SHEAVE
Design Manual
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Higher Loads & Increased Safety
Redco™ Sheaves offer numerous advantages over conventional steel:
Lightweight Design
· 1/8th the weight of traditional steel and plastic sheaves
· Improves lifting capabilities and eases installation of mobile/fixed boom cranes
Longer Rope Life
· Suits “on again, off again” loading styles typical for this application
· Enhanced material memory and resiliency increases rope support
Increased Load Capacity
· Flexible design decreases telescoping crane arm weight & increases contact
area between the groove and rope.
$
Reduce Operating Costs
· Lubricated grades of Redco™ Cast Nylon ensure the needs for regular
lubrication is reduced/omitted.
Corrosion Resistant
· Redco™ Cast Nylon Sheaves will not rust or corrode.
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Sheave Diameter
The outer diameter of the sheave depends on the size of both the rope and load.
The guideline for the sheave diameter is given by the Power Crane & Shovel Associations
and American National Standards Institute.
This guideline is given as a ratio between the “Pitch Diameter” of the sheave and the “Rope
Diameter”. The minimum recommended ratio is 18:1; European standards require 24:1.
To determine the Pitch Diameter and outer diameter of the sheave:
The Outer Diameter is based on a recommended groove depth
that is 1.75x the rope diameter.
Fig. 1
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Design Specifications
Hub Width
The hub width is usually determined by the space available for the sheave and other loading
and stability requirements. The hub is typically as wide or wider than the rim. The outer
diameter of the hub is calculated by:
H = 1.5B
H = Hub Diameter B = Bore diameter
The minimum wall thickness of the hub is 1”. The transition between the hub and web
should either be a radius or a slope to avoid sharp angles.
Web for Redco™ Sheave
To further reduce the weight of a Redco™ Sheave, material can be removed
between the rim and the hub. Reducing the weight can ease installation and
increase the carrying capacity of a boom style crane.
The minimum thickness of the web area is calculated as: W=1.2r
(W = Web thickness r = rope diameter).
To avoid sharp angles, the transition between the web and the rim should
either be a radius or a slope.
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Design Specifications contd.
Rim Dimensions
For sufficient side-loading support, minimum shoulder width (distance between
the outer edge of the rim and inside the groove) should be 1/8”.
Below is a table to determine the rim width based on the rope diameter, 30° groove angle, and
1/8” shoulder. The minimum thickness of the sheave at the rim (T) can be expressed as a
function of the rope diameter (r).
T = Thickness at the rim r = rope diameter
This helps calculate the Length-through-bore (LTB) on a straight-walled, machined Redco™
Sheave.
Groove Design
Groove depth should be at least 1.75x the rope diameter
(r). The radius at the bottom of the groove (G) should be
slightly larger than the rope: G = 1.05 * r/2
Typically, the groove angle is 30° for better rope support.
On occasion,a 45° angle is required for increased fleet
angles (up to 4°).
Fig. 2
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Design Specifications contd.
Bore Dimension
To increase the load bearing capacity of a Redco™ Sheave, a metallic bushing or roller
bearing can be used. The roller bearing increases PV (pressure velocity), as well
as increases load capacity.
Special attention must be given to the press fit of the bearing or bushing into the sheave.
A press fit that is too small will cause the sheave to walk-off the bearing at increased
temperatures. The recommended amount of press fit can be calculated as:
p = .009 √Db
p = press fit Db = Diameter of the bearing or bushing
The diameter of the bore must be machined to the size of the bearing/bushing less the
calculated press fit. On larger sheaves, a hydraulic press is required to install the bearing.
It is not recommended to heat up the sheave above 200°F as this can impart stress in
the Redco™ Sheave.
For thin-walled bushings or bearings, a reduction in the press fit can be made. To avoid
“walk-off” problems, the temperature swing should be kept to a minimum. For added
bearing stability, retaining rings can be used. Thrust washers or collars can be attached
to the shaft to keep the sheave from sliding from side-to-side.
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Load Capacity (with bearings)
Groove and bore pressure can be calculated as follows:
For rope wrap angle of 180° For rope wrap angle of 90°
Pg = 2∙T/r∙Dt Pg = 1.414∙T/r∙Dt
Pb = 2∙T/B∙LTB Pb = 1.414∙T/B∙LTB
Pg = Groove Pressure (psi) T = Line Pull (lbs)
r = rope diameter (in.) Dt = Tread Diameter (in.)
Pb = Bore Pressure (psi) B = Bore Diameter
LTB = Length through bore
Please refer to Figure 1. on page 3
To calculate the MAXIMUM BORE AND GROOVE PRESSURE acting
on the sheave, substitute the rope’s maximum line pull into the above Fig. 4
equations.
The maximum static pressure for a Redco™ Sheave is 4,000 psi. Intermittently, Redco™
Sheaves can withstand up to 8,000 psi for a few minutes. Using 4,000 psi as the maximum
pressures, the above equations can be used to calculate the maximum line pull (Tmax).
For rope wrap angle of 180° For rope wrap angle of 90°
Groove Tmax = 2000∙r∙Dt Groove Tmax = 2828∙r∙Dt
Bore Tmax = 2000∙B∙LTB Bore Tmax = 2828∙B∙LTB
Note: For a sheave ratio greater than 18:1, calculate only bore pressure.
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Load Capacity for Redco™ Sheaves
without bearings (Redco™ Sheave directly on shaft)
The main consideration for a sheave without bearings is Pressure Velocity (PV).
In this case, the Redco™ Sheave is the bearing. To calculate the load capacity for
this situation, use the maximum PV value of the grade of Redco™ Cast Nylon to be used.
From here, calculate the MAXIMUM BORE PRESSURE by:
PB = PV/V
PB = Maximum Bore Pressure (psi)
PV = Pressure Velocity rating for the grade to be used (psi∙fpm)
V = Surface speed of the bore of the sheave on the shaft (fpm)
For a Redco™ MD sheave, the bore pressure should not exceed 1,000 psi. With this, the
MAXIMUM LOAD can be calculated.
Lmax = 1000∙S∙LTB
Lmax = Maximum Load (lbs), S = Shaft Diameter (in.) LTB = Length through bore (in.)
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For more information on Redco™ products:
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We cannot anticipate all conditions under which this information and our products or the products of other manufacturers in combination with our products
may be used. We accept no responsibility for results obtained by the application of this or the safety and suitability of our products, whether alone or in
combination with other products. Users are advised to make their own test to determine the safety and suitability of each such product or product
combination for their own purposes. Unless otherwise agreed in writing, we sell the products without warranty, and buyers and users assume all
responsibility and liability for loss or damage arising from the handling and use of our products, whether used alone or in combination with other products.
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