Design and Fabrication of Hydraulic Floo

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/Assets/Products/MaterialHandling_FloorCrane_HeavyDuty.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.
Trinity Institute of Technology & Research, Bhopal | Department of Mechanical engineering Page 1
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 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 permissible 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.
Fig1.2. Morphology Of Design
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 desired 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(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
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. Vertical column
3. Ball bearings
4. Horizontal arm
5. Hook
6. Nuts and Bolts
7. Wheels
8. Pulleys
9. 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.
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
transportation while supporting a load, or performing labor in machines. In our project we are 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 Pascals Principle. The principle states that 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)
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 (on-
rubber) loads and travelling speeds.
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.
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
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.
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 capacities.
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
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.
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 mechanical advantage.
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 roughly 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.
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. Arrangement of four wheels on the four the base plate.
2. Assembly of fixture for holding the bearing and the vertical column.
3. Assembly horizontal arm.
4. Assembly of hydraulic jack.
5. Connection of hoses with the hydraulic Jack.
6. Installing Pulleys in horizontal and vertical arm.
7. Installing high steel cable on the pulleys.
8. Attaching a hook on the high steel cable.
CHAPTER- 7
Design and Calculation
SERIAL SYMBOL DESCRIPTION

NO.
1 ID Inner diameter
2 PN Power in kw
3 N Motor speed in rpm
4 Q Discharge in l/min
5 f Frequency in Hz
6 IN 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 Density of fluid at room temp.
15 A Cross sectional area of hose
16 V Velocity of fluid in hoses
Table 7.1 List of symbols
Table 7.2 Specifications of the Project
Serial Name Material Dimensions

No.
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
8. Hydraulic Jack 3ton
High Steel
9. Wire 200 cm
Mild Steel
10. Jack Holder Length 12.7cm
Width 12.7cm
Fig 7.1 Dimensions
Fig 7.2. Dimensions
7.1. Calculation of floor load :-

Floor load is a measure of pressure on the floor of truck. It is necessary 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
R cylinder = RA
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
= 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
= 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
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
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
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 all = 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
Fig 7.4 Material Testing
Fig 7.4 Material Testing of Horizontal Arm
Fig 7.5. Material Testing of Horizontal Arm
Material name: AISI 1018 Steel (MS)
Material Model Type: Linear Elastic Isotropic
Default Failure Criterion: Max von Mises Stress
Property Name Value Units
Elastic modulus 2.05e+011 N/m^2
Poisson's ratio 0.29 NA
Shear modulus 8e+010 N/m^2
Mass density 7850 kg/m^3
Tensile strength 5.85e+008 N/m^2
Yield strength 2.8269e+008 N/m^2
Thermal
expansion 1.1e-005 /Kelvin
coefficient
Thermal
52 W/(m.K)
conductivity
Specific heat 486 J/(kg.K)
Hardening factor
(0.0-1.0;
0.85 NA
0.0=isotropic;
1.0=kinematic)
Table 7.3. Material Properties
Fig 7.6 View 1
Fig 7.8 View 2
Fig 7.9 View 3
Fig 7.10 View 4
Serial No. Name Quantity Rate Total

Amount
1. Hydraulic 1 1800 5800
Jack
2. Base frame 1 2400 2400
(MS)
3. Vertical arm 1 1600 1600
(MS)
4. Horizontal 1 1200 1200
arm (MS)
5. Cable(HS) 2 meter 300 600
6. Pulley 3 200 600
7. Wheel 4 200 800
8. Cable 1 600 600
Collector
(MS)
9. Bearing 1 600 600
10. Hook 1 300 300
11. Handle 1 350 350
12 Nut Bolt 1 100 100
13. Welding 3000 3000
Charge
14. Lathe charges 3000 1750
15. Paint 300 300
16. Miscellaneous 4000 4000
Total Amount Spent 20000
Table 7.4 Bill of Materials
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.
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 manufacturers recommendations.
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.
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
Appendix
Full Assembeled View Vertical Arm
Horizontal Arm with Hook Pulleys with Adjustment Bolts,

Nuts and fittings

Design and Fabrication of Hydraulic Floo

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Design and Fabrication of Hydraulic Floo

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Design & Fabrication of Hydraulic Floor Crane 2014

Fig 1.1. A Type of Hydraulic Floor Crane

1.1 MORPHOLOGY OF DESIGN

Production: The component, as per the drawing, is manufactured in the workshop.

Fig1.2. Morphology Of Design

1.2 NEED ANALYSIS.

1.2.1 Parts and descriptions of hydraulic floor crane

1. Base plate/ Truck/Pallet:-

3. Vertical column:- This is mounted on the pallet/base plate/truck in longitudinal or Y-direction. It

Fig 2.1 A Ball Bearing (6400)

Fig 2.2 Nuts and Bolts (Number 10)

Fig 2.3. A hydraulic Jack (3 Ton)

3.1 Types of hydraulic crane:-

The Component of Tower Crane:-

4.1 Application of Cranes

2. Extremely stable in use:-

3. Very easy to maintain:-

5. Quite simple Design:-

5.1 DESIGN WORK

5.2 DESIGN CRITERIA:-

1. The crane must be able to lift the weight of the load;

5.3 LIFTING CAPACITY:-

SERIAL SYMBOL DESCRIPTION

3 N Motor speed in rpm

11 F Fiber stress in bending

14 Density of fluid at room temp.

15 A Cross sectional area of hose

16 V Velocity of fluid in hoses

Table 7.1 List of symbols

Table 7.2 Specifications of the Project

Serial Name Material Dimensions

Inner Dia - .8cm

2. Horizontal Arm Mild Steel Length 55.88 cm

3. Vertical Arm Mild Steel Length 100 cm

4. Ball Bearing Stainless Steel 6400

5. Wheels High Steel 7 cm

6. Handle Mild Steel Length 38.1 cm

7. Base Mild Steel Width 60.96 cm

8. Hydraulic Jack 3ton

Fig 7.1 Dimensions

Fig 7.2. Dimensions

7.1. Calculation of floor load :-

Total weight= 50kg

Length= 100cm= 1.00m

Breadth= 56cm= 0.56m

Floor load= total weight/total floor area

7.2. FORCES ON CYLINDER

Reaction in the direction of cylinder will be given by

Fig 7.3. Reaction on horizontal arm

Mo = 5000*(560cos45) + RA* (77cos45)

Reaction in the direction of cylinder will be given by

7.3 Calculation For Crane Stability

Load applied to the arm at the hook is 50kg i.e.= 50*9.81

Volume of overhanging arm= L*B*H

Density of the material used is = 7850 kg/cu m

Mass of the overhanging arm= Volume*Density

Weight of the overhanging arm = 2.2898*9.81

Force on part two-

Volume of remaining arm= L*B*H

Density of material used = 7850 kg/cu m

Mass of the remaining arm = Volume*Density

Weight of remaining arm = .000265740*9.81

Force on part three-

Volume of column= L*B*H

Mo = 5000(560cos45) + RA (77cos45)

Volume of overhanging arm= LBH

Volume of remaining arm= LBH

Volume of column= LBH

Volume of base = LBH

Volume of base arm= LBH