WINCH DESIGN CALCULATOR

High-Rise Building Panel Lifting System

Rope Diameter · Motor Capacity · Anti-Sway Rope · Safety Design

Instructions: Select building height, panel weight, and lifting speed. The calculator will compute all rope diameters, motor capacity, safety factors, and anti-sway rope dimensions for your winch design. Wind load (6 m/s avg) is included automatically.

Input Parameters

Building Height (metres)

Panel Weight (kg)

Lifting Speed (m/s)

Wind Speed (m/s)

Panel Dimensions – Width (m)

Panel Dimensions – Height (m)

Safety Factor (Wire Rope) (recommended: 8–10)

Reeving / Pulley System

WINCH DESIGN REPORT

High-Rise Panel Lifting System – Engineering Guidance Calculator

1. Input Summary

2. Load Analysis

Parameter	Formula / Basis	Value	Unit

3. Main Hoist Rope Design

Parameter	Basis	Value	Unit

4. Safety Rope Design

Parameter	Basis	Value	Unit

5. Motor & Drive System Design

Parameter	Basis	Value	Unit

6. Anti-Sway Bottom Rope Design

Parameter	Basis	Value	Unit

7. Design Summary & Recommendations

8. Assumed Friction & Design Coefficients

Parameter	Value Used	Reference / Note
Sheave/Pulley Efficiency per sheave	0.96	Standard steel sheave, IS/BS guidance
Drum Bearing Friction Factor (μ)	0.02	Standard roller bearing, well-lubricated
Wire Rope Drag/Bending Loss	3%	Per IS 3973 / BS 302
Gear/Transmission Efficiency	0.90	Helical gearbox, standard quality
Drive (VFD/Remote) Efficiency	0.92	Variable Frequency Drive
Wind Drag Coefficient (Cd)	1.3	Flat panel, IS 875 Part 3
Air Density	1.225 kg/m³	Standard atmosphere, 15°C at sea level
Wire Rope Tensile Grade	1770 N/mm²	6×37 IWRC construction, IS 2266
Wire Rope Fill Factor	0.40	6×37 IWRC rope construction
Dynamic Load Factor (hoist start)	1.25	IS 807 / FEM 1.001 standard
Safety Rope Grade (Fibre/Steel)	1570 N/mm²	IWRC 6×19 safety rope
Anti-Sway Rope Tension Multiplier	0.3 × Wind Force	Each bottom corner rope

9. Calculation Notes (Guidance)

Rope Breaking Load: MBL = (Safe Working Load × Safety Factor) / Reeving parts. Rope diameter from: MBL (kN) = 0.355 × d² × U_ts × Fill Factor / 1000 → d = √(MBL×1000 / (0.355 × 1770 × 0.40))

Wind Force: F_wind = 0.5 × ρ × Cd × A × V² where ρ=1.225 kg/m³, Cd=1.3, A=panel area, V=wind velocity.

Total Hoist Load: Dynamic load = (Panel weight + rigging) × Dynamic Factor + Wind uplift component.

Motor Power: P = (Total Load × Lifting Speed) / (η_gear × η_drive × Reeving Efficiency) where reeving efficiency = 0.96ⁿ for n sheaves.

Anti-Sway Rope: Tension = 0.3 × Wind Force per corner. Rope sized with SF=6 and same tensile grade.

Safety Rope: Sized to hold full dynamic load with SF=12 (independent of main hoist rope, as per BS EN 13157).

Standards Referenced: IS 2266 (Wire Ropes), IS 3973 (Pulley Blocks), IS 807 (Crane Design), IS 875 Part 3 (Wind Loads), BS 302 (Wire Ropes), BS EN 13157 (Hoists), FEM 1.001 (Crane Classification).

DISCLAIMER – FOR STUDY & GUIDANCE PURPOSE ONLY
This calculator is intended solely as a preliminary engineering guidance tool. All results are approximate and based on standard engineering formulae and referenced codes. These calculations do not replace a formal structural or mechanical engineering design by a qualified professional engineer. Before any actual installation or procurement, all rope sizes, motor capacities, and structural attachments must be independently verified by a licensed engineer in accordance with applicable national and local standards. The authors accept no responsibility for any loss, damage, or injury arising from the use of this tool.