HYDRAULIC FLOOR CRANE

360 DEGREE

SYNOPSIS
 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.
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 create mechanical 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, 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. Inner and outer
boom is suitably reinefoast the bow structure for better distribution of force. Inner boom has
3 locking points telescopes into the outer boom with 360° rotating forged steel hook. Moving
on 4 Nos wheels, two wheels are fixed and two wheels are on swivel castors easy directional
movement and all wheels are equipped with sealed ball bearing / tapper roller bearings for
better mobility. 2 Nos screw disc ground arrested are provided to prevent movement when
transfer of load track. The hydraulic crane was invented in Newcastle by William Armstrong
in about 1845 to help load coal into barges at the Quayside.
 MAIN COMPONENTS & DESCRIPTIONS

Components of hydraulic floor crane 360 degree

1. Base plate/ Truck/Pallet

2. Hydraulic tank
3. Hydraulic hoses
4. Direction control valve
5. Vertical column
6. Ball bearings
7. Horizontal arm
8. Secondary horizontal arm
9. Hydraulic cylinder
10. Hook
11. Nuts and Bolts
12. Wheels
13. Viper motor

1. Base plate/ Truck/Pallet:-

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.

2. Hydraulic tank:- It is filled with engine oil. It consists of an A.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 4 litre.

3. Hydraulic hose:- These are for carrying the fluid (Engine Oil) 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 can sustain fluid
pressure in ranges from 180 bar – 350 bar. 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 four hoses for various
applications. There are separate hoses for suction, pressure, flow, and return
of fluid.
4. Direction control valve:- This is a Lever operated 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.

5. 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 360◦ rotation of the column so that the load can be
dropped at the required position. It consists of roller bearing at the base in
the circumferential manner to reduce friction at the time of rotating the
vertical column.

6. Thrust ball bearings:- Ball bearings are called as ‘anti friction bearings’.
This is a misnomer because friction is always present in such bearings,
mainly owing to rolling resistance between the balls or rollers and the race. It
carries the vertical thrust and axial load.

7. Horizontal arm:-It is fixed horizontal arm on which our hydraulic piston

and cylinder is mounted. It is fixed with the vertical column with welded
joint which can rotate with the rotating vertical column to 360° rotation.

8. Secondary horizontal arm:-It is horizontal arm which can move in up and

down with the load or without the load. A is fixed to it through which we can
attach the load.

9. 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.

10. 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.

11. Nuts and Bolts: Nuts and bolts are the hardware fasteners which are used
to fasten the various different parts .in our project we have used around 20
nut and bolts.

12. Wheels:- A wheel is a circular component that is intended to rotate on an

axial bearing. The 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 supporting a load, or performing labor in machines. In
our project we are using four wheels of diameter 12cm.
13. Viper motor:-
 1.3Types of hydraulic crane:-

a. Truck Cranes
b. Crawler-Mounted Cranes
c. Overhead crane
d. Tower Cranes

1.4 ADVANTAGES:-
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 effort from one place to another, and
hydraulic cranes are amongst the most efficient lifting systems available in the
modern workplace.
2. Extremely 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.

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.
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.
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.
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.

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.

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 the mechanical 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 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.

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
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.
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 20kg which is capable of lifting load
up to 10kg using hydraulic power.