Hydraulic Floor Crane

International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

DESIGN AND FABRICATION OFA HYDRAULIC FLOOR CRANE Author:V.Jose Ananth Vino,AP,Bharath University.

ABSTRACT

In material handling, the cranes play a vital role in modern manufacturing industries. In our project we aim to fabricate a hydraulic operated floor crane for handling various kinds of materials. The hydraulic floor crane consists of truck, hydraulic cylinder, hydraulic tank, hydraulic hoses, DCV, beam and hooks. The beam one end is fixed to the truck and another end is attached to the hooks. The hydraulic cylinder is connected to the horizontal arm. The hydraulic tank is pumping to the hose in upward direction. At the same time material is lifted with the help of hook and hydraulic cylinder released to the pressure valve so the material is unloaded. The material from one place goes to the other place with the help of hydraulic floor crane. The crane reduces the worker’s fatigue and increases the overall efficiency of production processes with good safety. The crane is fabricated with complete clear front, small compact frame, good reach, high lift and with low center of gravity. The crane has the capacity of lifting 10 kg with wide spread application in the shop floor. Thus the floor crane would serve as a safe and versatile model for material handling operations.

1.1 Introduction 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 createmechanical 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.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. Strong, robust, study and built to very standard. Laden, these cranes are manoeuvrable and loading, unloading and shifting of heavy load. Crane structure consists of chasis, verticalcolumn, inner boom and outer boom, and thehydraulic pump with ISSN: 2249-0183

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cylinder assembly. The boxframe can take heavy loads effectively, avoidsand damage under rough and unskilled handling.Inner and outer boom is suitably reinefoast the bow structure for better distribution of force. Innerboom has 3 locking points telescopes into theouter boom with 360° rotating forged steel hook. 2.1 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 2.2 DESIGN CRITERIA:There are three major considerations in the design of cranes. 2.2.1 The crane must be able to lift the weight of the load; 2.2.2 The crane must not topple; 2.2.3The crane must not rupture.

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 themechanical 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

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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.

1

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 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.

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.

MANUFACTURING PROCESS 3.1 Manufacturing:The hydraulic crane which was manufactured has 12 parts. They are Base plate/ Truck/Pallet, Hydraulic tank, Hydraulic hoses,Direction control valve, Vertical column, Ball bearings, Horizontal arm, Secondary horizontal arm, Hydraulic cylinder,

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Roller, Hook, Nuts and Bolts,Wheels. Base platesare made of caste iron metal rod. The rodsare 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 system are selected according to the power required and capacity of tank.

3.2Machining process:3.2.1 3.2.2 3.2.3 3.2.4

Surface finishing Metal cutting Surface grinding Welding

3.2.1 SURFACE FINISHING: Surface finishing is done mainly by abrasive sand paper , in order to remove the dust particles and the rusting which gets formed because of the exposure to the moisture using a sand paper we can obtain the shiny surface and the other operations become much easier and convenient ,marking can be done easily for cutting ,welding and drilling operations.

Fig.3.1 Abrasive Sand Paper

3.2.2 METAL CUTTING:

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

Metal cutting is basically done to get the right dimensions and size as per the required design, using machines that have single point cutting tool or multi-point cutting tool. Initially the dimensions are marked and then the metal cutting operation is done.

Fig. 3.2 Automatic Metal Cutting Saw

3.2.3 METAL WELDING: Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the joint between two parts is melted and caused to intermix - directly, or more commonly, with an intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. Since the joining is an intermixture of metals, the final weld element potentially has the same strength properties as the metal of the parts. This is in sharp contrast to non-fusion processes of joining (i.e. soldering, brazing etc.) in which the mechanical and physical properties of the base materials cannot be duplicated at the joint.

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Fig. 3.3 The basic arc-welding circuit In arc welding, the intense heat needed to melt metal is produced by an electric arc. The arc is formed between the actual work and an electrode (stick or wire) that is manually or mechanically guided along the joint. The electrode can either be a rod with the purpose of simply carrying the current between the tip and the work. or, it may be a specially prepared rod or wire that not only conducts the current but also melts and supplies filler metal to the joint. Most welding in the manufacture of steel products uses the second type of electrode.

3.2.4 GRINDING: Grinding is done on the edges for getting the smooth finish, the grinding machine removes the material from the metal surface in the form of sparks as shown in the figure

Fig.3.4 Grinding operation

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

Fig 3.5 Grain Structure in a Grinder

3.3 ASSEMBLING : The assembly of the various parts and structure of our project is done using nuts and bolts, welded fixtures, fasteners, etc.

3.3.1 NUT AND BOLT TIGHTENING: Nuts and bolt are tightened using spanners up to the required limit.

3.3.2 INSTALLATION OF THE BEARINGS: The bearings hold the vertical column axial direction and allow the set up to rotate 360° so that the material handling becomes easier.

3.3.3 INSTALLATION OF THE HYDRAULIC CIRCUIT: The hydraulic circuit consists of piston-cylinder assembly, direction control valve, polyhose, hydraulic tank. The installations of these parts are very very important only the crane will function properly. The parts are fastened and welded using fixtures and nut and bolts.

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

3.3.4 FITTING OF THE VERTICAL COLUMN: The fitting of the vertical column allows it to rotate 360° along the axis. The fitting arrangement is achieved by bracket ,bearings, welded portions , nut and bolts.

3.3.5 POSITIONING OF THE ROLLER: The roller guides the extended horizontal arm to move upwards and lift the objects, so the roller is actually fixed at the end of the piston , whenever the roller is moving there is negligible friction between the piston and the horizontal arm.

3.3.6 WIRING USING 3-PHASE A/C SUPPLY: The hydraulic crane consumes more electricity compared to normal home appliances, because of the presence of the motor in it. The 3-phase A/C supply is required for the running of our machine.

3.3.7 DIRECTION CONTROL VALVE AND HOSE INSTALLATION: The direction control valve contains lever which is connected to a spring. It has 3 positions forward, neutral and backward motion .The installation is done using welded fixtures , nut and bolts.

3.3.8 FASTENING OF THIN METALLIC STRIP FOR THE HYDRAULIC TANK: The hydraulic tank is an independent part and it is of big size so using a thin metallic strip the tank is being fastened to the base of the crane. When it is been fastened the hydraulic tank will not move from its position.

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

MATERIAL SELECTION

4.1 SELECTION OF MILD STEEL FRAMES: The material selection is also very much important because : what material we are using whether it is capable of sustaining that load or not. For our project it is of medium load capacity so we are using mild steel of composition : C 15 Mn 75. The percentage of carbon varies from 0.1 to 0.2 % and this material can easily sustain the load.

4.2 SELECTION OF BEARINGS: The bearing which corresponds to our hydraulic crane is Bearing No.2006 for the vertical column and Bearing No.2004 for the wheels correspondingly. CHROME STEEL (AISI 52100 OR EQUIVALENT) This is the standard material used for ball bearing applications where load capacity is the main consideration. The machinability of this steel is excellent, giving smooth, low noise raceway finishes, together with superior life. Chrome steel material is recommended in applications where corrosion is not a factor. C Si Mn P S Cr CARBO SILICO MANGANES PHOSPHORO SULPHU CHROMIU N N E US R M 1.2 .95 - 1.1 .15 - .35 Max .5 Max .025 Max .025 1.6

Mo MOLYBDENU M -

4.3SELECTION OF WHEELS:

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PREMIUM Rubber Caster Wheels PREMIUM rubber caster wheels have a special compound of highly resilient soft rubber bonded to thick aluminum wheel centers. Unlike Conventional Moldon rubber caster wheels, PREMIUM rubber caster wheels can be moved manually when loaded to their rated capacities.

4.4 SELECTION OF HOSES: SAE 100R1 hose should be used with petroleum- and water-based hydraulic fluids, within a temperature range from140° to 100° C. Type A consists of an inner tube of oilresistant synthetic rubber, a single wire braid reinforcement, and an oil- and weatherresistant synthetic rubber cover. A ply, or braid, of suitable material may be used over the inner tube or over the wire reinforcement (or both) to anchor the synthetic rubber to the wire. Type AT has the same construction as Type A, except AT has a cover designed to assemble with fittings that do not require removal of the cover or any portion of it.

Fig 4.1 Sectional view of Hydraulic Hose

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

Fig 4.2 Different types of Hoses

4.5 SELECTION OF HYDRAULIC OIL/FLUID Hydraulic fluids, also called hydraulic liquids, are the medium by which power is transferred in hydraulic machinery. Common hydraulic fluids are based on mineral oil or water.[1] Examples ofequipment that might use hydraulic fluids include excavators and backhoes, hydraulicbrakes,powersteering systems, transmissions, garb agetrucks, aircraft flight control systems, lifts, and industrial machinery. Typically lubricants contain 90% base oil (most often petroleum fractions, called mineral oils) and less than 10% additives. Additives deliver reduced friction and wear, increased viscosity, improved viscosity index, resistance to corrosion and oxidation, aging or contamination, etc. Lubricants such as 2-cycle oil are added to fuels like gasoline which has low lubricity. Sulfur impurities in fuels also provide some lubrication properties, which has to be taken in account when switching to a low-sulfur diesel; biodiesel is a popular diesel fuel additive providing additional lubricity.

4.5.1Importance of Choosing Hydraulic Oil Using the correct hydraulic oil in your hydraulic system is extremely important. We have to consider the following while selecting a hydraulic oil:1) Use a hydraulic oil with properties that meet the equipment manufacturer’s performance specifications. . 2) Use a hydraulic oil with the correct ISO viscosity rating for your local climate.

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

4.5.2 Hydraulic System Overheating When hydraulic systems overheat several things can occur that can damage the system. These include; (1) Breakdown of the hydraulic oil producing “sludge”, (2) Deterioration of hose lining releasing rubber particles into the system, (3) O-rings and seals become less pliable and begin to leak. (4) Increased formation of acids that can begin to corrode components.

4.5.3Importance of Clean Hydraulic Oil TimberPro hydraulic systems use piston pump sand motors that operate at pressures as high as 6500 PSI. These state-of-the-art components must be manufactured with very tight tolerances to provide high performance and efficiency. The tighterthe tolerances, the more damage contamination will cause. Types Of Contaminates: There are many types of contaminates. The most common are: Particulate (dust, dirt, sand, fibre, rust, rubber, paint chips, metal flakes, etc.)

DESIGN CALAULATIONS

5.1 DESIGN SPECIFICATION:1. Polyhose : Inner diameter(ID)=3/8˝ Working pressure=350bar(5000psi) 2. Lever operated Direction Control Valve : Polyhydron 4DL06 SGS-02.5 12/11 3. Hydraulic Tank: PN = 0.75 kwUN= 380 Y V N= 1420 rev/minIN= 2,2 A Q= 2.5 l/min f= 50 Hz

4. Wheel: B Triopines 5 X1 3/16 5. Truck:ISSN: 2249-0183

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

Length of truck=65cm=0.65m Breadth of truck=45cm=0.45m Height of vertical column=100cm=1m

5.2 DESIGN OF TRUCK

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= 20kg Length= 65cm= 0.65m Breadth= 45cm= 0.45m Floor load= total weight/total floor area = W/(l*b) =20/ (0.65*0.45) = 68.37kg/m2 or 68.37 N

2. Calculation of floor capacity:Beam strength formula:Maximum load in the beam= FBD2/9L; Where:F- Fiber stress in bending, usually F=1000 N/m2 B- Breadth of floor= 0.45m D- Depth of joist= 0.76m L- Length of joist= 0.16m Maximum load in beam= (1000*0.45*0.76 2)/(9*0.16) = 180.5 N/m2

5.3 HYDRAULIC SYSTEM HYDRAULIC POWER:1. Power input

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

=[speed(rev/min)*pump displacement(cc/rev) *pressure(bar)*100]/[600*motor efficiency(%)] =[1420*1*350*100]/[600*90] =920watt

2. Flow = [motor speed(rev/min)*pump displacement(cc/rev)]/1000 =1420*1.76/1000 =2.1cc/min

3. Shaft torque = [pump displacement(cc/min)*pressure(bar)]/[20*P*I*3.142] =[1.73*350]/[20*920*3.142] =53N-m

4. Power out =[speed(rev/min)*pump displacement(cc/min)*pressure(bar)*100]/600 =[1420*1.73*350*100]/600 =830watt 5.Fluid velocity in hose

Continuity equation:-

Q= ρAV

Q = ρ*(πd2/4)*V V=[(Q*4)/(ρ*πd2)] =[(2.5*4)/(899*π*0.01 2)] = 35.40 m/s (Density of fluid at room temperature = ρ= 899 kg/m3)

FORCE ANALYSIS IN FRAME ISSN: 2249-0183

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FREE BODY DIAGRAM

F F

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ASSEMBLY DIAGRAM

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ISOMETRIC VIEW OF HYDRAULIC FLOOR CRANE

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FRONT VIEW OF HYDRAULIC FLOOR CRANE

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International Journal of Biotech Trends and Technology (IJBTT) – Volume2 Issue 1 Number1–Jan 2012

CHAPTER: 8 SNAP SHOTS

SNAPSHOTS OF ASSEMBLED VIEW AND INDIVIDUAL PARTS

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SNAPSHOT OF HYRAULIC FLOOR CRANE

SNAPSHOT OF HYDRAULIC PISTON-CYLINDER ASSEMBLY

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CONCLUSION

The aim of our project was to build a fully functional HYDRAULIC FLOOR CRANE mechanism which is capable of lifting load up to 10 kg . We accurately achieved our first goal of lifting the load and 360° rotary motion of the vertical column . We feel that our design and fabrication was a great success both in terms of strength and stiffness. Our project weighed 10kg which is capable of lifting load up to 10kg using hydraulic power.

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

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