DESIGN AND ANALYSIS OF 100 TON

CAPACITY OVERHEAD CRANE

Prepared By:
Dudia Anand
M.Tech(cad/cam)
08MME003

Guided By:
Dr. D.S.Sharma
Institute Of Technology, NIRMA
UNIVERSITY

Index

Motivation
Scope
Introduction
Types of material handling equipment
Crane definition
Types of cranes
List of components used in Electric overhead traveling crane
Indian standards used in design of component
Crane classification
Modeling, Meshing, and Analysis
Matlab Progaramme and its Output

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Motivation

During my tenure of Industrial Summer Training at Safex

Equipment Private Limited(At vatava GIDC, phase-4,
Ahemadabad) I found that they are Designing and
manufacturing an Overhead Crane of generally from 3 to 60
Ton Capacity.
So, under the Experience and Guidance of both our faculty
member professor D.S.Sharma and Mr. Alpesh Patel who is
the Design Manager of Safex Equipment Private Limited, I
am Designing the Overhead Crane of 100 Ton Capacity and
also I thought to give my sincere and through effort in this
direction.

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Scope

Design of overhead carne system as per required IS(Indian

Standard) code

After that carry out FEA analysis of each and every part
either with the help of Hypermesh or Ansys Software

To study the Dynamic Response of an Overhead Crane

System this include the investigation of the influence of
traverse motion(carriage travel) and travel motion(beam
girder travel) on the pendulum motion And also to study
the influence of pendulum length and payload mass on the
pendulum motion(swing of the pendulum)

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Introduction
Material handling equipment is employed for moving loads
in premises or areas, department, factories and palnts, at
construction sites, point of storage and reloading, etc.
As distinct from the so-called long distance
transport(railway, automobile, water, air) moves load over
a considerable distance, material handling equipment
moves loads over comparatively short distances.

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Types of Material Handling Equipment

Hoisting Equipment
It is a group of machine with lifting gear intended for moving
loads mainly in batches
It is intended mainly for unit loads
1.Hoisting machinery
2.Cranes
3.Elevators

Conveying Equipment
It is a group of machine which may have no lifting gear and
which move loads in a continuous flow
It can be used handle either only bulk or only unit load
It include all types of conveyor

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Cranes

A crane is a machine that is capable of raising and lowering

heavy object and, while holding them suspended,
transporting them through limited lateral distance.
Cranes are distinguished from hoists, which can lift objects
but that cannot move them sideways.
Cranes are also distinguished from conveyors, that lift and
move bulk materials, such as grain and coal, in a
continuous process.
The word crane is taken from the fact that these machines
have a shape similar to that of the tall, long-necked bird of
the same name.

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Types of cranes

Electric Overhead Traveling (EOT) Cranes

Gantry Cranes
Jib Cranes
Tower Cranes
Derrick Cranes
Crawler Cranes
Truck mounted Cranes

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1. Electric Overhead Traveling Crane

Overhead traveling cranes operate using three motorized
movements ( lifting, trolley traverse, and bridge traverse ),
which provide handling within the volume of space under the
crane.
Application:
Storing and moving steel products in storage yard
Airports, shipyards, and automobile plants
Thermal power plant

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2. Gantry crane

Unlike EOT cranes, Goliath cranes run on gantry rails

mounted on floor level. The bridge girders are supported
on a pair of legs which are supported on end carriages .
Application:
Extremely used in shipyards and industrial installation

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3. Jib crane

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.
Application:
Jib cranes are used in industrial premises and on military
vehicles

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4. Tower crane

It is a crane of fixed type which by virtue of height of its

supporting tower frame is capable of hoisting, luffing, and
slewing its loads over high obstruction.
Application:
most widely used in construction of tall building.

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5. Derrick crane

Derrick is a strut with guys so arranged as to permit of

inclination of strut in any direction, the load being raised or
lowered by a hoisting mechanism.

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6. Crawler crane
A crawler is a crane mounted on an undercarriage with a set
of tracks (also called crawlers) that provide stability and
mobility.

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List of components used in

Electric overhead traveling crane
Flexible hoisting appliances
Pulleys and drum
Load handling attachment
Drives(motors)
Transmissions
Transmission components (axle and shaft, bearings
and step bearing)
Rail and traveling wheels
Machine structure (crane frames)
Control device
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Indian standards used in design of

component listed in previous slide

IS 807:2006 Design, erection and testing (structural

portion) of cranes and hoists code of practice (Second
revision)

IS 3177:1999 Code of practice for electric overhead

travelling cranes and gantry cranes other than steel work
cranes (second revision)

IS 5749:1970 Specification for Forged ram shorn hooks

IS 15560:2005 Point hooks with shank upto 160 tonnes Specification(Merging of IS 3815, 6294 and 8610)

IS 6132:2003 Forged shackles for general lifting purposes

Dee shackles and Bow shackles (merging IS 6132 Pt 1, Pt 2
and Pt 3)
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IS 8686:1995 Cranes - Design principles for loads and load

combinations - Part 5 Overhead travelling and portal bridge
cranes

IS 13156:1991 Sheave pulley blocks for wire rope_Specification

IS 4137 Specification for sheave assembly for EOT cranes

IS 13558:1993 Cranes - Controls - Layout and

characteristics: Part 5 Overhead travelling cranes and
postal bridge cranes

IS 13834:1993 Cranes - Classification: Part 5 Overhead

travelling and portal bridge cranes

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IS 14467:1997

Cranes - Wind load assessment

IS 14470:1997 Cranes - Test code and procedures

IS 2315:1978 Thimbles for wire ropes (first revision)

IS 2361:2002 Bulldog grips - Specification (third revision)

IS 2485:1979 Drop forged sockets for wire ropes for

general engineering purposes (first revision)

IS 2266:2002 Steel wire rope for general engineering

purpose- Specification

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IS 3973:1984 Code of practice for the selection,

installation and maintenance of wire ropes

IS 2365:1977 Specification for steel wire suspnesion ropes

for lifts, Elevator, and hoists

IS 3938:1983 Specification for electric wire rope hoist

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Crane classification
Cranes have been broadly classified into M1,M2,to M8
depending upon their duty and numbers of hours in service
per year
MECHNIS
M CLASS

NUMBER
OF
HOURS IN
SERVICE
per
YEAR

STARTING
CLASS
STARTS
per
HOUR

RECOMMEN
DED CYCLIC
DURATION
FACTOR

M1

UP TO
1000

90

25

M2

UP TO
1000

90

25

M3

UP TO
1000

150

25

M4

UP TO
150
2000
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M5

UP TO

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150 TO 300 25 TO 40

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MECHNIS DESCRIPTION OF THEIR DUTY AND EXAMPLES

M
CLASS
M1

CRANE FOR OCCASIONAL USE ONLY, SUCH AS HAND AND

LIGHT POWER OPERATED CRANES

M2

CRANE FOR OCCASIONAL USE ONLY, SUCH AS ENGINE

AND POWER HOUSE CRANE

M3

MEDIUM-DUTY INDUSTRIAL CRANES FOR INTERMITTENT

USE IN MAINTANANCE SHOP

M4

MEDIUM-DUTY INDUSTRIAL CRANES FOR INTERMITTENT

USE IN STORES AND LIGHT MACHINE SHOP

M5

FOR GENERAL USE IN FACTORIES, WORKSHOPS, AND

WAREHOUSES, SUCH AS HEAVY DUTY INDUSTRIAL CRANE
FOR NON-FERROUS FOUNDRIES, STOCKYARDS, RAILWAY
GOODS YARDS, LIGHT IRON FOUNDRIES

M6

STEELWORKS SERVICE AND LIGHT PROCESS CRANES,

HEAVY DUTY FOUNDARY WORKS, LIGHT MAGNET AND
GRABBING DUTY,

M7
M8

SAME AS M6
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SUCH AS CONTINUOUS MAGNET WORK, CONTINUOUS

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3-D model of single point hook

Dimensions for 100 Ton capacity

L Grade
FROM IS 15560:2005
Shank diameter 212 mm
Seat diameter- 315 mm
Depth of section- 355 mm
Width of section- 280 mm
Height of hook- 1115 mm
Throat opening diameter-250 mm
Material : class 1A steels of
IS 1875 may be used for grade L

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Meshing of single point hook in hypermesh

Meshing is to be done in hypermesh

In 3D tool >> tetramesh>> volume
Tetramesh
types of element used in meshing
2D- trias
3D- tetras
Element size- 10
Min element size- 2

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Stress analysis of single point hook

Result of the analysis indicate

that max stress is induced at
the intrados of single point hook
Max stress- 140 N/mm2

Stress result

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3-D model of ramshorn hook

Dimensions for 100 Ton capacity

FROM B.S.S. 3017
Shank diameter- 162 mm
Seat diameter- 225 mm
Depth of section- 229 mm
Width of section- 160 mm

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Stress analysis of ramshorn hook

Stress result

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3-D Model of crosspiece

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Stress analysis of crosspiece

Stress result

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Matlab Programme
rh=input('Enter the value of Safe Working Load in tons')
rd=input('Enter the value of load due to dead weight of the mechanism in tons')
v=input('Enter the value of hoist speed in m/min')
t=input('Enter the time in which above speed is to be attained')
a=v/(t*60)
rm=((rh+rd)*a)/9.81
fprintf('Dynamic load arising from the acceleration or breaking of load is=%f\n',rm)
m=input('Enter the class of Mechanism')
switch(m)
case 1
impactfactor=1.06
zp=4
Cdf=1.18
case 2
impactfactor=1.12
zp=4
Cdf=1.25
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case 3
impactfactor=1.18
zp=4
Cdf=1.32
case 4
impactfactor=1.25
zp=4
Cdf=1.40
case 5
impactfactor=1.32
zp=4
Cdf=1.50
case 6
impactfactor=1.40
zp=4
Cdf=1.60
case 7
impactfactor=1.40
zp=6
Cdf=1.60
case 8
impactfactor=1.50
zp=6
Cdf=1.70

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otherwise
disp('Invalid choice')
end
fprintf('Impact factor for given class of mechanism is=%f\n',impactfactor)
fprintf('minimum partial coefficient of utilization for given class of mechanism is=%f\n',zp)
fprintf('Duty factor for given class of mechanism is=%f\n',Cdf)
f=input('Enter the number of falls used 1 for 4 falls, \n 2 for 6 falls, \n 3 for 8 falls, \n 4 for 10
falls, \n 5 for 12 falls')
switch(f)
case 1
PulleyEfficiency=.94
ropeparts=4
case 2
PulleyEfficiency=.92
ropeparts=6
case 3
PulleyEfficiency=.90
ropeparts=8
case 4
PulleyEfficiency=.87
ropeparts=10

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case 5
PulleyEfficiency=.84
ropeparts=12
otherwise
disp('Invalid choice')
end
fprintf('Pulley efficiency for given number of rope falls is=%f\n',PulleyEfficiency)
total1=(rh+rd+rm)*1000*9.81
total2=((rh*impactfactor)+rd)*1000*9.81
w=max(total1,total2)
disp('**************WIRE ROPE SELECTION***********')
s=(w/(PulleyEfficiency*ropeparts))
fprintf('maximum tension in rope is=%f\n',s)
fo=(s*zp*Cdf)/1000
fprintf('minimum breaking load is=%f\n',fo)
disp('**Now select the rope from IS 2266:2002 accorading to minimum breaking load*')
d=input('enter the wire rope diameter from IS 2266:2002')
disp('****************DRUMDESIGN*****************')
r=(.56*d)
fprintf('radius of groove of drum is=%f\n',ceil(r))
depth=(.3*d)
fprintf('depth of groove of drum is=%f\n',ceil(depth))
s1=1.08*d
fprintf('pitch of groove of drum is=%f\n',ceil(s1))
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c=input('Enter 1 for 6x36 or 6x37 wire rope constriction, \n 2 for 6x24wire rope
constriction, and \n 3 for 6x19wire rope constriction')
switch(c)
case 1
Crc=1
case 2
Crc=1.12
case 3
Crc=1.25
end
fprintf('Factor depending upon the cunstruction of wire rope is=%f\n',Crc)
Dd1=(12*d*Cdf*Crc)
fprintf('Diameter of drum measured at the bottom of groove is=%f\n',Dd1)
disp('***now select the standardised dimension of drum diameter from IS 3177:1999***')
Dd=input('Enter the standardised diameter of drum')
wt=(.02*Dd)+10
fprintf('wall thickness of drum is=%f\n',ceil(wt))
h=input('Enter the height to which load is to be raised')
i=ropeparts/2
fprintf('ratio of pulley system is=%f\n',i)
n=((h*i)/(3.14*Dd))+2
fprintf('Number of turns on each side of the drim is=%f\n',ceil(n))
l=((((2*h*i)/(3.14*Dd))+12)*s1)+100
fprintf('full length of drum is=%f\n ',ceil(l))
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disp('********Now check the drum in crushing******')

sigmaC=(s/(wt*s1))
fprintf('Induced Crushing stress is=%f\n',sigmaC)
disp('*******Now check the drum in Shearing*******')
mt=(s*(Dd+d))/2
fprintf('Torque on the drum is=%f\n',mt)
D1=Dd-(2*wt)
shearstress=(16*mt*Dd)/(3.14*((Dd^4)-(D1^4)))
fprintf('Induced Shear stress is=%f\n',shearstress)
disp('******Now check the drum in bending********')
sigmaB=(8*s*l*Dd)/(3.14*((Dd^4)-(D1^4)))
fprintf('Induced Bending stress is=%f\n',sigmaB)
disp('********SHEAVE DIMENSION**************')
r1=.56*d
fprintf('radius of groove of sheave is=%f\n',ceil(r1))
depth1=1.5*d
fprintf('depth of groove of sheave is=%f\n',ceil(depth1))
Nt=input('Enter the total number of bends in receving system')
if Nt<=5
Crr=1
elseif Nt>=6&&Nt<=9
Crr=1.12
else Nt>=10
Crr=1.25
end
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fprintf('coefficient depending upon the type of receiving system is=%f\n',Crr)

Ds=12*d*Cdf*Crc*Crr
fprintf('Diameter of sheave measured at the bottom of groove is=%f\n',ceil(Ds))
Ds1=.62*Ds
fprintf('Diameter of Equalizing sheave measured at the bottom of groove is=%f\n',ceil(Ds1))
disp('*******PIN DESIGN********')
m=input('Enter the value of maximum bending moment')
sigmaB=input('Enter the permissible value of bending stress for pin material')
Dpin=((32*m)/(3.14*sigmaB))^(1/3)
fprintf('Diameter of pin is=%f\n',ceil(Dpin))
disp('***Now check the pin in bearing OR crushing***')
lb=input('Enter the bearing length')
crushingstress=((2*s)/(Dpin*lb))
fprintf('Induced Crushing stress is=%f\n',crushingstress)
disp('***Now check the pin in shearing***')
sf=input('Enter the value of maximum shear force')
shearstress=((2*sf)/(3.14*Dpin*Dpin))
fprintf('Induced Shear stress is=%f\n',shearstress)
disp(****CROSS PIECE DESIGN*****')
lc=input('Enter the length of cross piece')
mc=(w*lc)/4
bc=input('Enter the width of cross piece')
dc=input('Enter bearing diameter in cross piece')
sigmaC=input('Enter the permissible
value of bending stress for cross piece material')
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hc=((6*mc)/((bc-dc)*sigmaC))^(1/2)
fprintf('Height of the Cross piece is=%f\n',hc)
disp('***NOW check the cross piece trunion in bending***')
ts=input('Enter the thickness of side plate')
ts1=input('Enter the thickness of support plate')
mct=(w/2)*((ts+ts1)/2)
dct=input('Enter the diameter of cross piece trunion')
sigmaBct=(mct*32)/(3.14*dct*dct*dct)
fprintf('Bending stress induced in cross piece trunion is=%f\n',sigmaBct)
disp('***NOW check the cross piece trunion in crushing***')
sigmaCct=w/(2*dct*(ts+ts1))
fprintf('Crushing stress induced in cross piece trunion is=%f\n',sigmaCct)
disp('***SIDE PLATE DESIGN***')
reaction1=w/( PulleyEfficiency*2)
reaction2=w/( PulleyEfficiency*2)
disp('check the side plate in tension at critical section without providing support plate')
b=input('Enter the width of side plate')
sigmaT=((reaction1)/((b-dct)*ts))
fprintf('Induced Tensile stress in side plate without providing support plate is=%f\n',sigmaT)
disp('check the side plate in tension at critical section by providing support plate')
sigmaT1=((reaction1)/((b-dct)*(ts+ts1)))
fprintf('Induced Tensile stress in side plate by providing the support plate is=%f\n',sigmaT1)
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OUTPUT:
Enter the value of Safe Working Load in tons
rh =100
Enter the value of load due to dead weight of the mechanism in tons
rd =4
Enter the value of hoist speed in m/min
v=2
Enter the time in which above speed is to be attained
t =10
a = 0.003
rm = 0.0353
Dynamic load arising from the acceleration or breaking of load is=0.035338
Enter the class of Mechanism
m =5
impactfactor = 1.3200
zp = 4
Cdf =1.5000
Impact factor for given class of mechanism is=1.320000
minimum partial coefficient of utilization for given class of mechanism is=4.000000
Duty factor for given class of mechanism is=1.500000
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Enter the number of falls used 1 for 4 falls, 2 for 6 falls, 3 for 8 falls, 4 for 10 falls, 5 for 12 falls
f =5
PulleyEfficiency = 0.8400
ropeparts =12
Pulley efficiency for given number of rope falls is=0.840000
total1 = 1.0206e+006
total2 = 1334160
w =1334160
***********************WIRE ROPE SELECTION*******************************
s = 1.3236e+005
maximum tension in rope is=132357.142857
fo =794.1429
minimum breaking load is=794.142857
******Now select the rope from IS 2266:2002 accorading to minimum breaking load*******
enter the wire rope diameter from IS 2266:200238
d = 38
********************DRUM DESIGN***************************
r = 21.2800
radius of groove of drum is=22.000000
depth = 11.4000
depth of groove of drum is=12.000000
s1 = 41.0400
pitch of groove of drum is=42.000000
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Enter 1 for 6x36 or 6x37 wire rope constriction, 2 for 6x24wire rope constriction, and 3 for
6x19wire rope constriction
c=1
Crc = 1
Factor depending upon the cunstruction of wire rope is=1.000000
Dd1 = 684
Diameter of drum measured at the bottom of groove is=684.000000
***now select the standardised dimension of drum diameter from IS 3177:1999***
Enter the standardised diameter of drum
Dd = 710
Wt= 24.2000
wall thickness of drum is=25.000000
Enter the height to which load is to be raised
h = 28000
i= 6
ratio of pulley system is=6.000000
n = 77.3566
Number of turns on each side of the drim is=78.000000
l = 6.7777e+003
full length of drum is=6778.000000
************Now check the drum in crushing**********
sigmaC =133.2676
Induced Crushing stress is=133.267627
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***********Now check the drum in Shearing***************

mt = 4.9502e+007
Torque on the drum is=49501571.428571
D1 = 661.6000
shearstress = 2.8644
Induced Shear stress is=2.864372
**********Now check the drum in bending****************
sigmaB = 25.9545
Induced Bending stress is=25.954541
****************SHEAVE DIMENSION*******************
r1 = 21.2800
radius of groove of sheave is=22.000000
depth1 = 57
depth of groove of sheave is=57.000000
Enter the total number of bends in receving system
Nt = 11
Crr = 1.2500
coefficient depending upon the type of receiving system is=1.250000
Ds = 855
Diameter of sheave measured at the bottom of groove is=855.000000
Ds1 = 530.1000
Diameter of Equalizing sheave measured at the bottom of groove is=531.000000
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****************PIN DESIGN**********************
Enter the value of maximum bending moment
m = 102703600
Enter the permissible value of bending stress for pin material
sigmaB =140
Dpin = 195.5357
Diameter of pin is=196.000000
*******Now check the pin in bearing OR crushing**********
Enter the bearing length
lb =120
crushingstress = 11.2816
Induced Crushing stress is=11.281586
********Now check the pin in shearing******************
Enter the value of maximum shear force
sf = 529400
shearstress = 8.8193
Induced Shear stress is=8.819263
***************CROSS PIECE DESIGN****************
Enter the length of cross piece
lc =476
mc = 158765040
Enter the width of cross piece
bc = 420
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Enter bearing diameter in cross piece

dc = 315
Enter the permissible value of bending stress for cross piece material
sigmaC = 80
hc = 336.7545
Height of the Cross piece is=336.754510
********NOW check the cross piece trunion in bending*************
Enter the thickness of side plate
ts =38
Enter the thickness of support plate
ts1 =18
mct =18678240
Enter the diameter of cross piece trunion
dct = 200
sigmaBct = 23.7939
Bending stress induced in cross piece trunion is=23.793936
**********NOW check the cross piece trunion in crushing***********
sigmaCct = 59.5607
Crushing stress induced in cross piece trunion is=59.560714
*************SIDE PLATE DESIGN****************
reaction1 = 7.9414e+005
reaction2 =7.9414e+005
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***check the side plate in tension at critical section without providing support plate****
Enter the width of side plate
b = 600
sigmaT = 52.2462
Induced Tensile stress in side plate without providing support plate is=52.246241
*****check the side plate in tension at critical section by providing support plate*****
sigmaT1 = 35.4528
Induced Tensile stress in side plate by providing the support plate is=35.452806

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Thankyou

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