Design and analysis of overhead crane

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 1

• 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

Institute Of Technology, NIRMA

UNIVERSITY 2

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.

• 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)

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.

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.Cranes3.Elevators

• Conveying EquipmentIt is a group of machine which may have no lifting gear and

which move loads in a continuous flowIt can be used handle either only bulk or only unit loadIt include all types of conveyor

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.

Types of cranes

• Electric Overhead Traveling (EOT) Cranes• Gantry Cranes• Jib Cranes• Tower Cranes• Derrick Cranes• Crawler Cranes• Truck mounted Cranes

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 yardAirports, shipyards, and automobile plantsThermal power plant

2. Gantry craneUnlike 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

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

4. Tower craneIt 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.

5. Derrick craneDerrick 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.

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.

List of components used in Electric overhead traveling crane

Flexible hoisting appliancesPulleys and drumLoad handling attachmentDrives(motors)TransmissionsTransmission components (axle and shaft, bearings and step bearing)Rail and traveling wheelsMachine structure (crane frames)Control device

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)

• 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

• 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

• 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

Crane classification• Cranes have been broadly classified into M1,M2,……to M8

depending upon their duty and numbers of hours in service per year

MECHNISM CLASS

NUMBER OF HOURS IN SERVICE per YEAR

STARTING CLASSSTARTS perHOUR

RECOMMENDED CYCLIC DURATION FACTOR

M1 UP TO 1000 90 25

M2 UP TO 1000 90 25

M3 UP TO 1000 150 25

M4 UP TO 2000 150 25

M5 UP TO 2000 150 TO 300 25 TO 40

M6 2000 T0 3000 300 40

UP TO 3000UP TO 4000

300300 TO 600

MECHNISMCLASS

DESCRIPTION OF THEIR DUTY AND EXAMPLES

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,

SAME AS M6CONTINUOUS PROCESS CRANES FOR STEEL WORKS, SUCH AS CONTINUOUS MAGNET WORK, CONTINUOUS GRABBING DUTY

3-D model of single point hook

Dimensions for 100 Ton capacityL GradeFROM IS 15560:2005Shank diameter – 212 mmSeat diameter- 315 mmDepth of section- 355 mmWidth of section- 280 mmHeight of hook- 1115 mmThroat opening diameter-250 mmMaterial : class 1A steels of IS 1875 may be used for grade L

Meshing of single point hook in hypermesh

Meshing is to be done in hypermeshIn 3D tool >> tetramesh>> volumeTetramesh

types of element used in meshing2D- trias3D- tetrasElement size- 10Min element size- 2

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

3-D model of ramshorn hook

Dimensions for 100 Ton capacityFROM B.S.S. 3017Shank diameter- 162 mmSeat diameter- 225 mmDepth of section- 229 mmWidth of section- 160 mm

Stress analysis of ramshorn hook

Stress result

3-D Model of crosspiece

Stress analysis of crosspiece

Stress result

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)/9.81fprintf('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

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

otherwise disp('Invalid choice')endfprintf('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

case 5 PulleyEfficiency=.84 ropeparts=12 otherwise disp('Invalid choice')endfprintf('Pulley efficiency for given number of rope falls is=%f\n',PulleyEfficiency)total1=(rh+rd+rm)*1000*9.81total2=((rh*impactfactor)+rd)*1000*9.81w=max(total1,total2)disp('**************WIRE ROPE SELECTION***********')s=(w/(PulleyEfficiency*ropeparts))fprintf('maximum tension in rope is=%f\n',s)fo=(s*zp*Cdf)/1000fprintf('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*dfprintf('pitch of groove of drum is=%f\n',ceil(s1))Institute Of Technology, NIRMA

UNIVERSITY 32

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=1.25endfprintf('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)+10fprintf('wall thickness of drum is=%f\n',ceil(wt))h=input('Enter the height to which load is to be raised')i=ropeparts/2fprintf('ratio of pulley system is=%f\n',i)n=((h*i)/(3.14*Dd))+2fprintf('Number of turns on each side of the drim is=%f\n',ceil(n))l=((((2*h*i)/(3.14*Dd))+12)*s1)+100fprintf('full length of drum is=%f\n ',ceil(l))

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))/2fprintf('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*dfprintf('radius of groove of sheave is=%f\n',ceil(r1))depth1=1.5*dfprintf('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=1elseif Nt>=6&&Nt<=9 Crr=1.12else Nt>=10 Crr=1.25end Institute Of Technology, NIRMA

UNIVERSITY 34

fprintf('coefficient depending upon the type of receiving system is=%f\n',Crr)Ds=12*d*Cdf*Crc*Crrfprintf('Diameter of sheave measured at the bottom of groove is=%f\n',ceil(Ds))Ds1=.62*Dsfprintf('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)/4bc=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')

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)

OUTPUT:

Enter the value of Safe Working Load in tonsrh =100Enter the value of load due to dead weight of the mechanism in tonsrd =4Enter the value of hoist speed in m/minv = 2Enter the time in which above speed is to be attainedt =10a = 0.003rm = 0.0353Dynamic load arising from the acceleration or breaking of load is=0.035338Enter the class of Mechanismm =5impactfactor = 1.3200zp = 4Cdf =1.5000Impact factor for given class of mechanism is=1.320000minimum partial coefficient of utilization for given class of mechanism is=4.000000Duty factor for given class of mechanism is=1.500000

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 fallsf =5PulleyEfficiency = 0.8400ropeparts =12Pulley efficiency for given number of rope falls is=0.840000total1 = 1.0206e+006total2 = 1334160w =1334160***********************WIRE ROPE SELECTION*******************************s = 1.3236e+005maximum tension in rope is=132357.142857fo =794.1429minimum 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 2266:200238d = 38 ********************DRUM DESIGN***************************r = 21.2800radius of groove of drum is=22.000000depth = 11.4000depth of groove of drum is=12.000000s1 = 41.0400pitch of groove of drum is=42.000000

Enter 1 for 6x36 or 6x37 wire rope constriction, 2 for 6x24wire rope constriction, and 3 for 6x19wire rope constriction

c = 1Crc = 1Factor depending upon the cunstruction of wire rope is=1.000000Dd1 = 684Diameter 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 drumDd = 710Wt= 24.2000wall thickness of drum is=25.000000Enter the height to which load is to be raisedh = 28000i = 6ratio of pulley system is=6.000000n = 77.3566Number of turns on each side of the drim is=78.000000l = 6.7777e+003full length of drum is=6778.000000 ************Now check the drum in crushing**********sigmaC =133.2676Induced Crushing stress is=133.267627

***********Now check the drum in Shearing***************mt = 4.9502e+007Torque on the drum is=49501571.428571D1 = 661.6000shearstress = 2.8644Induced Shear stress is=2.864372**********Now check the drum in bending****************sigmaB = 25.9545Induced Bending stress is=25.954541****************SHEAVE DIMENSION*******************r1 = 21.2800radius of groove of sheave is=22.000000depth1 = 57depth of groove of sheave is=57.000000Enter the total number of bends in receving systemNt = 11Crr = 1.2500coefficient depending upon the type of receiving system is=1.250000Ds = 855Diameter of sheave measured at the bottom of groove is=855.000000Ds1 = 530.1000Diameter of Equalizing sheave measured at the bottom of groove is=531.000000

****************PIN DESIGN**********************Enter the value of maximum bending momentm = 102703600Enter the permissible value of bending stress for pin materialsigmaB =140Dpin = 195.5357Diameter of pin is=196.000000*******Now check the pin in bearing OR crushing**********Enter the bearing lengthlb =120crushingstress = 11.2816Induced Crushing stress is=11.281586********Now check the pin in shearing******************Enter the value of maximum shear forcesf = 529400shearstress = 8.8193Induced Shear stress is=8.819263***************CROSS PIECE DESIGN****************Enter the length of cross piecelc =476mc = 158765040Enter the width of cross piecebc = 420

Enter bearing diameter in cross piecedc = 315Enter the permissible value of bending stress for cross piece materialsigmaC = 80hc = 336.7545Height of the Cross piece is=336.754510********NOW check the cross piece trunion in bending*************Enter the thickness of side platets =38Enter the thickness of support platets1 =18mct =18678240Enter the diameter of cross piece truniondct = 200sigmaBct = 23.7939Bending stress induced in cross piece trunion is=23.793936**********NOW check the cross piece trunion in crushing***********sigmaCct = 59.5607Crushing stress induced in cross piece trunion is=59.560714*************SIDE PLATE DESIGN****************reaction1 = 7.9414e+005reaction2 =7.9414e+005

***check the side plate in tension at critical section without providing support plate****Enter the width of side plateb = 600sigmaT = 52.2462Induced 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 = 35.4528Induced Tensile stress in side plate by providing the support plate is=35.452806

Thankyou

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