Design & Fabrication of Hydraulic Floor Crane
2014
CHAPTER-1 Introduction .
These hydraulic floor cranes provide an efficient, low cost alternative to other material handling equipments. Strong, robust, sturdy and built to very standard, these cranes are maneuverable in loading, unloading and shifting of heavy loads. Crane structure consists of chassis, vertical column, horizontal arm, and the hydraulic pump with cylinder assembly. The box crane can take heavy loads effectively, avoids damage under rough and unskilled handling. The hydraulic cranes used in the industry are efficient but they only have the ability to lift the load and put it down at some other position. In this general design, the arm of the crane moves in the vertical plane only, i.e it has constrained motion. The aim of our project is to re-design the hydraulic crane and give its arm the rotational ability. The ball bearing provides rotational motion to the column. The hydraulic crane was invented in Newcastle by William Armstrong in about 1845 to help load coal into barges at the Quayside.
Fig 1.1. A Type of Hydraulic Floor Crane ( Source: http://www.c1call.co.uk/c1/Asse http://www.c1call.co.uk/c1/Assets/Products/MaterialHandling_FloorCrane_Heavy ts/Products/MaterialHandling_FloorCrane_HeavyDuty.jpg) Duty.jpg)
The main aim of the project is the design, analysis and production of a hydraulic floor crane having vertical arm motion of 360 degree, horizontal arm motion up and down as well as movement of carrying hook using pulleys.
Design & Fabrication of Hydraulic Floor Crane
2014
1.1 MORPHOLOGY OF DESIGN In designing a machine component, there is no rigid rule. The problem may be attempted in several ways. However the general procedure to solve a design problem is as follows: Recognition of need: First of all, make a complete complete statement of the problem, indicating the need, aim or purpose for which the machine is to be designed. Synthesis (mechanisms): Select the possible mechanism or group of mechanism, which will give the desired motion. Analysis of forces: Find the forces acting on each member of the machine and the energy transmitted by each member. Material selection: Select the material best suited for each member of the machine. Design of elements (size and stresses): Find the size of each member of the machine by considering the forces acting on the member and the permissible stresses for the material used. It should be kept in mind that each member should not deflector deform than the permiss ible limit. Modification: Modify the size of the member to agree with the past experience and judgment to facilitate manufacture. The modification may also be necessary by considering of manufacturing to reduce overall cost. Detailed drawing: Draw the detailed of each component and the assembly of the machine with complete specification for the manufacturing process suggested. Production: The component, as per the drawing, is manufactured in the workshop.
Design & Fabrication of Hydraulic Floor Crane
2014
1.1 MORPHOLOGY OF DESIGN In designing a machine component, there is no rigid rule. The problem may be attempted in several ways. However the general procedure to solve a design problem is as follows: Recognition of need: First of all, make a complete complete statement of the problem, indicating the need, aim or purpose for which the machine is to be designed. Synthesis (mechanisms): Select the possible mechanism or group of mechanism, which will give the desired motion. Analysis of forces: Find the forces acting on each member of the machine and the energy transmitted by each member. Material selection: Select the material best suited for each member of the machine. Design of elements (size and stresses): Find the size of each member of the machine by considering the forces acting on the member and the permissible stresses for the material used. It should be kept in mind that each member should not deflector deform than the permiss ible limit. Modification: Modify the size of the member to agree with the past experience and judgment to facilitate manufacture. The modification may also be necessary by considering of manufacturing to reduce overall cost. Detailed drawing: Draw the detailed of each component and the assembly of the machine with complete specification for the manufacturing process suggested. Production: The component, as per the drawing, is manufactured in the workshop.
Design & Fabrication of Hydraulic Floor Crane
2014
1.2 NEED ANALYSIS. The primary goal for a manufacturing this crane is to solve the dexterity versus strength trade off in the context of machine tools and flexible manufacturing/assembly systems. Synthesis We have selected group of mechanism, which will give the des ired motion. We have used revolute configuration to give motion to the column. Column will revolve over the base (360 °) and in between arm and column. Arm will revolve 360 360°(vertically) about the column for picking and placing of object. This configuration will help in searching the object Material selection We have chosen the cheap and best material which is very commercially available i.e. iron due to its good strength. Design of Element We have calculated the specification of arm, column, and base after considering the forces and permissible stresses of individual component. Modification We can further modify our crane by employing other configuration, for this we do not need have to change the whole mechanical design. Detailed drawing We have made isometric drawing of our robotic arm with the help of AUTO-CAD 3D software labeling all the necessary parts with complete dimensions. Production All the manufactured and fabricated part of our project is accomplished in workshop itself. We have drawn AUTO-CAD drawings in our college laboratory provided by our college
Design & Fabrication of Hydraulic Floor Crane
2014
CHAPTER 2 Literature Survey Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions. Hydraulic cranes are an important part of the material handling equipments. The hydraulic cranes that are being used work on manual power. A crane is a type of machine, generally equipped with a hoist, wire ropes or chains, and sheaves, that can be used both to lift and lower materials and to move them horizontally. It is mainly used for lifting heavy things and transporting them to other places. It uses one or more simple machines to create mechanical advantage and thus move loads beyond the normal capability of a man. Cranes are commonly employed in the transport industry for the loading and unloading of freight, in the construction industry for the movement of materials and in the manufacturing industry for the assembling of heavy equipment
1.2.1 Parts and descriptions of hydraulic floor crane 1.
Base plate/ Truck/Pallet
2. 3. 4.
Vertical column Ball bearings Horizontal arm
5. 6. 7. 8. 9.
Hook Nuts and Bolts Wheels Pulleys Hydraulic jack
1. Base plate/ Truck/Pallet:It is a plate that serves as a base or support. It is used for carrying the overall weight of the project. It is made of mild steel. In this 4 bars are welded by using Electric Arc Welding to give it a rectangular shape. It is made up of cast iron. 2. Pulleys:A pulley is a wheel on an axle that is designed to support movement and change of direction of a cable or belt along its circumference. Pulleys are used in a variety of ways to lift loads, apply forces, and to transmit power. A pulley is also called a sheave or drum and may have a groove between two flanges around its circumference. The drive element of a pulley system can be a rope, cable, belt, or chain that runs over the pulley inside the groove.
Design & Fabrication of Hydraulic Floor Crane
2014
3. Vertical column:- This is mounted on the pallet/base plate/truck in longitudinal or Y-direction. It consists of a short handle which is welded to the vertical column for 360 ◦ rotation of the column so that the load can be dropped at the required position. It consists of roller bearing at the base in the circumferential manner to reduce friction at the time of rotating the vertical column. 4. Thrust ball bearings: - Ball bearings are called as ‘anti friction bearings’. This is a misnomer because friction is always present in such bearings, mainly owing to rolling resistance, between the balls or rollers and the race. It carries the vertical thrust and axial load.
Fig 2.1 A Ball Bearing (6400) (Source: http://www.bizearch.com/images /products/01/53/15364.jpg)
5. Horizontal arm: - It is fixed horizontal arm on which our hydraulic piston and cylinder is mounted. It is fixed with the vertical column with welded joint which can rotate with the rotating vertical column to 360° rotation. 6. Hook: Hook is fixed with the cable moving on pulleys. Hook is used for attaching the load to horizontal arm which moves up and down due which the connected loads are lifted and rotates. 7. Nuts and Bolts: Nuts and bolts are the hardware fasteners which are used to fasten the various different parts .in our project we have used around 20 nut and bolts.
Fig 2.2 Nuts and Bolts (Number 10) ( Source: http://www.made-from-india.com/gallery/20c1483b0a4ccd39e2a20861964c168b.jpg)
8. Wheels: A wheel is a circular component that is intended to rotate on an axial bearing. The wheel is one of the main components of the wheel and axle which is one of the six simple machines. Wheels, in conjunction with axles, allow heavy objects to be moved easily facilitating movement or
Design & Fabrication of Hydraulic Floor Crane
2014
transportation while supporting a load, or performing labor in machines. In our project we ar e using four wheels of diameter 7cm. 9. Hydraulic jack: - A hydraulic jack is a jack that uses a liquid to push against a piston. This is based on Pascal’s Principle. The principle states t hat pressure in a closed container is the same at all points. If there are two cylinders connected, applying force to the smaller cylinder will result in the same amount of pressure in the larger cylinder. However, since the larger cylinder has more area, the resulting force will be greater. In other words, an increase in area leads to an increase in force. The greater the difference in size between the two cylinders, the greater the increase in the force will be. A hydraulic jack operates based on this two cylinder system.
Fig 2.3. A hydraulic Jack (3 Ton) (Source: http://www.pappumarine.com/images/Hydraulic_Bottle_Jack.jpg)
Design & Fabrication of Hydraulic Floor Crane
2014
CHAPTER- 3 Types of Hydraulic Crane 3.1 Types of hydraulic crane:a. Truck Cranes b. Crawler-Mounted Cranes c. Overhead crane d. Tower Cranes
a. Truck Cranes:A crane mounted on a truck carrier provides the mobility for this type of crane. This crane has two parts: the carrier, often referred to as the Lower, and the lifting component which includes the boom, referred to as the Upper. These are mated together through a turntable, allowing the upper to swing from side to side. These modern hydraulic truck cranes are usually single-engine machines, with the same engine powering the undercarriage and the crane. The upper is usually powered via hydraulics run through the turntable from the pump mounted on the lower. In older model designs of hydraulic truck cranes, there were two engines. One in the lower pulled the crane down the road and ran a hydraulic pump for the outriggers and jacks. The one in the upper ran the upper through a hydraulic pump of its own. Many older operators favor the two-engine system due to leaking seals in the turntable of aging newer design cranes. Generally, these cranes are able to travel on highways, eliminating the need for special equipment to transport the crane unless weight or other size constrictions are in place such as local laws. If this is the case, most larger cranes are equipped with either special trailers to help spread the load over more axles or are able to disassemble to meet requirements. An example is counterweights. Often a crane will be followed by another truck hauling the counterweights that are removed for travel. In addition some cranes are able to remove the entire upper. However, this is usually only an issue in a large crane and mostly done with a conventional crane such as a Link-Belt HC -238. When working on the job site, outriggers are extended horizontally from the chassis then vertically to level and stabilize the crane while stationary and hoisting. Many truck cranes have slow-travelling capability (a few miles per hour) while suspending a load. Great care must be taken not to swing the load sideways from the direction of travel, as most anti-tipping stability then lies in the stiffness of the chassis suspension. Most cranes of this type also have moving counterweights for stabilization beyond that provided by the outriggers. Loads suspended directly aft are the most stable, since most of the weight of the crane acts as a counterweight. Factory-calculated charts (or electronic safeguards) are used by crane operators to determine the maximum safe loads for stationary (outriggered) work as well as (onrubber) loads and travelling speeds.
Design & Fabrication of Hydraulic Floor Crane
b. Crawler-Mounted Cranes:A crawler is a crane mounted on an undercarriage with a set of tracks (also called crawlers) that provide stability and mobility. Crawler cranes range in lifting capacity from about 40 to 3,500 short tons (35.7 to 3,125.0 long tons; 36.3 to 3,175.1 t). Crawler cranes have both advantages and disadvantages depending on their use. Their main advantage is that they can move around on site and perform each lift with little set-up, since the crane is stable on its tracks with no outriggers. In addition, a crawler crane is capable of traveling with a load. The main disadvantage is that they are very heavy, and cannot easily be moved from one job site to another without significant expense. Typically a large crawler must be disassembled and moved by trucks, rail cars or ships to its next location.
c. Overhead crane Overhead crane being used in typical machine shop. The hoist is operated via a wired pushbutton station to move system and the load in any direction. An overhead crane, also known as a bridge crane, is a type of crane where the hook-and-line mechanism runs along a horizontal beam that itself runs along two widely separated rails. Often it is in a long factory building and runs along rails along the building's two long walls. It is similar to a gantry crane. Overhead cranes typically consist of either a single beam or a double beam construction. These can be built using typical steel beams or a more complex box girder type. Pictured on the right is a single bridge box girder crane with the hoist and system operated with a control pendant. Double girder bridge are more typical when needing heavier capacity systems from 10 tons and above. The advantage of the box girder type configuration results in a system that has a lower deadweight yet a stronger overall system integrity. Also included would be a hoist to lift the items, the bridge, which spans the area covered by the crane, and a trolley to move along the bridge. The most common overhead crane use is in the steel industry. At every step of the manufacturing process, until it leaves a factory as a finished product, steel is handled by an overhead crane. Raw materials are poured into a furnace by crane, hot steel is stored for cooling by an overhead crane, the finished coils are lifted and loaded onto trucks and trains by overhead crane, and the fabricator or stamper uses an overhead crane to handle the steel in his factory. The automobile industry uses overhead cranes for handling of raw materials. Smaller workstation cranes handle lighter loads in a work-area, such as CNC mill or saw. Almost all paper mills use bridge cranes for regular maintenance requiring removal of heavy press rolls and other equipment. The bridge cranes are used in the initial construction of paper machines because they facilitate installation of the heavy cast iron paper drying drums and other massive equipment, some weighing as much as 70 tons.
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Design & Fabrication of Hydraulic Floor Crane
d. Tower Cranes:Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to the ground on a concrete slab (and sometimes attached to the sides of structures as well), tower cranes often give the best combination of height and lifting capacity and are used in the construction of tall buildings. The base is then attached to the mast which gives the crane its height. Further the mast is attached to the slewing unit (gear and motor) that allows the crane to rotate. On top of the slewing unit there are three main parts which are: the long horizontal jib (working arm), shorter counter-jib, and the operators cab. Tower crane cabin. The long horizontal jib is the part of the crane that carries the load. The counter-jib carries a counterweight, usually of concrete blocks, while the jib suspends the load to and from the center of the crane. The crane operator either sits in a cab at the top of the tower or controls the crane by radio remote control from the ground. In the first case the operator's cab is most usually located at the top of the tower attached to the turntable, but can be mounted on the jib, or partway down the tower. The lifting hook is operated by the crane operator using electric motors to manipulate wire rope cables through a system of sheaves. The hook is located on the long horizontal arm to lift the load which also contains its motor. A tower crane rotates on its axis before lowering the lifting hook.In order to hook and unhook the loads, the operator usually works in conjunction with a signaller (known as a 'dogger', 'rigger' or 'swamper'). They are most often in radio contact, and always use hand signals. The rigger or dogger directs the schedule of lifts for the crane, and is responsible for the safety of the rigging and loads. The Component of Tower Crane:Tower Cranes are used extensively in construction and other industry to hoist and move materials. There are many types of tower cranes. Although they are different in type, the main parts are the same, as follows: 1. Mast The mast is the main supporting tower of the crane. It is made of steel trussed sections that are connected together during installation. 2. Slewing Unit The slewing unit sits at the top of the mast. This is the engine that enables the crane to rotate. 3. Operating Cabin The operating cabin sits just above the slewing unit. It contains the operating controls. 4. Jib The jib, or operating arm, extends horizontally from the crane. A "luffing" jib is able to move up and down; a fixed jib has a rolling trolley that runs along the underside to move goods
2014
Design & Fabrication of Hydraulic Floor Crane
horizontally. 5. Hook The hook (or hooks) is used to connect the material to the crane. It hangs at the end of thick steel cables that run along the jib to the motor. 6. Weights Large concrete counterweights are mounted toward the rear of the mast, to compensate for the weight of the goods lifted. A tower crane is usually assembled by a telescopic jib (mobile) crane of greater reach (also see "self-erecting crane" below) and in the case of tower cranes that have risen while constructing very tall skyscrapers, a smaller crane (or derrick) will often be lifted to the roof of the completed tower to dismantle the tower crane afterwards, which may be more difficult than the installation.
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Design & Fabrication of Hydraulic Floor Crane
CHAPTER- 4 Application & merits of hydraulic floor crane 4.1 Application of Cranes Cranes exist in an enormous variety of forms – each tailored to a specific use. Sometimes sizes range from the smallest jib cranes, used inside workshops, to the tallest tower cranes, used for constructing high buildings. For a while, mini - cranes are also used for constructing high buildings, in order to facilitate constructions by reaching tight spaces. Finally, we can find larger floating cranes, generally used to build oil rigs and salvage sunken ships. These days hydraulics principle is being used extensively in material handling processes through cranes. Depending on the loads to be handled and the operations to be performed there are different types of cranes like Crawler Cranes, Truck Cranes, Floor Cranes. Hydraulic Crawler cranes are used for picking and moving huge amount of loads. Generally loads are kept in containers for Bulk loading. Hydraulic truck cranes have good flexibility with high load carrying capacit ies. Hydraulic workshop foldable crane used in industries for moving small to medium sized materials from one place to other. The load carrying capacity can vary from 80 kg to half ton or more.
4.2 Merits :1. Most powerful means of lifting objects:It is one of the most powerful means of lifting objects is with the strength of a hydraulic crane. By harnessing the strength that liquid under pressure gives, and the ease with which it can be used, it is possible to transfer a relatively small amount of effort from one place to another, and hydraulic cranes are amongst the most efficient lifting systems available in the modern workplace. 2. Extremely stable in use:Because the hydraulic cranes use a fixed system of pipes, constant pressure can be maintained once a part of the system has been moved into place, and this makes them extremely stable in use, and able to support relatively large weights.
3. Very easy to maintain:Hydraulic cranes are amongst the simplest systems that you can use within any industrial process, and are very easy to maintain. Provided that all the pumps and pistons are regularly checked for any leaks, and potential stress points where the levers are supported are inspected
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Design & Fabrication of Hydraulic Floor Crane
for damage, the crane will continue to operate completely reliably for long periods of time 4. A very versatile tool:Most hydraulic cranes are comparatively light weight, and the ease with which they can be moved from one area to another within the factory or distribution center, makes them a very versatile tool with lots of uses on a day to day basis. From simple loading jobs in your loading bay area where the portable hydraulic cranes can be used to lift objects into a waiting truck to more complex jobs within the main factory, the lifts will come in very useful. 5. Quite simple Design:A hydraulic system works with a system of pumps and pistons that are filled with a liquid, usually a light oil or water. By moving the liquid under pressure from the pumps, pistons can be extended or reduced, and when these pistons are connected to a system of levers, the pistons can be used to lift surprisingly heavy weights.
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Design & Fabrication of Hydraulic Floor Crane
CHAPTER- 5 Relevant Theory
5.1 DESIGN WORK The designing work was carried out using Pro E software. The required dimensions of the driver and the driven wheels were taken as per the design equations. Pro E is the most widely used design software's which helps in designing 2 as well as 3 dimensional models using simplified alphabetical and numerical commands. Both the driving and the driven wheels were drawn to the required dimensions using the circle command. A slot was cut on the Geneva wheel using the trim tool. It was then edited using polyline command and the remaining slots were constructed using the array tool. The crank pin and the driving wheel were drawn to the required dimensions
5.2 DESIGN CRITERIA:There are three major considerations in the design of cranes. 1. The crane must be able to lift the weight of the load; 2.
The crane must not topple;
3.
The crane must not rupture.
5.3 LIFTING CAPACITY:The lifting capacity of hydraulic crane mainly depends on following. 1. The lever :A balance crane contains a horizontal beam (the lever ) pivoted about a point called the fulcrum. The principle of the lever allows a heavy load attached to the shorter end of the beam to be lifted by a smaller force applied in the opposite direction to the longer end of the beam. The ratio of the load's weight to the applied force is equal to the ratio of the lengths of the longer arm and the shorter arm, and is called the mechanical advantage.
2. The Pulley:A jib crane contains a tilted strut (the jib) that supports a fixed pulley block. Cables are wrapped multiple times round the fixed block and round another block attached to the load. When the free end of the cable is pulled by hand or by a winding machine, the pulley system delivers a force to the load that is equal to the applied force multiplied by the number of lengths of cable passing between the two blocks. This number is the mech anical advantage.
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Design & Fabrication of Hydraulic Floor Crane
3. The hydraulic:This can be used directly to lift the load or indirectly to move the jib or beam that carries another lifting device. Cranes, like all machines, obey the principle of conservation of energy. This means that the energy delivered to the load cannot exceed the energy put into the machine. For example, if a pulley system multiplies the applied force by ten, then the load moves only one tenth as far as the applied force. Since energy is proportional to force multiplied by distance, the output energy is kept ro ughly equal to the input energy (in practice slightly less, because some energy is lost to friction and other inefficiencies). The same principle can operate in reverse. In case of some problem, the combination of heavy load and great height can accelerate small objects to tremendous speed. Such projectiles can result in severe damage to nearby structures and people. Cranes can also get in chain reactions; the rupture of one crane may in turn take out nearby cranes. Cranes need to be watched carefully.
5.4 STABILITY:For stability, the sum of all moments about any point such as the base of the crane must equate to zero. In practice, the magnitude of load that is permitted to be lifted (called the "rated load" in the US) is some value less than the load that will cause the crane to tip (providing a safety margin). Standards for cranes mounted on ships or offshore platforms are somewhat stricter because of the dynamic load on the crane due to vessel motion. Additionally, the stability of the vessel or platform must be considered. For stationary pedestal or kingpost mounted cranes, the moment created by the boom, jib, and load is resisted by the pedestal base or kingpost. Stress within the base must be less than the yield stress of the material or the crane will fail.
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Design & Fabrication of Hydraulic Floor Crane
CHAPTER- 6 Manufacturing Process Manufacturing:The hydraulic crane which was manufactured has 12 parts. They are Base Plate/Truck/Pallet, Hydraulic Jack, Hydraulic hose, Vertical column, Ball bearing, Horizontal arm, Roller, Hook, Nuts and Bolts, Wheels, pulleys, cable, handle. Base plates are made of caste iron metal rod. The rods are cut according to the dimensions and they are welded using metal arc welding. Then bearing was selected according to the thrust and axial load and vertical column are fitted on the bearing so that it can rotate to a 360°.The horizontal arm is hinged and contains pulley in it so that hook can travel up and down. Hydraulic system is selected according to the power required.
Assembly:1. 2. 3. 4. 5.
Arrangement of four wheels on the four the base plate. Assembly of fixture for holding the bearing and the vertical column. Assembly horizontal arm. Assembly of hydraulic jack. Connection of hoses with the hydraulic Jack .
6. 7. 8.
Installing Pulleys in horizontal and vertical arm. Installing high steel cable on the pulleys. Attaching a hook on the high steel cable.
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Design & Fabrication of Hydraulic Floor Crane
CHAPTER- 7 Design and Calculation
SERIAL
SYMBOL
DESCRIPTION
1
ID
Inner diameter
2
P N
Power in kw
3
N
Motor speed in rpm
4
Q
Discharge in l/min
5
f
Frequency in Hz
6
I N
Current in ampere
7
l
Length of truck
8
b
Breadth of truck
9
H
Height of truck
10
W
Total weight
11
F
Fiber stress in bending
12
D
Depth of joist
13
L
Length of joist
14
ρ
Density of fluid at room temp.
15
A
Cross sectional area of hose
16
V
Velocity of fluid in hoses
NO.
Table 7.1 List of symbols
2014
Design & Fabrication of Hydraulic Floor Crane
Table 7.2 Specifications of the Project
Serial No.
Name
Material
Dimensions
1.
Pulley
Fiber
Outer Dia – 3.81 cm Inner Dia - .8cm Length - 5 cm
2.
Horizontal Arm
Mild Steel
Length – 55.88 cm Width – 5.08 cm Thickness- 2cm
3.
Vertical Arm
Mild Steel
Length – 100 cm Diameter - 15.24 cm
4.
Ball Bearing
Stainless Steel
6400
5.
Wheels
High Steel
7 cm
6.
Handle
Mild Steel
Length – 38.1 cm Dia – 1.9 cm
7.
Base
Mild Steel
Width – 60.96 cm Length – 91.44 cm Thickness – 5.08 cm
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Design & Fabrication of Hydraulic Floor Crane
8.
3ton
Hydraulic Jack High Steel
9.
Wire
200 cm Mild Steel
10.
Jack Holder
Fig 7.1 Dimensions
Length – 12.7cm Width – 12.7cm
2014
Design & Fabrication of Hydraulic Floor Crane
Fig 7.2. Dimensions
7.1. Calculation of floor load :
Floor load is a measure of pressure on the floor of truck. It is necessar y to avoid the catastrophic failure.
•
Total weight= 50kg
•
Length= 100cm= 1.00m
•
Breadth= 56cm= 0.56m
•
Floor load= total weight/total floor area = W / (l*b) = 50 / (1.00*0.56) = 89.2870kg/m2 or 89.2870N
7.2. FORCES ON CYLINDER 1. At middle position•
Mo = 5000*560 - RA*77 = 0
•
RA= 36363.63 N
•
Reaction in the direction of cylinder will be given by
2014
Design & Fabrication of Hydraulic Floor Crane
•
R cylinder = 36363.63
•
R cylinder = 36363.63 N
•
Ro = 41363.63 N
3"
Ro
Ra
50kg
Fig 7.3. Reaction on horizontal arm
2. At upper position•
Mo = 0
•
Mo = 5000*(560cos45) + RA* (77cos45)
•
RA = -36363.63 N
•
Reaction in the direction of cylinder will be given by
•
R cylinder= RA(cos15)
•
R cylinder= -35124.56 N
•
Ro = - 40124.56 N
•
7.3 Calculation For Crane Stability Forces on part one•
Load applied to the arm at the hook is 50kg i.e.= 50*9.81 =490.5N
•
Volume of overhanging arm= L*B*H =283.2*20*51.50
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Design & Fabrication of Hydraulic Floor Crane
= 291696 cu mm = .000291696cu m •
Density of the material used is = 7850 kg/cu m
•
Mass of the overhanging arm= Volume*Density = 0.000291696*7850 = 2.2898kg
•
Weight of the overhanging arm = 2.2898*9.81 = 22.4630N
Force on part two•
Volume of remaining arm= L*B*H = 258*20*51.50 = 265740cu mm = .000265740 cu m
•
Density of material used = 7850 kg/cu m
•
Mass of the remaining arm = Volume*Density = 0.000265740*7850 =2.08605kg
•
Weight of remaining arm = .000265740*9.81 =20.4642N Force on part three-
•
Volume of column= L*B*H = 1000*18820.527 = 18820527.60cu mm = 0.018820527cu m
•
Density of material used= 7850 kg/cu m
•
Mass of the column = volume*Density
2014
Design & Fabrication of Hydraulic Floor Crane
= 0.018820527*7850 = 147.77 kg •
Weight of the column = 147.77*9.81 = 1449.3406740 N Force on part four-
•
Volume of base = L*B*H = 620*20*51.50 = 638600cu mm = 0.000638600 cu m
•
Density of material used= 7850 kg/cu m
•
Mass of the base= volume*Density = 0.0315*7850 = 5.0130 kg
•
Weight of the base= 5.0130*9.81 = 50 N Force on part five-
•
Volume of base arm= L*B*H = 1000*20*51.50 = 1030000.00 cu mm = 0.00103000 cu m
•
Density of material used= 7850 kg/cu m
•
Mass of the base arm= volume*Density = 0.0013000*7850 = 8.085500 kg
•
Weight of the base arm= 8.085500*9.81 =79.3187 N
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Design & Fabrication of Hydraulic Floor Crane
7.4. DESIGN OF CYLINDER •
Assuming the internal pressure,
•
(Pi)= 110 N/mm2
•
Material used for cylinder is Mild steel =226
•
Yield strength of mild steel = 250 N/mm2
•
Ultimate tensile strength of mild steel = 410 N/mm2
•
Factor of safety = 1.5 (assumed)
•
Pi= F/A
•
A = F/Pi
•
= 35124/110
•
A = 319.30mm2
•
But, A = (#/4) d2
•
319.30
•
= (#/4) d2
•
d =20.16mm
•
Using cylinder of standard diameter,
•
Bore diameter =20mm
•
# = PIA(3.1415926)
•
Now, allowable tensile strength σall = Syt/ FOS = 250/1.5 = 166.66 N/mm2
•
Allowable shear stress Tall = Ssy/ FOS
•
Ssy = Yield strength in shear of the cylinder material, N/mm2
•
Tall = 0.5Syt/ FOS = 0.5*250/1.5 = 83.33 N/mm2
2014
Design & Fabrication of Hydraulic Floor Crane
Fig 7.4 Material Testing
Fig 7.4 Material Testing of Horizontal Arm
2014
Design & Fabrication of Hydraulic Floor Crane
Fig 7.5. Material Testing of Horizontal Arm
2014
Design & Fabrication of Hydraulic Floor Crane
•
Material name:
•
AISI 1018 Steel (MS)
•
Material Model Type:
•
Linear Elastic Isotropic
•
Default Failure Criterion:
•
Max von Mises Stress
•
Property Name
•
Value
•
•
Elastic modulus
•
2.05e+011
•
N/m^2
•
Poisson's ratio
•
0.29
•
NA
•
Shear modulus
•
8e+010
•
N/m^2
•
Mass density
•
7850
•
•
Tensile strength
•
5.85e+008
•
N/m^2
•
Yield strength
•
2.8269e+008
•
N/m^2
Thermal expansion coefficient
•
1.1e-005
•
/Kelvin
Thermal conductivity
•
52
•
W/(m.K)
Specific heat
•
486
•
J/(kg.K)
Hardening factor (0.0-1.0; 0.0=isotropic; 1.0=kinematic)
•
0.85
•
•
•
•
•
•
Table 7.3. Material Properties
Units
kg/m^3
NA
2014
Design & Fabrication of Hydraulic Floor Crane
Fig 7.6 View 1
Fig 7.8 View 2
2014
Design & Fabrication of Hydraulic Floor Crane
Fig 7.9 View 3
Fig 7.10 View 4
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Design & Fabrication of Hydraulic Floor Crane
Serial No.
Name
Quantity
1.
Rate
Hydraulic 1 1800 Jack 2. Base frame 1 2400 (MS) 3. Vertical arm 1 1600 (MS) 4. Horizontal 1 1200 arm (MS) 5. Cable(HS) 2 meter 300 6. Pulley 3 200 7. Wheel 4 200 8. Cable 1 600 Collector (MS) 9. Bearing 1 600 10. Hook 1 300 11. Handle 1 350 12 Nut Bolt 1 100 13. Welding 3000 Charge 14. Lathe charges 3000 15. Paint 300 16. Miscellaneous 4000 Total Amount Spent 20000 Table 7.4 Bill of Materials
Total Amount 5800
2400 1600 1200 600 600 800 600
600 300 350 100 3000 1750 300 4000
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Design & Fabrication of Hydraulic Floor Crane
CHAPTER 8 Instructions for use Features •
Overload safety
•
Lifting/lowering speed control
•
Position holding by check valve
•
Hydro-mechanical lock
•
Hose burst safety valves
•
Electrical safety interlocks
•
Simple to use and maintain
•
Compact structure
8.1 Moving the Load 1. LIFT the load slowly and smoothly. Make sure the load is balanced and securely attached before lifting. 2. Operate the Hydraulic jack to raise or lower the load. 3. Raise the load by smoothly pumping the hydraulic jack with the handle. With new equipment, a whining noise may occur when pumping. 4. Lower the load by slowly turning the release valve counterclockwise. 5. Too many full turns will unscrew the valve and release oil. 6. Close the valve by tightening it clockwise. 7. Pull the crane backward to move the load, with the load close to the floor and tied to the mast and legs to prevent swinging. 8. Move the load slowly and smoothly, especially when making turns. 9. Move the crane by hand only Do not use powered devices to push or pull the crane.
8.2 Cleaning the Crane
Clean the crane to remove dirt and help prevent rust and corrosion. Clean the crane every six months or whenever it is dirty. Wipe all equipment to remove dirt and grease. Leave a light film of oil on all surfaces to protect against rust and corrosion. Wipe off excessive amounts of oil to avoid the accumulation of dirt. Remove unnecessary objects from the area surrounding the crane.
2014
Design & Fabrication of Hydraulic Floor Crane
8.3 Lubricating the Crane 1. Lubricate the crane properly to help protect it from wear and rust. Read the following instructions carefully. 2. Partial disassembly may be required to lubricate the crane properly to help protect from wear and corrosion. 3. Lubricate the wheels at least every 6 months. Use a grease brush to apply a light fi lm of NLGI #2 grease to the roller bearings on the rear caster wheels. Apply 2 to 3 drops of 150 grade gear oil to the shafts on the front wheels, rotate the wheels to allow oil to penetrate, and wipe off excess oil to avoid accumulation of dirt. 4. Lubricate all pins at least every 6 months. Use a grease brush to apply a ligh film of NLGI #2 grease to all pins. 5. Lubricate the swivel hook at least every 6 months. Apply 2 to 3 drops of 150 grade gear oil, rotate the hook to allow oil to penetrate, and wipe off excess oil to avoid accumulation of dirt. 6. Lubricate the jack pivot pins and other moving parts after 10 cycles. 7. Lubricate Equipment by following the manufacturer’s recommendations.
2014
Design & Fabrication of Hydraulic Floor Crane
CHAPTER - 9 CONCLUSION The aim of our project was to build a fully functional HYDRAULIC FLOOR CRANE mechanism which is capable of lifting load up to 50 kg with the hook and pulley system and a load of 105+ kg from the hook attached to the horizontal arm . We accurately achieved our first goal of lifting the load from both the hooks and 360° rotary motion of the vertical column as well as up and down movement of the horizontal arm. We feel that our design and fabrication was a great success both in terms of strength and stiffness. Our project weighed 60kg which is capable of lifting load up to 150kg using hydraulic power.
2014
Design & Fabrication of Hydraulic Floor Crane
References
1. DR. T. J. PRABHU (2010) ‘A text book of Design of Transmission Elements’. 2. Design data book- Mahadevan 3. www.e4training.com 4. www.freepatentsonline.com 5. www.howstuffworks.com 6. International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-3, Issue-2, December 2013 7. Machine Design by Khurmi Gupta 8. Strength of Materials, Se Mech 9. http://www.c1call.co.uk/c1/Assets/Products/MaterialHandling_FloorCrane_HeavyDuty.jp g 10. http://www.hydraulicjackind.com/ 11. http://www.thomasnet.com/articles/machinery-tools-supplies/bearing-types 12. http://www.engineeringtoolbox.com/metal-alloys-densities-d_50.html 13. http://www.bizearch.com/images/products/01/53/15364.jpg 14. http://www.made-from-india.com/gallery/20c1483b0a4ccd39e2a20861964c168b.jpg 15. http://www.pappumarine.com/images/Hydraulic_Bottle_Jack.jpg 16. Production Technology RK Jain 17. RK Rajpoot- Machine Component & Design
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Design & Fabrication of Hydraulic Floor Crane
2014
Appendix
Full Assembeled View
Horizontal Arm with Hook
Vertical Arm
Pulleys with Adjustment Bolts, Nuts and fittings
Trinity Institute of Technology & Research, Bhopal | Department of Mechanical engineering
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