PROJECT REPORT

COURSE CODE

ENGR-1026

COURSE NAME

ENGINEERING DESIGN 1

SECTION NUMBER

PROJECT NUMBER

NAME OF PROJECT
NAME

INTERNAL BRAKE SHOE

DESIGN
NEEL PATEL

STUDENT NUMBER

0799038

CLASS NUMBER

PEME1-E

SUBMISSION DATE

16TH, OCTOBER 2016

NEEL PATEL (0799038)

SYSTEMATIC SOLUTION FOR HOIST DESIGN

STEP: 1
THE PROBLEM:
In this given Internal Brake Shoe Design problem, the system has
to be delivered 1600 N-m of braking torque. Also the inside rim diameter
of the drum is 420mm and that can accommodate shoe widths between
50 to 80mm. Moreover, the brake shoes have maximum pressure
limitation of 1200kPa. On the top of these the actuating force (F) cannot
exceed 6.5 kN. The system has friction of 0.32. The Design for such
system as per my assumption and calculation as below.

STEP: 2
IDENTIFICATION OF THE GIVEN KNOWN VALUES:
i.
ii.
iii.
iv.
v.
vi.
vii.

NEEL PATEL (0799038)

Braking Torque: 1600 N-m,

The inside rim diameter (D): 420mm,
Radii of rim (r): 210mm,
Shoe widths must be between 50mm to 80mm,
Maximum Pressure Limitation: 1200kPa,
The Actuating Force (F): 6.5kN (Should not be exceed),
Coefficient of Friction (f): 0.32.

STEP: 3
IDENTIFICATION OF UNKNOWNS AND SOLUTION
STRATEGY:
There are lots of unknown parameters that are required for the
solution and strategy such as;
b : Width of Shoe, m,
a : Distance from the center of the pin to the center
of the set, m,
Mf : Moment of Frictional Force, N.m,
Mn : Moment of Frictional Force, N.m,
F : The actuating force, N,
Rx : The Horizontal Reaction, kN,
Ry : The Vertical Reaction, kN,
R: Resultant on the hinge pin, kN,
TL : Torque applied to left-hand shoe, N.m,
TR : Torque applied to Right-hand shoe, N.m.
Pa : Maximum allowable pressure, kPa.

SOLUTION STRATEGY:
I.
II.
III.

NEEL PATEL (0799038)

Select all unknown variables,

Find Out Mf, Mn, TL, TR, in terms of unknown variables F,
Pa, and b,
From above derived equation of Mf, Mn, TL, TR; find the
value of maximum operating pressure Pa for each shoe,
the actuating force (F) that should not be exceed than
6.5kN, shoe width (b), and hinge pin reaction for each
shoe (R).

STEP: 4
ALL ASSUMPTION AND DECISIONS:
From below sketch, I have made such assumption as per below,

r
2

Counter Clock Wise

NEEL PATEL (0799038)

1. From above fig. value of C,

C = X+Y= 90+110 = 200 mm = 0.2m.
2. The value of E and G,
E = 70mm = 0.07m,
G = 80mm = 0.08m.
3. From the value of X, Y, E, and G; I got the values of a, , , 2 as per
below,
a = 2 + 2
a = 702 + 1102
a = 130.3840mm
4. = tan1
= 32.47

110

5. = tan1
= 41.63

70

80
90

6. Substance Angle (2),

2 = 180 - (+ )
2 = 180 - (32.470+ 41.630)
2 = 105.900
7. In this design the brake shoe is started from hinge pin point that is why
the 1 is 00 and the angle (a) at which the pressure is maximum that is
900,
1= 0 and sin(a) = 1
Now from above assumption my design for braking system has derived
in next step: 5.

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STEP: 5
First of all, in this design, I have assumed that the rotation of the rim
drum is Counter Clock Wise. So from that the Left side shoe has
become Self Energizing shoe and Right side has become Non
Energizing.
Moment of Frictional Force (Mf), Here 1 is zero so equation is,

a
Mf =
*{ cos 2 2 2)
sin a

Mf=0.32

0.210
1

*{0.210 0.210 cos 105.90

0.130384

Mf = 0.013926*Pa*b..A

2 105.90}

Moment of Frictional Force (Mn), Here 1 is zero so equation is,

Mn =
Mn =

*{

sin 2 2/4 }

sin a
2
0.2100.130384

105.90

2180

*{

sin 2 105.90/4 }

Mn = 0.028911*Pa*bB
Now the actuating force (F) for left shoe (Self Energizing shoe) and
Right shoe (Non Energizing shoe) has calculated as per below,
F for Left shoe (Self Energizing shoe),
F=
F=

MnMf
C
0.028911Pab0.013926Pab
0.200

.From Equation A & B

F = 0.074925*Pa*b C
Pa*b = 13.34668*F D

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 F for Right shoe (Non Energizing shoe),

F=
F=

Mn+Mf
C
0.028911Pab+0.013926Pab
0.200

.From Equation A & B

F = 0.214185*Pa*b E
Pa*b = 4.66886*F F
The torque for the both shoe,
Torque for Left shoe (Self Energizing shoe),
TL =
TL =

fPabr2 (cos 1cos 2)

sin a
0.3213.34668F0.2102 (cos 0cos 105.90)
1

From Equation D, 1=0

TL = 0.2399498*F G*
Torque for Right shoe (Non Energizing shoe),
TR =
TR =

fPabr2 (cos 1cos 2)

sin a
0.324.66886F0.2102 (cos 0cos 105.90)
1

From Equation F, 1=0

TR = 0.083937*F H*
Now for Actuating Force,
Total Torque (T) is given (T = 1600kN),
T = TL+TR
1600 = 0.2399498*F +0.083937*F...From Equation G* & H*

F = 4.94 kN I

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 HERE THE DERIVED F FOR DESIGN IS 4.94 KN

THAT IS BELOW THE 6.5 KN THAT MEANS THE
DESIGN IS FULL FILL THE GIVEN CONDITION.
The next step is to calculate the Pa as per the assumption of the shoe
width (b), I have chosen b = 70mm= 0.07m,
The maximum Pressure at Left shoe (Self Energizing shoe),
Pa*b = 13.34668*F
Pa*(0.07) = 13.34668*4.94 .From Equation I

Pa = 941.89 kPa For Left shoe J

The maximum Pressure at Right shoe (Non Energizing shoe),
Pa*b = 4.66886*F
Pa*(0.07) = 4.66886*4.94 .From Equation I

Pa = 329.49 kPa For Right shoe .K

b = 70mm = 0.07m
STEP: 6
EVALUATION OF THE SOLUTION:
=0.5sin22
A = 0.5sin2105.90

A = 0.462473
B = [(2/2)*( /180) (sin22/4)]
B = [(105.90/2)*(/180) (sin2*105.90/4)]

B = 1.05589
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 D for Left and Right side,

DLeft =

DLeft = 941.89 0.070

0.210
1

.From Equation J

DLeft = 13.8458 kN
DRight =

sin a

DRight = 329.49 0.070

0.210
1

.From Equation K

DRight = 4.84350 kN

Hinge Pine reaction for each shoe (counter Clock Wise Direction):
For Left side shoe:
x = Left ( + ) *sin . = 32.470
x = 4.84350 (0.462473 + 0.32*1.05589) 4.94 *sin 32.47
x = 8.4295158 kN and
y = Left (B - A) *sin
y = 4.84350 (1.05589 0.32*0.462473) - cos 32.47
y = 8.4028401 kN
So finally the Resultant Hinge reaction at Left shoe is,
=[ x2 + y2]0.5
= [8.4295158 2 + 8.4028401 2]0.5

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 = 11.902 kN For Left side shoe

For Right side shoe:
x = Right ( - ) *sin . = 32.470
x = 4.84350 (0.462473 - 0.32*1.05589) 4.94 *sin 32.47
x = -2.04864 kN and
y = Left (B + A) *sin
y = 4.84350 (1.05589 + 0.32*0.462473) - cos 32.47
y = 1.66326 kN
So finally the Resultant Hinge reaction at Left shoe is,
=[ x2 + y2]0.5
= [-2.04864 2 + 1.66326 2]0.5

= 2.369 kN For Right side shoe

REFERENCE
1. Shigleys Mechanical Engineering Design, Tenth Edition
Instructor: Jason Martinez

NEEL PATEL (0799038)