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CHAPTER 1 INTRODUCTION
Portable Jib Crane is a small lifting, and material handling equipment used in engineering workshops as well as in godowns & ware houses. Jib Cranes can be used for lifting of different type of material in the segments where frequent lifting & handling of material activity is required. The purpose of these devices is simply to help workers move objects weighing from 50kg to 400kg from one point to another. Portable Jib Cranes is electrically powered for lifting operation, according to the need. Special types of Jib Cranes are also used in positioning the cameras in shootings. The two degrees of freedom in the horizontal plane are provided by the wheels provided, while the third, vertical degree of freedom is provided by a hoist. Because of low cost and versatile use, there is a very good application for the jib cranes. . The designing and fabrication of this portable jib crane uses application of mechanics of solids ,manufacturing technology and various subjects of mechanical engineering.
4. Mobile jib cranes consisting of truck mounted and crawler mounted cranes
Wall cranes are used in ware houses for handling light weight and when there is little or no wharf between them and the water front. Slewing or rotational motion of the crane is possible within restricted angle and the motion is slow. Hoisting and lifting speeds are comparable to those of wharf cranes. In some modified version these cranes can have travelling speed along the wall.
3.2Wharf Cranes:
These are used in shipyard and port for handling unit and bulk load. These are usually self-propelled balanced level luffing type with full circle slewing motion facility. Wharf cranes may be of different types, depending on the type of structure on which it is mounted. The choice of structure for mounting depends on site condition.
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4.4 Long Travel Motion: It may be required when the whole crane structure has to be shifted to a distant place along a rail track or along a road.
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Although you will only have to do it once, crane installation should also be taken into consideration. If you have to close down your factory for several days while someone installs a crane, you will lose a significant amount of working hours and therefore finished products. Once the type of crane is determined, then manufacturing needs should be taken into consideration. And the crane must suit your current production line. The crane might need it to move things around bends. All of these needs must be taken into account when selecting a crane. QUALITY The jib crane must be able to handle everything in terms of lifespan and duty cycle. Some additional points that are taken into consideration are the consistency of the material used in the construction of the crane, the in-house quality control of the manufacturer, and the testing process. A high-quality product will last longer than a low-quality product. If you simply purchase the cheapest crane on the market, you might end up with higher long-term costs. COST The price of the crane is one important factor. It must also add in the cost of installation, maintenance, and future needs. As mentioned before, every hour your factory is closed down for installation is an hour that cant be spent manufacturing your product. Then it is even required to pay for extra labour if the installation requires special tools or welding. DESIGN Since a numerous designs are available for the jib cranes, it is much relevant to select jib cranes according to specific applications. The design may vary with types of jib, methods of mounting, modes of motion or rotations etc. TYPES The general types of jib cranes available are: floor mounted type, wall mounted type, portable type etc. ACCOMMODATING THE FACILITIES The jib crane should suite for the existing facilities in the work area. So the type, dimensions, size of jib crane should be suited for the available work space.
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6.1 COMPONENTS
The various components of the jib crane are: jib and frame (mild steel), electric motor (250 W), worm gear set, winding drum, pulleys, wheels, rope, hook, and forward and reverse switch.
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Figure 6.1 frame The jib is the horizontal arm which is connected to the vertical column by welding. The jib, vertical column and the base together withstand the bending stress produced by the load. The design of the jib is done such that the stress induced will be almost equal throughout the jib span.
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There is a forward and reverse switch for controlling the motor in both directions. The motor is connected to the winding drum through gear set.
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Figure 6.3 Gear set The gear set is having a gear ratio of 320.This gear ratio is obtained by two worm gear sets of gear ratios 16 and 20.worm gear is selected because it is non-return type. Major problems with the worm gear are less efficiency and high noise.
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6.1.5 Rope
Figure 6.4 Rope The function of rope is to transmit the rotary motion of drum to the linear vertical motion of the hoist. The load in the rope is completely tensile. High contact stress will be induced during the winding on drum and pulley. The selected material of rope is wire steel. The diameter of the rope is 0.8mm.
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6.1.6 Pulley
Figure 6.5 Pulley The pulley acts as a guide way for the movement of the rope. The material of the pulley is sand cast iron. The outer diameter is 10cm and the inner diameter is 1.5cm. Here totally four pulleys are used.
6.1.7 Wheels
Wheels are attached to the base of the crane for mobility of the jib crane. Here totally four wheels are used. The front wheels are fixed type and back wheels are revolving type. Since the crane is moved by pushing from the rear side, the revolving type wheels make the steering easier. Each wheel is having a capacity to carry 200 kg.
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6.1.8 Hook
Figure 6.6 Hook Hook is used to hold the materials to be lifted. The material of the hook is forged iron. The capacity of the specific hook is 1 tonne.
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The design load of the jib crane is decided as 400 kg. So the aim is to design the jib, frame and other components to withstand the stresses due to the loading and the power requirements for lifting the load properly. Manual calculation and stress analysis using solid works 2011 are used for designing the components.
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factor of safety. The F.O.S can be 2.5 to 3 for MS in normal shock condition. Then the allowable stress will be 80 to 96 Mpa. The load is acting upon the frame is such a way that the hook transmit the load to the rope, then from rope to the jib, then to the vertical portion and finally to the base of the crane. The load is acting on the jib at the end of it, which produces a bending moment in the jib. The moment will be maximum at the farthest point from the load, which is at the rear end of jib and at the vertical column. From the elementary mechanics we have
= Where,
y/I
is the maximum bending moment induced duo to the force. The perpendicular distance is the smallest distance between the vertical column and the point at which the load is acting. This distance was initially decided as 65 cm.
Now,
is the maximum stress induced in the material y is the distance from the centroid to the extreme point of the jib-cross section. And, I is the moment of area of the section
= 4009.80.65 = 2550Nm
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Various section were studied for the designing of the jib and among them, varying rectangular section were find suit for the jib and square pipe section were selected for the vertical column and the base The stress will be maximum at the column. The stress induced in various section were calculated and the stress induced in the column with a section of 3 3 inch pipe of thickness 4mm were calculated as, =
Induced stress in the vertical column was found as72 Mpa in tension and 82 Mpa in compression, hence it found to be safe. Hence 3 3 inch pipe of thickness 4mm were selected for fabrication and since the stress in the jib will be less than that of the column, the same section is selected for the jib and the construction of the jib is such that two halves of pipe section is arranged conically and inter connected them by welding with small rods as shown in figure.
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The figure shows the stress distribution in the jib and column. The values are in Pascal. The maximum stress shown by the software solid works is in the range 70 to 80 Mpa which is nearer to the value got in manual calculations. The stress in the jib is almost uniformly distributed throughout, but less than the stress in the column. It is to compensate the stress concentration in welding portion as it is neglected in the calculations.
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Calculation of Power The operation speed is an important factor in calculating the power, the load should be lifted and placed slowly and a maximum speed of 1 cm/s is allowable. So, power requirement were calculated as, P = load velocity/ Where, P = power (W) = overall efficiency of system Since non return type worm gear is used, the efficiency will be less than 50 %. It is assumed to be as 40 %, then P = 400 9.8 0.01/0.4 = 98 W Hence 0.25 hp motor is sufficient (185 W) but the selected motor has a capacity of 250 W. The end-load will induce tension in rope, here the loop type rope and pulley arrangement reduces the load in to half of the actual load, so the tension on the rope will be half of the weight to be loaded. The rope tension will produce a turning moment on the winding drum T = F 0.5D Where, T = the torque (Nm)
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F = the tension in rope = load 0.5 (N) D = mean diameter of the winding drum and winded rope (m) The diameter is initially assumed to be 7 cm, then, T = 200 9.8 0.5 0.7 = 168 Nm Since the motor speed and power are constant, the gear ratio can be varied so as to get the required torque in the winding drum, the input torque to the drum should overcome the torque induced by the load. The required minimum speed of the drum is found as, N=
= = 5.5 rpm This speed will meet the torque requirements but the speed of operation found to be high, hence the drum speed is selected as 4.5 rpm. The average o/p velocity of the hook was calculated as 0.82 cm/s.
7.2 Gears
The gear ratio is 320, which cant be obtained by using one gear set. Here two worm gear sets are used to get required gear ratio of 320. The individual gear sets of gear ratio of 16 and 20 can give a total ratio of 320. The gears should design to withstand the contact stress as well as the bending stress. The induced contact stress and bending stress can be calculated by the equations,
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[ ]
[ ] Where, = induced contact stress in Mpa. = induced bending stress in Mpa = number of teeth in the wheel. = form factor, taken it as 11. = center distance =0.5 mx (q + z) in mm. [ ] = design torque on wheel in Nmm. = the form factor. = axial module in mm.
The selection gear started with the known value of[ ] and all other values were assumed initially. The values of and were checked with different configurations of
gears and finally reached configuration only is describing here Gear set 1 Taking material as carbon steel, = 2.5 and = 32 and i = 16,
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= 231 Mpa The design contact stress for the material carbon steel-[ ] is 875 Mpa, so [ ], hence the design is safe. Now checking for the bending stress, [ = 8.1 Mpa This is very less than the design stress Gear set 2 Taking material as C-14, = 2.5 and = 40 and i = 20, ] <
= 424 Mpa The design contact stress for the material carbon steel-[ ] is 875 Mpa, so [ ], hence the design is safe. Now checking for the bending stress, [ = 124 Mpa The design bending stress for the material C-14 steel-[ hence the design is safe. ] is 130 Mpa, so < [ ], ] <
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Where, = Equalant torque in Nm, = Equalant bending moment in Nm, = combined shock and fatigue factor for bending(taken as 2) = combined shock and fatigue factor for torsion(taken as 1.5) M = Bending moment in Nm = = tension in the rope in N = length of the drum in m ,it is teken as 30 cm. M = 150 Nm T = Torque in Nm
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Then, = 391Nm ( = 345 Nm Let, = the diameter of shaft according ti equalant torque = the diameter of shaft according ti equalant bending )
= 3.6 cm
= 3.5 From the above two values higher value is to be selected,the actual diameter is taken as 4 cm.
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CHAPTER 8 ADVANTAGES
It can be used in a massive number of areas from vehicle garage to dockyards ,construction site to ware houses They may be even present in smaller version on the back of lorries for loading and unloading Jib cranes are suitable for most places due to the fact that they take up minimal They take up minimal space but primarily they present a much quicker and safer way lifting objects Less personnel injuries It can save expenditure by allowing the job to be finished quicker and by reducing time off for accidents and all the implications that may arise from them So together with the large variety of possibilities and accessories offered, the jib crane is a hugely adaptable lifting piece of equipment ,suitable for many lifting and placing application in the majority of areas
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DISADVANTAGES
It is designed for positioning a work piece or total ,rather than for moving a product along in the work flow like an overhead crane It is also unsuitable to use when there is a need for precise locating of heavy loads ,a large area of hook coverage or frequent use for heavy loads The hook coverage is limited to the boom length (typically a maximum of 20ft).the hook operates along a boom which rotates about a fixed point
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CHAPTER 10 CONCLUSIONS
The difference between jib cranes and other kinds of crane is that a jib crane is a free standing device that usually sits on its own pedestal. These cranes look and function like the mobile cranes seen at construction sites and elsewhere. They have a motor usually contained in a base and a long arm that takes the hook over the object to be lifted. As on mobile cranes the arm can be moved into position to pick up an object then moved again to transfer it to a location. Jib cranes can either be manually operated or motorized depending the weight of the loads lifted. The biggest advantage to using a jib crane is that no overhead structure is required. This means that no costly engineering work may be needed. Also a jib crane can be transferred from one location to another with much engineering or construction work. It can simply be moved via a forklift or other such device. The can be used outside without a gantry. This makes it ideal for loading or unloading trucks. Such cranes will also be quite a bit cheaper than overhead cranes or gantry cranes. They will be cheaper because no structure will be needed for them. No complex structure of machinery will be required either.
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RECOMMENDATIONS
Even though the designed jib crane is of portable and motorized, this type of jib cranes have some limitations based on the situations and working environment.The biggest drawback is that they can take up quite a bit of floor space in a factory or workshop. This can be an issue in a facility that requires quite a bit of machinery. Another challenge is that the loads lifted by jibs can be quite limited. It may not lift large amounts of tonnage. This particularly designed jib crane is able to lift loads upto 400 kg. The heights that this crane reaches is also very limited, it usually cant lift objects more than a few feet off the door. This can limit the usefulness of the jib crane in repair and manufacturing work. This type of jib crane cannot be used to transfer objects around a factory or facility the way overhead cranes can. This can limit their use and require the use of other machines such as forklift. Also a 3600 jib rotation is recommended for the efficient lifting operation. It would probably be best to use these types of jib cranes in smaller facilities where only limited lifting would be required. An example of this would be a garage where mechanics need to lift engines out of cars. Other locations where they might be of use include small machine shops, farms, boat yards and smaller factories.
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REFERENCES
1. Al- Ajmi , M.S, T.G. Abu-El Yazied , S.Y. Abu-El- Hagag. 2010. Dynamic Modeling and load Sway Simulation of Jib Cranes.10 (1): 33-39 2. Al-Fares, F.S., T.G. Abu-El-Yazied, H. AlMubarak and M.S. Al-Jjmi, 2010. ElectroMechanical Modelling and Sway Simulation ofContainer Cranes with Hoisting. Australian Journal of Basic and Applied Sciences, AJBAS-4(2): 265273. 3. Baker J. Cranes in Need of Change, Engineering, v. 211, n. 3, p. 298. 1999. 4. Basu A., Majumdar A. K., Sinha S., An Expert System Approach to Control System and Analysis, IEEE Trans. on Systems, Mans and Cybernatics, v. 18, n. 5, pp. 685-694, 2009. 5. Erden Z., Erkan M. and Erden A., A Computer Based Design Support System for Automate Access to the F. E. M. Rules in a Crane Design Procedure, Proceedings of the 7th International Machine Design and Production Conference, pp. 575-583, Ankara, Turkey 1996. 6. H. D. HESS,1991, Machine Design of Hoists, Derricks ,Cranes , Cornell University , Philadelphia, U.S.A. 7. The Design and Construction of an Intelligent Power Assist Jib Crane, Harry M. Pearce. 8. Unsal (Erden), Z. and Erden, A., Computer Automated Access to the F.E.M. Rules for Crane Design, Proceedings of the International Conference on Engineering Software, pp. 135-142, Stafford, UK 1993.
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