IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES, VOLUME 4, ISSUE 1, JAN-JUNE /2017

ISSN (ONLINE): 2394-8442

DESIGN & MANUFACTURING OF HYDRAULIC CRANE:

AN OVERVIEW
M.D.Sirsat [1], G.N.Deshpande [2], N.S.Dongare [3]
[1,2,3]
Assistant Professor, Mechanical Engineering Department, Shreeyash College of Engineering & Technology, Aurangabad,
(M.S.), India
mangesh.sirsat@sycet.org

ABSTRACT
In this paper, design, fabrication and testing of hydraulic crane is intended to replace the local or traditional
method of lifting heavy load with hand with emphasis being laid on performance, safety and reliability. Also, hydraulic crane is
capable of carrying load up to 1000kg at a time was developed using locally available materials. The crane is comprised of six
primary load-carrying members that are joined together in a particular fashion, actuator, oil tank, hose, pipe and a pump that is
powered by a D.C. motor. The principle of operation, fabrication details and methods were critically analyzed, calculations were
clearly laid out and material selection and costing were also discussed. The machine Factor of Safety (FOS) is 2 and in the
performance evaluation, it indicated 81.2% efficiency.

Keywords: Pump, actuator, hydraulic crane, reliability, load, material handling

I. INTRODUCTION
In our daily life, the strength of human is very limited and cause difficulties in handling with huge materials. Cranes are essential machinery
on modern world and are used to perform tasks which require the movement of heavy loads in different fields of industry such as construction,
transportation or in manufacturing for the assembly of heavy components [1]. In order to utilize of manpower, heavy machinery is needed to
make the work become easier and less time to complete the task. Cranes are not merely the largest, the most conspicuous, and the most
representative equipment of construction sites but also, at various stages of the project, a real bottleneck that slows the construction process.

Although the crane can be found standing idle in many instances, yet once it is involved in a particular task, it becomes an indispensable link
in the activity chain [2], forcing at least two crews (during loading and unloading) to wait for the service. Nowadays, the improvement of
technology made 3-Crane System as one of the suitable heavy machinery transporter to be used in the industries. The purpose of 3-axis crane is
to transfer variety of material from one location to another location in order to load and unload of huge materials where heavy loads must be
moved with extraordinary precision [3]. The main aim of the project is the design and production of a 3-Axis crane having arm motion in the
vertical as well as horizontal plane with 180 degree rotation. These cranes provide an efficient, low cost alternative to other material handling
equipments. Strong, robust, sturdy and built to very standard, these cranes are manoeuvrable in loading, unloading and shifting of heavy loads.

II. BACKGROUND HISTORY OF CRANE EVOLUTION

Crane use and evolution started with the needs in the erection of anvil and structural works. Travelling cranes of the hand operated type were in
use in the 1880s [4]. About this time complicated designs of powered motion were offered by English and American builders involving a driving
shaft along the runway and multiple clutches for transferring the power of the driving shaft to the hoist, trolley or bridge motions. Successive
crane development ran thus: 1880 saw the hand powered crane, 1900 the electrical driven crane with a motor for each motion [5]; by 1920
definite standards had been established for cranes in general and for various types of services; 1940 brought the enclosed gear cases, roller
bearings and standardized designs; and 1960 produced the changes in crane control which resulted in smoother operation, safer handling of load,
remote operation and new safety features for protection of equipment and personnel (Greiner, 1967).

From the cranes used in building and structural engineering works, cranes have been developed for all cadre of material handling jobs in
manufacturing and service industries. As a result, many different varieties of crane exist. Broughton (1958) grouped all cranes into four main
categories, which remain applicable today [6], as enunciated by Thompson Geoffrey (2007):

Overhead Travelling Crane: This consist of fixed rails lying on one or two elevated girders with the trolley or crane bridge (with hoisting
apparatus) that can transverse the length of the rails.

The Jib Crane: This consists of an inclined member that can rotate about a central point and suspend the load from the outer end of the inclined
member.

To Cite This Article: M.D.Sirsat, G.N.Deshpande and N.S.Dongare, DESIGN & MANUFACTURING OF
HYDRAULIC CRANE: AN OVERVIEW. Advances in Natural and Applied Sciences ;Pages: 163-166
164. M.D.Sirsat, G.N.Deshpande and N.S.Dongare,. DESIGN & MANUFACTURING OF HYDRAULIC CRANE:
AN OVERVIEW. Advances in Natural and Applied Sciences; Pages: 163-166

Gantry Crane: This is a girder or girders connected to vertical members which are either fixed or move along tracks at the base of the vertical
member, the hoisting equipment can be usually traverse the bridge girder or girders.

Cantilever or Tower: This is a vertical mast with a horizontal cantilever that rotates horizontally around the vertical member. The trolley and
hoisting equipment move along the horizontal cantilever. The hydraulic shop crane is a small cantilever crane operated manually and can be
moved in all directions through the action of the steel or rubber tires installed at the base [7,8]. Current efforts in developed countries like
Germany and the US Aare geared towards the development of automated cranes; but Nigeria is yet to develop small cranes for small and
medium scale material handling in industries.

According to a document of control engineering practice, in the context of further automation of manufacturing processes, automated
transportation of heavy weight using crane becomes more and more important. Applying the skills or Robots to crane automation, a wide market
of new applications could be developed (Sawodny et al., 2002). A wide market of applications exists awaiting the development of matching
shop cranes in Nigeria.

III. TRANSPORTATION, ERECTION AND DISMANTLING

Engineering Requirements

Some cranes have high axle loads that create high ground pressures when they travel. Ground pressures can be even higher during erection
and dismantling [9]. Tower cranes and mobile cranes positioned on structures induce significant loads. The contract documents should require
the PC/GC/CM to advise the owner or the owner's representative of these crane-imposed loads. These loads and their effects are not always
obvious. For this reason, a Professional Engineer shall determine imposed loads, evaluate the effects of those loads and design such supports as
may be required.

Transportation

Mobile cranes and tower cranes require detailed movement planning, including appropriate travel routes with considerations for width,
height, and gross vehicle weight limitations [10]. The responsible party should resolve potential problems with the appropriate transportation
authorities. This may include securing special permits.

Transportation precautions include proper tie-downs that must prevent:

load shifting during transit;

damage to sensitive components from travel vibrations; and
Tie-down damage. Cable or chain tie-downs can easily damage lattice boom chords and diagonals.

Erection

Only qualified personnel shall supervise the erection of the crane. As defined by OSHA, 29 CFR 1926.32(l) states: "Qualified" means one who,
by possession of a recognized degree [11], certificate, or professional standing, or who by extensive knowledge, training and experience, has
successfully demonstrated his ability to solve or resolve problems relating to the subject matter, the work, or the project.

Before crane erection begins, a qualified person shall carefully inspect the crane for any damage that could affect the safe operation of the
crane. Personnel who are to be erecting or jumping the crane shall be specifically trained and have a copy of the manufacturers
procedures. Boom damage caused by tie downs may not be obvious but can have serious consequences. Such damage is likely to be
unobserved during a normal inspection.

Once the crane is erected, the damage may not be visible from the ground, so special care must be taken in this regard before erection.
Casual inspection is not adequate. All bolted and pinned connections shall be checked to assure that fasteners and keepers meet manufacturers
requirements and have been correctly installed.

For tower cranes, specialty cranes and mobile cranes, an erection plan shall be required. This plan shall be a component of the Crane Safety
Plan. It must include any specific procedures needed to carry out the instructions supplied by the crane manufacturer and to adapt them to the
particular site conditions [12]. The plan shall include drawings showing clearances to all potential obstructions. The locations for unloading
shipped components shall be shown on a site drawing. Local regulations may require third party inspection and/or certification before the crane
may be operated.

Dismantling

Dismantling is not the reverse of crane erection. New permanent structures that are now close to the crane location may create conditions that
make dismantling more difficult than assembly. Therefore, it is necessary that a dismantling plan be prepared along with the assembly plan for
all tower cranes and for larger mobile and specialty cranes [13]. The plan must follow the manufacturers recommendations. Clearances shall be
carefully determined. This plan will be a component of the Crane Safety Plan.

IV. DESIGN
Both the hydraulic plunger actuation and the crane operation are built on the simple lever principle. Characteristic parameters in hydraulic
cylinder and actuating pump as well as the crane boom operations are given hereunder.
165. M.D.Sirsat, G.N.Deshpande and N.S.Dongare,. DESIGN & MANUFACTURING OF HYDRAULIC CRANE:
AN OVERVIEW. Advances in Natural and Applied Sciences; Pages: 163-166

Force of Hydraulic Cylinder

The force of a hydraulic cylinder results from the pressure in the cylinder, p, on the piston of the cylinder.

The formula
(kg) = (bar)x (cm2 ) (1)

Where

F = Force acting on the cylinder in kg p = Operating pressure in bar

A = the cylinder effective area in cm which is calculated from the piston diameter:

A(cm ) = x d2/4 (2)

Figure 1: Hydraulic Cylinder

Actuating Pump Mathematics

When a hydraulic cylinder is operated by a hand pump, the cylinder plunger moves a certain distance per pump actuation. This distance depends
on the cylinders effective area and on the pumps oil flow per stroke [14]. When two-speed hand pumps are used, the low pressure oil flow VLP
applies for cylinder movements without load and the high pressure oil flow VHP applies for cylinder movements with loads.

The formula:

S (mm) = [V (cm).10.]/A (cm) (3)

Where

S = Cylinders shift in mm

V = Pumps oil flow per stroke in cm Cylinder area in cm

The Shop Crane

Figure 2: Actuating Pump

Figure 3: Schematic Drawing of the Shop Crane

166. M.D.Sirsat, G.N.Deshpande and N.S.Dongare,. DESIGN & MANUFACTURING OF HYDRAULIC CRANE:
AN OVERVIEW. Advances in Natural and Applied Sciences; Pages: 163-166

FABRICATION PROCESS

[Part Name, Material used , process of mfg.]

1. Hand lever- (MS), Welding , Grinding, Cutting with hack Saw
2. I-section column-(MS),Gas cutting, Grinding
3. Oil Tank-(Al Alloy sheet), Cutting, Welding, Grinding

V. ASSEMBLY
The assembly of various parts of the machine follows the order stated below: Welding of the various I-Sections to produce the skeletal view
of the machine, ram incorporated with bolts and fasteners, welding of chain and hook to the top plan lever arm of the machine, seating of the
pump mechanism inside the hydraulic crane frame, positioning of the oil tank in the middle of the machine [16], lightening of the level arm to
the top of the piston using M10 bolt, welding of oil tank to the frame extension and fixing removal of rough edges and surfaces using sand
papers and wire brush, removal of dirt and oil from surfaces using kerosene, and spraying of the machine with paint to prevent corrosion and add
to the beauty aesthetic values.

VI. TESTING
After the successful fabrication of the machine, performance test was carried out on the crane, this was aimed at accessing the performance
and ease at which different loads could be raised and dropped by the crane. Form the calculations; if the effort is more than the calculated values
hence, the following losses will occur: Frictional loss, viscous loss, leakage loss, and transmission loss.

VII. FUTURE WORK

In subsequent development a robotic device should be incorporated in the machine to enable it function automatically by self-manoeuvring.
In this way there will be work station for its mode of operation. This will save time and energy because it will be faster and more efficient. It will
also help to minimize accident in the workshops and factories.

VIII. CONCLUSION
The design of the hydraulic crane involved analysis of forces acting in various member of the crane structure, analysis of the links
mechanism, determination of pressure developed in the actuator at maximum load, material selection and cost evaluation. Its fabrication details
involved some workshop operations such as marking out, cutting, machining, welding and surface treatment which was accomplished using
locally available materials. Unlike the existing design that is powered manually, a motorized system was incorporated into the crane to drive the
pump using electricity. This motorized system can also be detached and the pump is powered manually making the crane a two-way powered
system. On performance and cost evaluation bases, the machine is efficient, reliable, and cost effective.

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