I. INTRODUCTION

Barrage structures play a crucial role in regulating river flow, providing irrigation water, flood control, and sediment management. The Rohin Barrage is a strategically developed hydraulic infrastructure on the Rohin River, designed to serve the irrigation demands of the region while managing sediment load and floodwaters. The project includes several gated structures, each engineered to handle specific operational and hydrodynamic conditions.

The Rohni (also known as Rohini or Rohin) is a river rise in the Chure or Sivalik Hills in Kapilvastu and Rupandehi Districts of Nepal's Lumbini Zone and flows south into Uttar Pradesh state, India. At Gorakhpur it becomes a left bank tributary of West Rapti River, which in turn joins the Ghaghara above Gaura Barhaj, then Ghaghara in turn joins the Ganges.

The barrage design includes three types of operational gates—sluice service gates, under sluice service gates, and head regulator gates—along with auxiliary systems like rope drum hoists, stoplog gates, and monorail-based handling equipment. Each component is designed based on site-specific hydraulic data, operational requirements, and Indian Standards (IS codes) for structural and mechanical safety. The use of steel gates with efficient lifting and control mechanisms ensures durability and reliable operation during high flows and maintenance periods.

Design of hydraulic gates and hoisting mechanisms has been widely studied in water resources engineering. Jack Lewin (1995) provided a comprehensive design framework for vertical lift gates in his work "Hydraulic Gates and Valves", emphasizing flow control, structural strength, and vibration analysis. IS codes such as IS 4622:2003 (Guidelines for the design of sluice gates) and IS 6938:1973 (Design of rope drum hoists) form the backbone of modern gate and hoist designs in India.

Recent case studies such as the design of Teesta Barrage (WBSEDCL, 2017) and Gandak Barrage (WRD Bihar, 2019) emphasize the importance of robust gate operation mechanisms and sediment management strategies. These works highlight the need for integrated mechanical systems like monorails and rope drum hoists to ensure ease of operation and maintenance. The present study builds on these principles, applying them in a real-world scenario with updated calculations and equipment specifications to meet the challenges posed by the Rohin River basin.

During the 2007-2008 floods, after the nearby dam broke an estimated 28-35 people died when an overloaded rescue boat capsized on the flooded Rohni River at Harakhpura village of Maharajganj, Uttar Pradesh. There were an estimated 85-90 passengers aboard the boat, which was only rated for 30 occupants. Most were women and children.

The barrage is built on the Rohini river, also known as Rohni or Rohin. The barrage is situated in the Natanwa block, in the village of Ratanpur, Maharajganj, Uttar Pradesh. It is a digital barrage constructed for irrigation purposes, benefiting 65 villages and 16,000 farmers. The barrage is being constructed at a cost of 148 crore rupees. A canal from the Rohini river, which connects to the Lakshmipur block, is also part of the project.

II. PROJECT OVERVIEW AND SCOPE OF THE ROHIN BARRAGE

The barrage is located on the Rohin River and includes sluice bays, under sluice bays, a head regulator, and associated lifting and handling systems. The design discharge, water levels, and silt characteristics dictated specific design considerations for all components.

The Rohin Barrage, located in Uttar Pradesh, India, is a critical hydraulic structure designed to address water management challenges in the region. Its multifaceted design and strategic functionality provide numerous socio-economic, agricultural, and environmental benefits. Below is a detailed breakdown of its key uses and advantages:

a) Agricultural Irrigation

Primary Use: Diverts river water into an extensive canal network to irrigate farmland across Uttar Pradesh.

Benefits:

• Ensures reliable water supply for crops like wheat, rice, and sugarcane, which are vital to the state's agrarian economy.
• Increases agricultural productivity, stabilizes farmer incomes, and enhances food security.
• Reduces dependency on erratic monsoon rains, enabling year-round cultivation.

b) Flood Control

Primary Use: Regulates river flow during monsoon seasons to prevent downstream flooding.

Benefits:

• Protects villages, urban areas, and critical infrastructure (e.g., roads, bridges) from flood damage.
• Mitigates loss of life, livestock, and crops, reducing economic disruptions.
• Incorporates High Flood Level (HFL) design to handle extreme weather events, ensuring resilience.

c) Water Supply for Domestic and Industrial Use

Primary Use: Channels water to nearby towns and industries.

Benefits:

• Provides clean drinking water to local communities, improving public health.
• Supports industrial activities (e.g., textiles, sugar mills) by ensuring consistent water availability.

d) Socio-Economic Development Benefits

• Employment Generation: Construction and maintenance of the barrage create jobs in engineering, agriculture, and logistics.

• Economic Growth: Enhanced agricultural output and industrial activity stimulate local economies.

• Rural Development: Improved irrigation infrastructure uplifts rural livelihoods and reduces migration to cities.

e) Environmental and Ecological

Benefits Features

• Fish Ladders: Facilitate fish migration, preserving aquatic biodiversity.
• Sediment Management: Balances sediment flow to maintain soil fertility downstream.

Benefits:

• Sustains river ecosystems by preventing abrupt changes in water flow.
• Supports fisheries, a key livelihood for many communities.

f) Operational Efficiency and Maintenance Design Innovations:

• 25T Rope Drum Hoists: Enable precise control of sluice gates for efficient water regulation.
• 15T Monorail System: Simplifies maintenance of gates and machinery, minimizing downtime.
• Stoplog Gates: Allow targeted repairs without shutting down the entire barrage.

Benefits:

• Ensures long-term durability with corrosion-resistant materials (e.g., stainless steel, IS 2062 structural steel).
• Reduces operational costs through modular and user-friendly maintenance systems.

g) Climate Resilience Design Features

• Engineered to withstand seismic activity and extreme hydrological events.
• Adaptive gate operations to manage both droughts and floods.

Benefits:

• Enhances climate adaptability in a region vulnerable to erratic weather patterns.
• Secures water resources for future generations.

The Rohin Barrage is a cornerstone of sustainable water management in Uttar Pradesh, harmonizing agricultural productivity, flood mitigation, economic growth, and ecological preservation. Its advanced engineering, compliance with Indian standards (e.g., IS 4622, IS 6938), and focus on operational efficiency make it a model for infrastructure projects in flood-prone and agrarian regions. By addressing both immediate needs and long-term challenges, the barrage plays a pivotal role in fostering resilience and prosperity in northern India.

III. PROBLEM AND REMEDY: ROHIN BARRAGE PROJECT

The Rohin Barrage, while engineered for robustness, faces challenges typical of large hydraulic structures. Below are key problems and their corresponding remedies, aligned with the project's design features and compliance with Indian Standards (IS codes):

a) Problem: Sedimentation in the Reservoir

Issue: Accumulation of silt reduces water storage capacity and obstructs gate operations. Remedy:

• Under-Sluice Gates (IS 4622): Designed to flush sediments during low-flow periods.
• Regular Maintenance: Scheduled sediment flushing via under-sluice gates to maintain reservoir efficiency.

b) Problem: Gate Malfunctions

Issue: Mechanical failures in hoists or seal leaks disrupt water regulation.

Remedy:

• 25T Rope Drum Hoists (IS 6938): Equipped with manual backup and fail-safe braking.
• High-Quality Seals: "Z"-type rubber seals (IS 11855) and stainless-steel seats (IS 1570) for watertight operation.
• Preventive Maintenance: Routine inspections of antifriction bearings (SKF/FAG) and hydraulic systems.

c) Problem: Structural Corrosion and Wear

Issue: Prolonged exposure to water and humidity causes metal degradation.

Remedy:

• Corrosion-Resistant Materials: Stainless steel rollers (20Cr13, IS 1570) and structural steel (IS 2062 Grade E250) with protective coatings.
• Replaceable Components: Sliding pads made of leaded tin bronze (IS 318 LTB) to minimize wear.

d) Problem: Flood Risks During Monsoon

Issue: Extreme hydraulic loads during High Flood Level (HFL) threaten structural integrity.

• HFL Design: Gates designed for $1.33\times$ permissible stresses (IS 4622, IS 5620) to withstand $5.40\mathrm{m}$ head.
• Reinforced Concrete Piers: Anchored with IS 2062 steel to resist hydrodynamic pressures.

e) Problem: Operational Inefficiency

Issue: Manual interventions delay response times.

Remedy:

• 15T Monorail System: Facilitates quick transport of stoplogs and machinery for maintenance.
• SCADA Automation: Remote operation of head regulator gates (IS 4622) for real-time adjustments.

f) Problem: Environmental Impact

Issue: Disruption to aquatic ecosystems and fish migration.

Remedy:

• Fish Ladders: Integrated into barrage design to support biodiversity (common practice, though not explicitly detailed in documents).
• Sediment Management: Balances silt distribution to maintain downstream soil fertility.

g) Problem: Maintenance Challenges

Issue: Difficulty accessing critical components for repairs. Remedy:

• Interchangeable Stoplog Elements: Modular design allows isolation of sections without full shutdown (IS 5620).
• Monorail Access: Enables efficient handling of heavy components like roller gates and hoists.

h) Problem: Seismic Vulnerability

Issue: Earthquake-induced forces risk gate misalignment or failure. Remedy:

• Seismic Analysis: Gates designed for hydrodynamic pressures during earthquakes (Zone IV as per IS 1893).
• Flexible Joints and Reinforced Anchors: Absorb seismic shocks while maintaining structural stability.

i) Problem: Human Error in Operations

Issue: Mismanagement during emergencies exacerbates risks. Remedy:

• Operator Training: Regular drills on manual hoist operation and emergency protocols.
• Sensor-Based Alarms: Monitor water levels, gate positions, and equipment health to alert staff.

The Rohin Barrage addresses these challenges through a blend of advanced engineering, material science, and adherence to IS codes. By integrating fail-safe mechanisms, corrosion-resistant materials, and modular maintenance systems, the project ensures long-term operational resilience, environmental sustainability, and safety for Uttar Pradesh's water management infrastructure.

IV. DESIGN OF COMPONENTS

a) Design of Sluice Service Gates

The sluice gates in the Rohin Barrage project are designed to regulate water discharge, control upstream water levels, and facilitate sediment flushing. These gates operate under variable hydraulic heads and are crucial for efficient barrage operation and flood control.

i. General Specifications

The sluice service gates for the Rohin Barrage (Uttar Pradesh) are designed as vertical roller gates in accordance with IS 4622:2003. Key technical details include:

• Number of gates: 5
• Vent dimensions: $10000\mathrm{mm}$ (width) $\times 2540\mathrm{mm}$ (height)
• Gate height: $3000\mathrm{mm}$
• Sill level: EL 96.500 m
• Pond level (FSL): EL 99.040 m
• High Flood Level (HFL): EL 101.400 m
• Design head (FRL): 2.54 m
• Center-to-center (C/C) of side seals: 10100 mm
• C/C of rollers: 10500 mm
• Operation: Independent rope drum hoist mounted on trestles.

ii. Material Specifications

iii. Hydraulic Load Calculations

a. Thrust on Gate

• At FRL (2.54 m head):

At HFL (4.90 m head):

• Load increase under HFL: Gate designed for HFL with permissible stress increased by 1.333 times.

iv. Structural Design of Gate Leaf

a. Horizontal Girders

• Girder 'B' (critical load case):

• Load: 34603 kg

• Bending Moment (BM):

Section Properties:

Skin plate: 12 mm thick (effective 10.5 mm after corrosion allowance) Co-acting width: 54.5 cm (as per IS 800)

Moment of Inertia $(I_{xx})$: 197577.3 cm ${}^4$, $(I_{yy})$: 40801.01 cm ${}^4$ Section Modulus (Z): 6164.477 cm ${}^3$ (top), 6373.28 cm ${}^3$ (bottom)

Stress Checks:

Bending stress (top): 765 kg/cm2 < 1530 kg/cm2

Shear stress:

v. Design of Roller Assembly

a. Roller and Axle

• Max roller load: 25 t

• Material: Cast steel (IS 1030, Grade 340-570W)

• Bearing stress: 7.53 t/cm2 < 9.3 t/cm2 (permissible)

• $\succ$ Bearing: Spherical roller bearing (SKF 22220E, static capacity $490\mathrm{kN}$ )
• $\succ$ Axle Material: 20Cr13 (AISI 410/420)

Bending stress:

b. Roller Track

• Track plate: $150\times 12\mathrm{mm}$ (20Cr13, hardness 200-220 BHN)

• Concrete bearing stress: (M300 concrete)

vi. Hoist Capacity Calculation

Proposed hoist: 25T rope drum hoist (8 m lift, 0.4 m/min speed).

vii. Seismic Analysis

• Hydrodynamic pressure during earthquake (Zone IV):

Where, $p=$ Hydrodynamic pressure in M at depth y i.e. 2.54 M

$C_s=$ Coefficient varies with slope and depth

$\alpha n=0.24$ (as per zone IV)

$w=$ Unit weight of water in t/M3 $=1$ t/M3

• Total head: 2.988 m → Thrust: 45.09 t (38.4% > FRL load)
• Conclusion: Gate already designed for HFL (103.02 t), which covers seismic loads.

viii. Miscellaneous Components

• Splice bolts: $16\mathrm{\Phi }$ high-strength friction grip bolts (104 kg/bolt, shear stress:
• Dogging beam: Supports gate during maintenance (bending stress: )

b) Design of Under Sluice Service Gates

i. General Specifications

The under-sluice service gates for the Rohin Barrage (Uttar Pradesh) are designed as vertical roller gates compliant with IS 4622:2003. Key technical details include:

• Number of gates: 2
• Vent dimensions: $10000\mathrm{mm}$ (width) $\times$ 3040 mm (height)
• Gate height: $3500\mathrm{mm}$
• Sill level: EL 96.000 m
• Pond level (FSL): EL 99.040 m
• High Flood Level (HFL): EL 101.400 m
• Design head (FRL): $3.04\mathrm{m}\mid$ HFL head: $5.40\mathrm{m}$
• Center-to-center (C/C) of side seals: 10100 mm
• C/C of rollers: 10500 mm
• Operation: Independent rope drum hoist mounted on wrestles.

ii. Material Specifications

The materials align with those used for sluice service gates (Section 2), with adjustments for higher hydraulic loads:

iii. Hydraulic Load Calculations

a. Thrust on Gate

• At FRL (3.04 m head):

At HFL (5.40 m head):

• Load increase under HFL: Gate designed for HFL with $1.333\times$ permissible stress.

iv. Structural Design of Gate Leaf

• Critical girder load (HFL condition): 34.6 t (per girder, similar to sluice gates but with reinforced sections).
• Bending Moment (BM):

• Section Modulus (Z): Adjusted for higher loads $\to Z\ge 6500{\mathrm{cm}}^3$ (vs. $6164{\mathrm{cm}}^3$ for sluice gates) b. Deflection Check

(Calculated deflection: $\sim 1.05$ cm $\to$ Safe)

v. Roller Assembly Design

a. Roller and Track i. Max roller load (HFL): 32.34 t (vs. 25 t for sluice gates) $\to$ Larger rollers ( $\varnothing$ 400 mm) and thicker track plates (20 mm) ii. Bearing stress:

(permissible) b. Axle Design

• Material: 20Cr13 (hardened)
• Diameter: $120\mathrm{mm}$ at bearings (vs. $100\mathrm{mm}$ for sluice gates)
• Shear stress:

vi. Hoist Capacity Calculation

vii. Seismic Analysis

• Hydrodynamic pressure (Zone IV):

• Total head: $3.576\mathrm{m}\to$ Thrust: 64.82 t (39% > FRL load)
• Conclusion: HFL design (129.36 t) covers seismic loads

viii. Key Differences from Sluice Gates

• Higher Loads: Wider vent (3.04 m vs. 2.54 m) and taller gates (3.5 m vs. 3.0 m) demand stronger girders and rollers.
• Larger Hoist: 32T vs. 25T due to increased self-weight and friction.
• Reinforced Track: Thicker plates (20 mm vs. 12 mm) to withstand higher roller loads.

The under-sluice gates are designed to manage higher hydraulic loads (up to 129.36 t at HFL) with reinforced structural elements, larger rollers, and a 32T hoist. Compliance with IS 4622:2003 ensures reliability under flood and seismic conditions.

ii. Material Specifications

iii. Hydraulic Load Calculations

a. Thrust on Gate

• Design head (1.254 m):

• Gate designed as a single unit with 2 horizontal girders due to low thrust

iv. Structural Design

a.Horizonal Girders

• Critical girder load: 2.589 t
• Bending Moment (BM):

Design of Head Regulator Gates

i. General Specifications

The head regulator gates for the Rohin Barrage are designed as vertical lift wheel gates compliant with IS 4622:2003. Key technical details include:

• Number of gates: 1 set (single opening)
• Vent dimensions: $4000\mathrm{mm}$ (width) $\times$ 4500 mm (height)
• Sill level: EL 97.786 m
• Pond level (FSL): EL 99.040 m
• Design head: $3.614\mathrm{m}$
• Center-to-center (C/C) of side seals: 4100 mm
• C/C of roller tracks: 4250 mm
• Operation: Rope drum hoist (unbalanced head condition)
• Seals: Musical note seals (sides) + wedge-type seals (bottom) per IS 11855

• Skin plate: 10 mm (effective 8.5 mm after corrosion)

• $\succ$ Co-acting width: $340\mathrm{mm}$ (per IS 800)

• Moment of Inertia (lxx): 11402.01705 cm[^4]

• Section Modulus (Z): 782 cm3 (bottom), 846 cm3 (top)

• Stress Checks:

• Bending stress (top): 594 kg/cm2 < 1020 kg/cm

• Shear stress:

b. Deflection Check

v. Roller Assembly

a. Roller Design

• Max roller load: 4.508 t → Adopted 4.5 t capacity rollers (Ø200 mm)
• Bearing: SKF 22211E (ID: 55 mm, OD: 100 mm)
• Track plate: Stainless steel (20Cr13) with machined surface

vi. Hoist Capacity Calculation

Proposed hoist: 7.5T double-stem screw hoist (manual operation).

vii. Key Features

• Compact Design: Single-unit gate for low-head applications.
• Manual Operation: Cost-effective for remote locations.
• Corrosion Resistance: Stainless steel rollers/tracks and rubber seals.

The head regulator gate is designed for a 26.78 t hydraulic load with a 5T manual hoist, ensuring reliability under unbalanced head conditions. Compliance with IS 4622:2003 and IS 11228 (for hoists) guarantees structural and operational safety.

d) Design of 15T Monorail Structure

i. General Specifications

The 15T monorail structure is designed for transporting heavy machinery, stoplogs, and maintenance equipment at the Rohin Barrage. Key specifications include:

• Capacity: 15 metric tons (with 1.1 impact factor)
• Span: $6.0\mathrm{m}$ (column-to-column)
• Operation: Manual lifting via double-stem screw hoist
• Standards: Compliant with IS 800:1984 (structural steel) and IS1367 (bolted connections)

ii. Monorail Beam Design

a. Load Calculations

Total Load:

• Reactions:

• Bending Moment (BM):

b. Section Selection

• Proposed Section: ISMB $600\times 210$ girder with $180\times 16\mathrm{mm}$ reinforcing plates on both flanges.
• Section Properties: Moment of Inertia (lxx): 143,653 cm4 Section Modulus (Zxx): 4,546 cm3 Cross-sectional Area: 213.6 cm2

c. Stress Checks

Bending Stress:

Shear Stress:

d. Bolted Connections

• Bolts: M20 Class 8.8 (IS 1367), 4 bolts per joint.
• Load per Bolt:

iii. Column Design

a. Vertical Loads

• Reactions:

Monorail load: $9750\mathrm{kg}$

Self-weight: $900\mathrm{kg}$

Wind load on stoplogs: 1248 kg

Total: $9750+900+1248=11898\mathrm{kg}$

b. Wind Load Analysis

• Wind Moment: 140,000 kg cm
• Section Properties: lxx: 25,658 cm4 | lyy: 10,236 cm4

Slenderness Ratio: 65 (Permissible stress: 1,085 kg/cm2) c. Stress Checks

• Compressive Stress:

• Bending Stress:

v. Key Components

Unity Check:

iv. Lifting Beam Design

a. Hook Design

• Material: EN8 Steel (UTS: 5,800 kg/cm2)
• Load per Hook:

• Stress Checks:

Bending Stress:

Combined Stress (Normal): 778 kg/cm2 < 2160 kg/cm2

BDT Condition:

b. Guide Rollers

• Load per Roller: 450 kg (5% of total load as per IS 4622)
• Line Contact Stress:

The 15T monorail structure is designed to safely handle operational and wind loads with a safety margin. Critical components (beam, column, hooks) comply with IS 800:1984 and IS 4622, ensuring structural integrity under normal and BDT conditions. The use of high-strength bolts (Class 8.8) and corrosion-resistant materials guarantees durability in the barrage environment.

e) Design of Stoplog Gates

i. General Specifications

The stoplog gates for the Rohin Barrage are sliding-type structures designed as per IS 5620 for maintenance and inspection of service gates. Key technical details include:

• Number of vents: 7 (5 for sluice gates, 2 for undersluice gates)
• Vent dimensions: $10000\mathrm{mm}$ (width) $\times$ 3040 mm (height)
• Stoplog elements: 3 interchangeable units (1,200 mm height each).
• Design heads:

FSL (Full Supply Level): 3.04 m

HFL (High Flood Level): 5.40 m

• Operation: Monorail crane with automatic lifting beam (balanced head for lower elements, unbalanced for top element).

ii. Material Specifications

iii. Permissible Stresses

a. Embedded Parts (Wet/Inaccessible)

• Direct compression/bending: $979-1020\mathrm{kg}/{\mathrm{cm}}^2$
• Shear stress: $734-765\mathrm{kg}/{\mathrm{cm}}^2$
• Combined stress: $1224-1275\mathrm{kg}/{\mathrm{cm}}^2$

b. Gate Leaf (Dry/Accessible)

• Direct compression/bending: 1346-1402 kg/cm2
• Shear stress: 979-1020 kg/cm2
• Combined stress: $1825-1910\mathrm{kg}/{\mathrm{cm}}^2$ Note: Stresses increased by $1.33\times$ under HFL conditions.

iv. Hydraulic Load Calculations

a. Thrust on Element

• At FSL (3.04 m head):

• At HFL (5.40 m head):

• Load Increase at HFL: Design governed by HFL

v. Structural Design of Horizontal Girders

a. Girder 'B' (Critical Load Case)

• Load: 29,088 kg
• Bending Moment (BM):

Section Properties:

Skin plate: 10 mm thick (effective 8.5 mm after corrosion) Co-acting width: 54 cm (per IS 800) Moment of Inertia (lxx): 155,114 cm ${}^4$

Section Modulus (Z): 4995 cm3 (top), 5136 cm3 (bottom) b. Stress Checks

• Bending stress (bottom):

Shear stress:

c. Deflection Check

vi. Auxiliary Components

a. Sliding Pads

• Material: Leaded Tin Bronze (IS 318 LTBI)
• Permissible bearing stress: $102\mathrm{kg}/{\mathrm{cm}}^2$
• Design load: $182\mathrm{kg}/\mathrm{cm}\to$ Actual stress:

b. Track Base

• Concrete grade: M200 (per IS 456:2000)
• Bending stress in track:
• Bearing pressure on concrete:

vii. Weight and Center of Gravity (CG)

The stoplog gates are designed to withstand HFL loads (58.18 t) with reinforced horizontal girders, sliding pads, and track bases. Compliance with IS 5620 ensures structural integrity under both balanced and unbalanced head conditions. Critical stress checks and deflection limits are satisfied, and the monorail-operated system facilitates efficient maintenance.

f) Design of 25T Rope Drum Hoist

i. General Specifications

The 25T rope drum hoist is designed for operating under-sluice service gates at the Rohin Barrage, Uttar Pradesh. Key specifications include:

• Number of hoists: 2
• Capacity: 25 metric tons (per hoist)
• Lifting speed: $0.40\mathrm{m}/\min$
• Lift height: $8.0\mathrm{m}$
• Standards: Compliant with IS 6938:1989 (for hoists) and IS 1367 (for bolted connections)

ii. Material Specifications

iii. Permissible Stresses

a. Normal Working Condition

b. Breakdown Torque (BDT) Condition

iv. Hoist Mechanism Design

a. Wire Rope Selection

Ropetension calculation (4 falls per drum):

• Proposed rope: 20 mm diameter, $6\times 36$ construction, galvanized, UTS $180\mathrm{kg}/{\mathrm{mm}}^2$
• Safety factor:

b. Motor and Brake

• Motor power calculation:

• Braking torque: $584\mathrm{kg}\mathrm{cm}\to$ Selected: $150\phi$ AC electromagnetic brake (6.6 kg m capacity)

c. Rope Drum Design

• Drum diameter: $500\mathrm{mm}$ (PCD)
• Groove details: Pitch: 22.5 mm.

Depth: 7.0 mm. Grooves per drum: 25

• Shell compressive stress check:

v. Gear Reduction System

a. Gear Train

• Total reduction ratio: 803:1
• Components:

Worm reducer: 60:1 ratio

Open gears: 98/24 (Module 8) and 80/24 (Module 5)

b. Shaft Design

Drum Shaft (Normal Condition)

• Material: IS 2062
• Diameter: 75 mm
• Stress checks:

Bending stress: Shear

Stress: