spring buffers which do not fully compress under the conditions.
(a) Buffer reaction
(Imperial Units)
R = W (1 + V2 / 64 .4 S ) (2.78)
(SI Units)
R = W 9.807 + V 2/ 2S (2.79)
P = 2R (2.80)
Buffer reaction and impact for spring buffer supports
The following formulas give the buffer reaction and the impact on the supports of car and
counterweight spring buffers which do not fully compress under the conditions.
(a) Buffer reaction
(Imperial Units)
R = 2W( 1 +V2 / 64.4S) (2.81)
(SI Units)
R = 2W( 9.807 + V2 / 2S (2.82)
(b) Impact
P=R (2.83)
where
P = impact, lbf (N)
R = buffer reaction, lbf (N)
S = buffer stroke, ft (m)
v = speed at impact, ft/sec (m/s)
W = weight of car plus rated load or weight of counterweight, lb (kg).