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CHAPTER 1
STUDY OF HYDRAULIC CRANE
1.1 INTRODUCTION
When water is contained within a pipe we can use it to create motion in a straight
line by using a cylinder and piston. The piston is a tight sliding fit in the cylinder
and when the water enters the cylinder it pushes the piston along. This method of
applying a FORCE and causing motion is called Hydraulics. The power of water
can be harnessed to do all sorts of things. Waterwheels were invented thousands of
years ago to turn mill wheels to grind wheat into flour and to power pumps to
raise water for crop irrigation and to supply cities with fresh water.
that represented the static friction force of the cylinder. In this concern, we varied
system pressure and cylinder load to study their influence on the friction force. By
means of the derived static friction maps we approached the cylinders dynamic
friction behavior and applied both step and ramp control inputs to examine the
spring-damping characteristics of the microscopic bristles in the contacting area.
The dynamic friction experiments have been exerted in the fashion of the LuGre
model. As a result we acquired different nominal friction parameters that we
necessarily used to developed adequate friction models. We are engaged in
manufacturing of a wide range of Cranes that is capable to handle heavy loads.
Available in different heights and capacity, these are mainly used when either
there is an involvement of heavy loads or wide spans of movement. Further, these
are stringently tested on well defined parameters to ensure high functionality at
clients' end.
1 Base Frame
2 Hydraulic Tank
3 Hydraulic Hoses
5 Vertical Column
6 Rectifier
7 Horizontal Arm
9 Hook
12 Transformer
13 Diode
14 Controlling Switch
4
A-frames are usually set up in rows so that they can have good stability. A saw
horse is a good example of this structure. More complex structures will have a
cross member connecting the two materials in the middle to prevent the legs from
bowing outwards under load, giving the structure the appearance of the capital
letter
1.3.5 TRANSFORMER
It is a step down transformer which converts high voltage to low voltage.
A transformer is an electrical device that transfers energy between two or more
circuits through electromagnetic induction.
A varying current in the transformer's primary winding creates a varying magnetic
flux in the core and a varying magnetic field impinging on the secondary winding.
This varying magnetic field at the secondary induces a varying electromotive
force (emf) or voltage in the secondary winding. Making use of Faraday's Law in
conjunction with high magnetic permeability core properties, transformers can
thus be designed to efficiently change AC voltages from one voltage level to
another within power networks. Transformers range in size from RF transformers
less than a cubic centimeter in volume to units interconnecting the power
grid weighing hundreds of tons. A wide range of transformer designs is
encountered in electronic and electric power applications.
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1.3.6 RECTIFIER
A rectifier is an electrical device that converts alternating current (AC), which
periodically reverses direction, to direct current (DC), which flows in only one
direction. The process is known as rectification. Physically, rectifiers take a
number of forms, including vacuum diodes, mercury-arc valves, copper and
selenium oxide rectifiers, semiconductor diodes, silicon-controlled rectifiers and
other silicon-based semiconductor switches. Historically, even synchronous
electromechanical switches and motors have been used. Early radio receivers,
called crystal radios, used a "cat's whisker" of fine wire pressing on a crystal
of galena (lead sulfide) to serve as a point-contact rectifier or "crystal detector".
Rectifiers have many uses, but are often found serving as components of
DC power supplies and high-voltage direct current power transmission systems.
Rectification may serve in roles other than to generate direct current for use as a
source of power. As noted, detectors of radio signals serve as rectifiers. In gas
heating systems flame rectification is used to detect presence of a flame. Because
of the alternating nature of the input AC sine wave, the process of rectification
alone produces a DC current that, though unidirectional, consists of pulses of
current. Many applications of rectifiers, such as power supplies for radio,
television and computer equipment, require a steady constant DC current (as
would be produced by a battery). In these applications the output of the rectifier is
smoothed by an electronic filter (usually a capacitor) to produce a steady current.
1.3.7 DIODE
1.3.12 Hook
Hook is fixed with the secondary horizontal arm. Hook is used for attaching the
load to secondary horizontal arm which moves up and down due which the
connected loads are lifted and rotates.
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supporting a load, or performing labor in machines. In our project we are using four
wheels of diameter 1cm.
CHAPTER 2
MECHANICAL PRINCIPLES
There are three major considerations in the design of cranes. First, the crane must
be able to lift the weight of the load; second, the crane must not topple; third, the
crane must not rupture.
applied force multiplied by the number of lengths of cable passing between the
two blocks. This number is the mechanical advantage.
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 (see trebuchet).
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.
2.2 STABILITY
For stability, the sum of all moments about the base of the crane must be close to
zero so that the crane does not overturn. 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, thus providing a safety margin. Under US
standards for mobile cranes, the stability-limited rated load for a crawler crane is
75% of the tipping load. The stability-limited rated load for a mobile crane
supported on outriggers is 85% of the tipping load. These requirements, along
with additional safety-related aspects of crane design, are established by the
American Society of Mechanical Engineers in the volume ASME B30.5-2011
Mobile and Locomotive Cranes. 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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CHAPTER 3
TYPES OF CRANE
Overhead cranes
Mobile Cranes
Fixed Cranes
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
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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. In many instances the cost of a bridge
crane can be largely offset with savings from not renting mobile cranes in the
construction of a facility that uses a lot of heavy process equipment.
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. Although most only rotate about 180 degrees, the more
expensive truck mounted cranes can turn a full 360 degrees.
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These telescopic cranes are single-engine machines, with the same engine powering
the undercarriage and the crane, similar to a crawler crane. In a rough terrain crane,
the engine is usually mounted in the undercarriage rather than in the upper, as with
crawler crane. Most have 4 wheel drive and 4 wheel steering which allows them to
traverse tighter and slicker terrain than a standard truck crane with less site prep. In
addition, there are rough terrain cranes with the operating cab mounted on the lower
as opposed to the P&H in the above image.
Australia was Franna, who have since been bought by Terex, and now all pick and
carry cranes are commonly referred to as "Frannas" even though they may be made
by other manufacturers. Nearly every medium and large sized crane company in
Australia has at least one and many companies have fleets of these cranes. The
capacity range is usually ten to twenty tonnes maximum lift, although this is much
less at the tip of the boom. Pick and Carry cranes have displaced the work usually
completed by smaller truck cranes as the set up time is much quicker. Many steel
fabrication yards also use pick and carry cranes as they can "walk" with fabricated
steel sections and place these where required with relative ease...
of the worlds Armed forces have purchased telescopic handlers and some of these are
the much more expensive fully rotating types. Their off road capability and their
onsite versatility to unload pallets using forks, or lift like a crane makes them a
valuable piece of machinery.
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.
long tons; 9,072 t) and have been used to transport entire bridge sections. Floating
cranes have also been used to salvage sunken ships. Crane vessels are often used in
offshore construction. The largest revolving cranes can be found on SSCV Thialf,
which has two cranes with a capacity of 7,100 tonnes (7,826 short tons; 6,988 long
tons) each. For fifty years, the largest such crane was "Herman the German" at the
Long Beach Naval Shipyard, one of three constructed by Hitler's Germany and
captured in the war. The crane was sold to the Panama Canal in 1996 where it is now
known as the "Titan."
CHAPTER 4
FIXED CRANE
Exchanging mobility for the ability to carry greater loads and reach greater heights
due to increased stability, these types of cranes are characterized by the fact that their
main structure does not move during the period of use. However, many can still be
assembled and disassembled. The structure basically is fixed in one place. Types of
fixed crane.
TOWER CRANE
SELF-ERECTING CRANE
TELESCOPIC CRANE
HAMMERHEAD CRANE
LEVEL LUFFING CRANE
GANTRY CRANE
DECK CRANE
JIB CRANE
BULK-HANDLING CRANE
LOADER CRANE
STACKER CRANE
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 (outrigger) work as well as (on-rubber) loads and
travelling speeds.
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
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structures), 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 operator's cab. 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.
COMPONENTS
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:
Mast: the main supporting tower of the crane. It is made of steel trussed
sections that are connected together during installation.
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Slewing Unit: the slewing unit sits at the top of the mast. This is the engine
that enables the crane to rotate.
Operating Cabin: the operating cabin sits just above the slewing unit. It
contains the operating controls.
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.
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.
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.
Dockyard in Sydney (1951). These cranes provided repair support for the battle fleet
operating far from Great Britain.
In the British Empire, the engineering firm Sir William Arrol & Co Ltd was the
principal manufacturer of giant cantilever cranes; the company built a total of
fourteen. Among the sixty built in the world, few remain; seven in England and
Scotland of about fifteen worldwide. The Titan Clydebank is one of the 4 Scottish
cranes on the Clydebank and preserved as a tourist attraction.
In the UK and Canada, this type of crane is often known colloquially as a "Hiab",
partly because this manufacturer invented the loader crane and was first into the UK
market, and partly because the distinctive name was displayed prominently on the
boom arm. A rolloader crane is a loader crane mounted on a chassis with wheels. This
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chassis can ride on the trailer. Because the crane can move on the trailer, it can be a
light crane, so the trailer is allowed to transport more goods.
CHAPTER 5
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 half ton to 2 ton or more. The storage of floor cranes in industries is a matter of
concern as the floor space available is limited, also employing a larger space for the
same will result in wastage of floor space especially in small scale industries.
effort from one place to another, and hydraulic cranes are amongst the most efficient
lifting systems available in the modern workplace.
Possibility of leakage of oil from the hydraulic cylinder thus making the work
area untidy
Load cannot be carried at an angle. (i.e rotation of arm is not possible)
Load on human labor increases thus increasing the possibility of manual error
Hydraulic fluid is highly corrosive to most of the aircraft materials.
Mishandling and constant exposure to hydraulic fluid and its gas fumes
without proper equipment and precautions is a health risk.
6.3 THREATS
Oil leakage in the hydraulic cylinder may lead to the failure of the entire system As
the number of moving parts increases due to the provision of adjustable arm and
foldable base, thus increasing the mechanical looses caused by friction ,also causes
wear of the moving parts
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CHAPTER 7
RELEVANT THEORY
CHAPTER 8
MANUFACTURING PROCESS
8.1 MANUFACTURING
Manufacturing process is a collection of technologies and methods used to define
how products are to be manufactured. Manufacturing of crane involves various
process
The hydraulic crane which was manufactured has 12 parts. They are
Base, Hydraulic hoses, Secondary horizontal arm, Hydraulic cylinder, Roller,
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Direction control valve, Hook, Nuts and Bolts, Wheels. 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
fixed horizontal arm is welded. And secondary horizontal arm was fixed with hook.
Hydraulic systems are selected according to the power required and capacity of tank.
8.2 FABRICATION
Manufacturing process in which an item is made (fabricated) from raw or semi-
finished materials instead of being assembled from ready-made components or parts.
it involves cutting ,bending and assembly process. Fabrication involves following
process:
Cutting Process
Forming
Machining Process
Tack Welding
Final Welding
Assembly
Surface Finishing
Testing
Painting
Common oxy-fuel cutting applications are limited to carbon and low alloy steel.
These materials can be cut economically, and the setup is quick.
9.2.2 FORMING
Forming process make use of suitable stresses like compression, tension, shear or
combined stresses to cause plastic deformation of the materials to produce required
shapes. In forming, no material is removed i.e. they are deformed and displaced.
Sheet Metal forming involves deformation of sheet metal to achieve the desired
shape. Forging Extrusion Rolling Sheet metal working Rotary swaging Thread rolling
Explosive forming Electromagnetic forming are the some of the methods used for
forming.
An advantage of this provisional assembly procedure is that if the alignment for final
welding is found to be incorrect, the parts can be disassembled easily, realigned, and
tack welded again.
8.2.6 ASSEMBLY
Final Assembly Schedule, often abbreviated as FAS and sometimes referred to as
finishing schedule, is a schedule of end items to finish the product for specific
customer orders in a make to order (MTO) or assemble-to-order (ATO) environment.
8.2.8 TESTING
The manufactured crane is tested for various load and if any failure occurs then the
corrective actions are taken out.
8.2.9 PAINTING
Spray painting is a painting technique where a device sprays a coating through the air
onto a surface. The most common types employ compressed gas usually air, to
atomize and direct the paint particles. Air gun spraying uses equipment that is
generally larger. It is typically used for covering large surfaces with an even coating
of liquid. Spray guns can be either automated or hand-held and have interchangeable
heads to allow for different spray patterns. We have used hand held type of spray
painting.
8.3 ASSEMBLY
2 Assembly of fixture for holding the bearing and the vertical column.
7 Connection of hoses with the piston, directional control valve, and the fuel
tank.
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CHAPTER 9
BILL OF MATERIALS
PHOTOGRAPHY
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CHAPTER 10
42
CONCLUSION
The aim of our project was to build a fully functional HYDRAULIC FLOOR
CRANE mechanism which is capable of lifting load up to 5 kg. We accurately
achieved our first goal of lifting the load and 360 rotary motion of the vertical
column. Using SWOT Analysis we evaluate the Strengths, Weaknesses,
Opportunities, and Threats to elaborate our conclusion
SWOT ANALYSIS
Strengths
Cost efficient
Manually operated Rotation ,thus reducing the electrical load
Skilled labour are not required
It can used for load varying applications
Higher range of reach can be achieved for lower load
i.e. for ton to 1 ton
We feel that our design and fabrication was a great success both in terms
of strength and stiffness. Our project is capable of lifting load up to 3 kg using
hydraulic power.
CHAPTER 11
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REFERENCES
3 www.e4training.com
4. www.freepatentsonline.com
5. www.howstuffworks.com
6. http://www.smartrigcranes.com/
7. http://www.womackmachine.com/engineering-toolbox/formulas-
calculations/hydraulic-motor-calculations.aspx
8. http://www.essortment.com/hydraulic-cranes-work-61698.html