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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.

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 and
unloading of freight, in the construction industry for the movement of materials
and in the manufacturing industry for the assembling of heavy equipment.

In material handling, the cranes play a vital role


in modern manufacturing industries. Hydraulic cranes are heavy equipment used
primarily for lifting. These Hydraulic floor Cranes, provide an efficient low cost
alternative to other material handling equipment. these cranes are maneuverable
and loading, unloading and shifting of heavy load. Crane structure consists of
chassis, vertical column, inner boom and outer boom, and the hydraulic pump
with cylinder assembly. The box frame can take heavy loads effectively, avoids
and damage under rough and unskilled handling.. Another major goal within the
thesis work was to estimate cylinder friction of the hydraulic actuators. We build
up a test rig and used a double-acting cylinder for determing its frictional
behaviour. For this, we ran open-loop experiments in order to create velocity-
friction maps
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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.

1.2 WORKING OPERATION

This crane works on hydraulic mechanism. When we give power to the


motor with the switch it drives the motor. Motor shaft is connected to the
hydraulic pump. Hence pump starts pumping oil which opens the valve and moves
the piston up. Then lifting arm lifts the object with the pressure created. When we
again press the other switch oil comes back and the arm comes down. It can be
operated by both AC/DC current.
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1.3 PARTS AND DESCRIPTIONS OF HYDRAULIC FLOOR CRANE

1 Base Frame

2 Hydraulic Tank

3 Hydraulic Hoses

4 Direction Control Valve

5 Vertical Column

6 Rectifier

7 Horizontal Arm

8 Double acting Hydraulic Cylinder

9 Hook

10 Nuts and Bolts

11 Ball Caster Wheels

12 Transformer

13 Diode

14 Controlling Switch
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1.3.1 BASE FRAME


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. This
article is about the basic structure. An A-frame is a basic structure designed to
bear a load in a lightweight economical manner. The simplest form of an A-frame
is two similarly sized beams, arranged in a 90-degree or less angle, attached at the
top. These materials are often wooden or steel beams attached at the top by rope,
welding, gluing, or riveting.

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

1.3.2 HYDRAULIC TANK


It is filled with oil or water. It consists of an D.C. Motor which is having four
connections to the outside of the tank for connecting it to the power supply. The
capacity of fuel tank is 2 liter.

1.1.3 HYDRAULIC HOSE


These are for carrying the fluid from the hydraulic tank to the cylinder at the time
of extending and from the cylinder to the hydraulic tank at the time of retraction.
These are made of polymer material with mild steel nuts at the ends to fix it with
the hydraulic cylinder and hydraulic tank. In our project we have two hoses for
various applications. There are separate hoses for taking and returning of fluid.

1.3.4 DIRECTION CONTROL VALVE


This is used for controlling the direction of fluid flow in the hydraulic hoses from
hydraulic tank to hydraulic cylinder and vice-versa during arm extension and arm
retraction simultaneously. Directional control valves are one of the most
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fundamental parts in hydraulic machinery as well and pneumatic machinery. They


allow fluid flow into different paths from one or more sources. They usually
consist of a spool inside a cylinder which is mechanically or electrically
controlled. The movement of the spool restricts or permits the flow, thus it
controls the fluid flow.

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

In electronics, a diode is a two-terminal electronic component with asymmetric


conductance; it has low (ideally zero) resistance to current in one direction, and
high (ideally infinite) resistance in the other. A semiconductor diode, the most
common type today, is a crystalline piece of semiconductor material with a pn
junction connected to two electrical terminals. A vacuum tube diode has two
electrodes, a plate (anode) and a heated cathode. Semiconductor diodes were the
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first semiconductor electronic devices. The discovery of crystals' rectifying


abilities was made by German physicist Ferdinand Braun in 1874. The first
semiconductor diodes, called cat's whisker diodes, developed around 1906, were
made of mineral crystals such as galena. Today, most diodes are made of silicon,
but other semiconductors such as selenium or germanium are sometimes used

1.3.8 Controlling switch


The most familiar form of switch is a manually operated electromechanical device
with one or more sets of electrical contacts, which are connected to external
circuits. Each set of contacts can be in one of two states: either "closed" meaning
the contacts are touching and electricity can flow between them, or "open",
meaning the contacts are separated and the switch is nonconducting. The
mechanism actuating the transition between these two states (open or closed) can
be either a "toggle" (flip switch for continuous "on" or "off") or "momentary"
(push-for "on" or push-for "off") type.

A switch may be directly manipulated by a human as a control signal to a system,


such as a computer keyboard button, or to control power flow in a circuit, such as
a light switch. Automatically operated switches can be used to control the motions
of machines, for example, to indicate that a garage door has reached its full open
position or that a machine tool is in a position to accept another workpiece.
Switches may be operated by process variables such as pressure, temperature,
flow, current, voltage, and force, acting as sensors in a process and used to
automatically control a system. For example, a thermostat is a temperature-
operated switch used to control a heating process. A switch that is operated by
another electrical circuit is called a relay. Large switches may be remotely
operated by a motor drive mechanism. Some switches are used to isolate electric
power from a system, providing a visible point of isolation that can be padlocked
if necessary to prevent accidental operation of a machine during maintenance, or
to prevent electric shock.
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1.3.9 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 90
1.3.10 HORIZONTAL ARM
It is fixed horizontally on vertical arm on which our hydraulic piston and cylinder
is mounted.

1.3.11 DOUBLE ACTING HYDRAULIC CYLINDER


A Hydraulic cylinder (also called a linear hydraulic motor) is a mechanical
actuator that is used to give a Unidirectional force through a unidirectional stroke.
Hydraulic cylinders get their power from pressurized hydraulic fluid, which is
typically oil. The hydraulic cylinder consists of a cylinder barrel, in which a
piston connected to a piston rod moves back and forth.

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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1.3.13 NUTS AND BOLTS


A nut is a type of fastener with a threaded hole. Nuts are almost always used
opposite a mating bolt to fasten a stack of parts together. The two partners are kept
together by a combination of their threads' friction, a slight stretch of the bolt, and
compression of the parts. In applications where vibration or rotation may work a
nut loose, various locking mechanisms may be employed: Adhesives, safety pins
or lock wire, nylon inserts, or slightly oval-shaped threads. The most common
shape is hexagonal, for similar reasons as the bolt head - 6 sides give a good
granularity of angles for a tool to approach from (good in tight spots), but more
(and smaller) corners would be vulnerable to being rounded off. Other specialized
shapes exist for certain needs, such as wing nuts for finger adjustment and captive
nuts for inaccessible areas. Nuts and bolts are the hardware fasteners which are
used to fasten the various different parts.

1.3.14 BALL CASTER WHEELS


A Ball caster wheels is a circular component that is intended to rotate on an axial
bearing. The caster 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
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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.

2.1 LIFTING CAPACITY


The lifting capacity of hydraulic crane mainly depends on following.

2.1.1 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.

2.1.2 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
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applied force multiplied by the number of lengths of cable passing between the
two blocks. This number is the mechanical advantage.

2.1.3 THE HYDRAULIC CYLINDER


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
others). 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.

Cranes illustrate the use of one or more simple machines to create


mechanical advantage. 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. 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. The hydraulic cylinder. This can
be used directly to lift the load or indirectly to move the jib or beam that carries
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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

3.1 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
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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.

3.2 MOBILE CRANE


The most basic type of mobile crane consists of a truss or telescopic boom mounted
on a mobile platform be it on road, rail or water. Common terminology is
conventional and hydraulic cranes respectively. Types of mobile crane.
TRUCK-MOUNTED CRANE
SIDELIFTER CRANE
ROUGH TERRAIN CRANE
PICK AND CARRY CRANE
CARRY DECK CRANE
TELESCOPIC HANDLER CRANE
CRAWLER CRANE
RAILROAD CRANE
FLOATING CRANE
AERIAL CRANE

3.2.1 TRUCK-MOUNTED CRANE


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
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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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3.2.2 SIDELIFTER CRANE


A side lifter crane is a road-going truck or semi-trailer, able to hoist and transport ISO
standard containers. Container lift is done with parallel crane-like hoists, which can
lift a container from the ground or from a railway vehicle.

3.2.3 ROUGH TERRAIN CRANE


A crane mounted on an undercarriage with four rubber tires that is designed for pick
and-carry operations and for off-road and "rough terrain" applications. Outriggers are
used to level and stabilize the crane for hoisting.

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.

A mobile crane with the necessary equipment to travel at speed on public


roads, and on rough terrain at the job site using all-wheel and crab steering. ATs
combine the readability of Truck-mounted Cranes and the maneuverability of Rough
Terrain Cranes.

3.2.4 PICK AND CARRY CRANE


A Pick and Carry Crane is similar to a mobile crane in that is designed to travel on
public roads, however Pick and Carry cranes have no stabilizer legs or outriggers and
are designed to lift the load and carry it to its destination, within a small radius, then
be able to drive to the next job. Pick and Carry cranes are popular in Australia where
large distances are encountered between job sites. One popular manufacturer in
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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...

3.2.5 CARRY DECK CRANE


A carry deck crane is a small 4 wheel crane with a 360 degree rotating boom placed
right in the centre and an operators cab located at one end under this boom. The rear
section houses the engine and the area above the wheels is a flat deck. Very much an
American invention the Carry deck can hoist a load in a confined space and then load
it on the deck space around the cab or engine and subsequently move to another site.
The Carry Deck principle is the American version of the pick and carry crane and
both allow the load to be moved by the crane over short distances.

3.2.6 TELESCOPIC HANDLER CRANE


Telescopic Handlers are like forklift trucks that have a telescoping extendable boom
like a crane. Early telescopic handlers only lifted in one direction and did not rotate,
however, several of the manufacturers have designed telescopic handlers that rotate
360 degrees through a turntable and these machines look almost identical to the
Rough Terrain Crane. These new 360 degree telescopic handler/crane models have
outriggers or stabilizer legs that must be lowered before lifting, however their design
has been simplified so that they can be more quickly deployed. These machines are
often used to handle pallets of bricks and install frame trusses on many new building
sites and they have eroded much of the work for small telescopic truck cranes. Many
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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.

3.2.7 CRAWLER CRANE


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.

3.2.8 RAILROAD CRANE


A railroad crane has flanged wheels for use on railroads. The simplest form is a crane
mounted on a flatcar. More capable devices are purpose-built. Different types of crane
are used for maintenance work, recovery operations and freight loading in goods
yards and scrap handling facilities.

3.2.9 FLOATING CRANE


Floating cranes are used mainly in bridge building and port construction, but they are
also used for occasional loading and unloading of especially heavy or awkward loads
on and off ships. Some floating cranes are mounted on a pontoon, others are
specialized crane barges with a lifting capacity exceeding 10,000 short tons (8,929
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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."

3.2.10 AERIAL CRANE


Aerial crane or 'Sky cranes' usually are helicopters designed to lift large loads.
Helicopters are able to travel to and lift in areas that are difficult to reach by
conventional cranes. Helicopter cranes are most commonly used to lift units/loads
onto shopping centers and high-rises. They can lift anything within their lifting
capacity, (cars, boats, swimming pools, etc.). They also perform disaster relief after
natural disasters for clean-up, and during wild-fires they are able to carry huge
buckets of water to extinguish fires. Some aerial cranes, mostly concepts, have also
used lighter-than air aircraft, such as airships.
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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

4.1 TOWER CRANE


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
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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
22

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.

4.1.1 ROTATING TOWER CRANE


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 'swampier'). 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.

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.
23

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.

4.2 SELF-ERECTING CRANE


Four self-erecting tower cranes mounted on the roof of 1st observatory (height 375
m) of Tokyo Sky tree (Tower tip and two crane operator as of 497 m) Generally a
type of tower crane, these cranes, also called self-assembling, jack-up, or "kangaroo"
cranes, lift themselves from the ground or lift an upper, telescoping section using
jacks, allowing the next section of the tower to be inserted at ground level or lifted
into place by the partially erected crane itself.
24

4.3 TELESCOPIC CRANE


A telescopic crane has a boom that consists of a number of tubes fitted one inside the
other. A hydraulic or other powered mechanism extends or retracts the tubes to
increase or decrease the total length of the boom. These types of booms are often used
for short term construction projects, rescue jobs, lifting boats in and out of the water,
etc. The relative compactness of telescopic booms make them adaptable for many
mobile applications. Though not all telescopic cranes are mobile cranes, many of
them are truck-mounted. A telescopic tower crane has a telescopic mast and often a
superstructure (jib) on top so that it functions as a tower crane. Some telescopic tower
cranes also have a telescopic jib.

4.4 HAMMERHEAD CRANE


The "hammerhead", or giant cantilever, crane is a fixed-jib crane consisting of a steel-
braced tower on which revolves a large, horizontal, double cantilever; the forward
part of this cantilever or jib carries the lifting trolley, the jib is extended backwards in
order to form a support for the machinery and counterbalancing weight. In addition to
the motions of lifting and revolving, there is provided a so-called "racking" motion,
by which the lifting trolley, with the load suspended, can be moved in and out along
the jib without altering the level of the load. Such horizontal movement of the load is
a marked feature of later crane design. These cranes are generally constructed in large
sizes and can weigh up to 350 tons. The design of hammer ran evolved first in
Germany around the turn of the 19th century and was adopted and developed for use
in British shipyards to support the battleship construction program from 1904 to
1914. The ability of the hammerhead crane to lift heavy weights was useful for
installing large pieces of battleships such as armour plate and gun barrels. Giant
cantilever cranes were also installed in naval shipyards in Japan and in the United
States. The British government also installed a giant cantilever crane at the Singapore
Naval Base (1938) and later a copy of the crane was installed at Garden Island Naval
25

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.

4.5 LEVEL LUFFING CRANE


Normally a crane with a hinged jib will tend to have its hook also move up and down
as the jib moves (or luffs). A level luffing crane is a crane of this common design, but
with an extra mechanism to keep the hook level when luffing.

4.6 GANTRY CRANE


A gantry crane has a hoist in a fixed machinery house or on a trolley that runs
horizontally along rails, usually fitted on a single beam (mono-girder) or two beams
(twin-girder). The crane frame is supported on a gantry system with equalized beams
and wheels that run on the gantry rail, usually perpendicular to the trolley travel
direction. These cranes come in all sizes, and some can move very heavy loads,
particularly the extremely large examples used in shipyards or industrial installations.
A special version is the container crane (or "Pertained" crane, named by the first
manufacturer), designed for loading and unloading ship-borne containers at a port.

4.7 DECK CRANE


Located on the ships and boats, these are used for cargo operations or boat unloading
and retrieval where no shore unloading facilities are available. Most are diesel-
hydraulic or electric-hydraulic.
26

4.8 JIB CRANE


A jib crane is a type of crane where a horizontal member (jib or boom), supporting a
moveable hoist, is fixed to a wall or to a floor-mounted pillar. Jib cranes are used in
industrial premises and on military vehicles. The jib may swing through an arc, to
give additional lateral movement, or be fixed. Similar cranes, often known simply as
hoists, were fitted on the top floor of warehouse buildings to enable goods to be lifted
to all floors.

4.9 BULK-HANDLING CRANE


Bulk-handling cranes are designed from the outset to carry a shell grab or bucket,
rather than using a hook and a sling. They are used for bulk cargoes, such as coal,
minerals, scrap metal etc.

4.10 LOADER CRANE


A loader crane (also called a knuckle-boom crane or articulating crane) is a
hydraulically powered articulated arm fitted to a truck or trailer, and is used for
loading/unloading the vehicle. The numerous jointed sections can be folded into a
small space when the crane is not in use. One or more of the sections may be
telescopic. Often the crane will have a degree of automation and be able to unload or
stow itself without an operator's instruction. Unlike most cranes, the operator must
move around the vehicle to be able to view his load; hence modern cranes may be
fitted with a portable cabled or radio-linked control system to supplement the crane-
mounted hydraulic control levers.

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
27

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.

4.11 STACKER CRANE


A crane with a forklift type mechanism used in automated (computer controlled)
warehouses (known as an automated storage and retrieval system (AS/RS)). The
crane moves on a track in an aisle of the warehouse. The fork can be raised or
lowered to any of the levels of a storage rack and can be extended into the rack to
store and retrieve product. The product can in some cases be as large as an
automobile. Stacker cranes are often used in the large freezer warehouses of frozen
food manufacturers. This automation avoids requiring forklift drivers to work in
below freezing temperatures every day.
28

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.

5.1 FLUID POWER SYSTEMS


The transmission of power by fluid power system is most convenient and highly
efficient. Due to this, the present conventional power transmission system are being
replaced and changed over to fluid transmission system. In this prime mover supplies
mechanical energy to a pump which is used to pressurize fluid. Then the pressurized
fluid is transmitted to different parts of the system through special pipings or
tubings. At desired places pressure energy is converted back to mechanical energy by
the devices called actuators consisting of hydraulic cylinders, hydraulic motors etc.
Since the power is transferred through the fluid as a medium, such a system is called
29

as fluid power system.


CHAPTER 6
ADVANTAGES & DISADVANTAGE OF HYDRAULIC CRANE

6.1 ADVANTAGES OF HYDRAULIC CRANE


Can be used effectively in small scale industries

Can be used in industries or application with space constrain.

Used in applications with wide range of load

It uses 'incompressible' fluid which results in a greater, more efficient &


consistent work or power output. This is due to the fact that hydraulic fluid
molecules are able to resist compression under heavy load hence minimal
energy loss is experienced and work applied is directly transferred to the
actuating surfaces.

As opposed to pneumatic system which uses air, a leakage in a hydraulic


system is easier to spot during ground maintenance operations.

Hydraulic fluid operates very well in a very hot working environment, it is


able to sustain its airworthiness viscosity, density & fluid temperature even if
it subjected under extreme heat. This is specially important on aircraft
structures that is abundant of hot working conditions during flight operations.

6.1.1 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
30

effort from one place to another, and hydraulic cranes are amongst the most efficient
lifting systems available in the modern workplace.

6.1.2Extremely 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

6.1.3 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.

7.1.4 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.

6.1.5 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.
31

6.2 DISADVANTAGE OF HYDRAULIC CRANE

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.

Due to the heavy loads experienced in a typical hydraulic system, structural


integrity is a must which also means higher structural weight for the aircraft in
addition to the weight of its hydraulic lines, pumps, reservoirs, filters, & etc.

Hydraulic system is susceptible to contaminations & foreign object damage


(FOD).

Mishandling and constant exposure to hydraulic fluid and its gas fumes
without proper equipment and precautions is a health risk.

If disposed improperly, a hydraulic fluid is an environmental 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
32

CHAPTER 7
RELEVANT THEORY

7.1 DESIGN WORK


The designing work was carried out using CATIA software. The required dimensions
of the driver and the driven wheels were taken as per the design equations. CATIA 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
33

7.2 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.


34

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,
35

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

8.2.1 CUTTING PROCESS


Our manufacturing process involves cutting via OXY-FUEL cutting method since it is
used for materials having low alloy steel.Oxy-fuel cutting is a cost-effective method
of plate edge preparation for bevel and groove welding. It can be used to easily cut
rusty and scaled plates and only requires moderate skill to produce successful results.
36

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.

9.2.3 MACHINING PROCESS


Machining is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process. The many
processes that have this common theme, controlled material removal, are today
collectively known as subtractive manufacturing, in distinction from processes of
controlled material addition, which are known as additive manufacturing. Turning,
milling, boring, drilling are the types of the machining process.

9.2.4 TACK WELDING


Tack welding, a necessary preliminary step in many welding projects, must be
performed correctly to achieve optimal results from the final weld and to minimize
part defects. Quality is as important in tack welding as it is in the final weld. This
article describes proper tack welding conditions been positioned as required,
generally by clamping them on suitable fixtures, tack welds are used as a temporary
means to hold the components in the proper location, alignment, and distance apart,
until final welding can be completed.
37

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.

8.2.5 FINAL WELDING


Welding is a material joining process in which two or more parts are coalesced
(joined together) at their contacting surfaces by a suitable application of heat and/or
pressure. Sometimes parts are united together by application of pressure only without
external heat. In the process of manufacturing we use the process of Electric Metal
Arc Welding. Arc welding is a type of welding that uses a welding power supply to
create an electric arc between an electrode and the base material to melt the metals at
the welding point. They can use either direct (DC) or alternating (AC) current, and
consumable or non-consumable electrodes. The welding region is usually.

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.

8.2.7 SURFACE FINISHING


Surface finishing is a broad range of industrial processes that alter the surface of a
manufactured item to achieve a certain property.] Finishing processes may be
employed to: improve appearance, adhesion or wet ability, solder ability, corrosion
resistance, tarnish resistance, chemical resistance, wear resistance, hardness, modify
electrical conductivity, remove burrs and other surface flaws, and control the surface
friction. In limited cases some of these techniques can be used to restore original
dimensions to salvage or repair an item Grinding is one such finishing process used to
improve surface finish, abrade hard materials, and tighten the tolerance on flat and
cylindrical surfaces by removing a small amount of material.
38

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

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 of secondary horizontal arm on fixed horizontal arm.

4 Assembly of hydraulic tank on the base plate.

5 Assembly of fixture for directional control valve.

6 Assembly of hydraulic piston on the fixed horizontal arm.

7 Connection of hoses with the piston, directional control valve, and the fuel
tank.
39

CHAPTER 9
BILL OF MATERIALS

S. NO. NAME QUANTITY RAT (RS.) TOTAL


AMOUNT

1. HYDRAULIC 1 200/- 2500/-


ARM
40

2. HYDROULIC 1 500/- 500/-


HOSE

3. ELECTIRCAL AS REQUIED 750/- 750/-


COMPONENTS

4. WELDING 250/- 250/-


COST

5. METAL FRAME AS REQUIED 400/- 400/-

6. BALL CASTER 4 70/- 280/-


WHEELS

7. NAME PLATE 1 400/- 400/-

TOTAL AMOUNT SPENT 5080/-

PHOTOGRAPHY
41

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
43

REFERENCES

1 DR. T. J. PRABHU (2010) A text book of Design of Transmission Elements.

2 Design data book- PSG Collage of Technology

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

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