History of cranes

 Ancient Greek cranes

 Ancient Roman cranes
 Medieval cranes
 Origins
 Harbor cranes
Types of cranes
 Railroad cranes
 Mobile crane
 Telescopic crane
 Tower crane
Types of cranes
 Truck-mounted

crane
 Rough terrain

crane
 Crawler crane
 Gantry crane
Types of cranes
 Floating crane
 Vessel (deck) crane
 Aerial crane
 Jib crane
OVERHEAD CRANE
OVERHEAD CRANE 12 TONS design
- Load =12 ton
 - Dimensions :

8 width & 24 length & 6 lifting distance (m)

 - Maximum speed of trolley = 0.25 m/s
 - Maximum speed of side cars = 0.25 m/s
 - Maximum speed of wire rope = 0.043 m/s lifting

speed
 - Factor of safety = 6 for all components
Parts:
 Hook
 Wire rope
 Side cars
 Trolley
 Hoist
Hook design
 Curved beam
 Take material 0.1% c steel (cd)
 Take :

 b = 70 mm
o
 bi = 200 mm
 ∴ A = 7178.05 mm2
Hook shank design
 Joint with bolt
 f.s = 6 & Sy = 470 Mpa
 σ ≤ σall

 do 2 =1912.454mm2
 d = 43.73 mm
o
 Take d = 70 mm
o
 Selection of nut
 Table (11) & M 50 height of nut = 40 mm
Hook dearing
FAG 6314 ok
C =80 KN
Co =63 KN
d = 70 mm

The thrust bearing :

At d = 70 mm
FAG 51110
Wire rope selection :
 Data
 Load = 12 ton
 Lifting speed = 2.5 m/ min = 0.0433m/s
 Hight L = 6m
 Select Wire rope [ 6 *19 – Monitor steel ]
 Su = 1600 Mpa
 Strength = 730 Mpa
 E = 80 Mpa
 Number of wires = 4
 Am (metallic area) = 0.38 d2
 Factor of safety = 7
 Assume D/dw = 800
Wire rope selection
 Total force acting on wire rope
 F = W +W +W +W
t 1 2 3 B
 W1 : dead load = 12 *103* 9.8/4 = 29400
 W2 : wire weight = 0.036 d2 *L = 0.216 d2
 W3 : Inertia load = ((w1 +w2)/2 )*a
 WB : Bending load = Am * E * dw/ D
Wire rope selection
 Design equation :
Ft ≤ Fallowable
 d = 27.246 mm
 ∴ Take d = 28 mm
 Assume Dpulley = 25 d
 ∴Take drum D = 900 mm
 Dpulley= 450mm

 Check for fatigue

∴ The wire rope is safe on fatigue
Side cars design
 Data :
 V = 15 m/min →wheel velocity
w
 Dw =150 mm →wheel diameter
 Load = 13 ton (weight +beam +carriage)
 N
motor = 1500 rpm
 µ = 0.08
 η = 95%
Selection of power
 O/Ppower = F * Vw
 = [(µ* load) *9.8 ] *Vw
 = [(0.8*13*103)*9.8 ] * 0.25
 = 2550 watt = 2.5 KW

 I/p = 2.684 Kw
 We take I/p power = 3 KW
Velovity reduction Vr

 No/p = 31.84 rpm

 Vr1= 7
 Vr2 =7
→two stages helical gears
Design of gears:
 We take :
 Uniform condition of load
 Gears are made of the same material
 Cut with high precision
 High degree of reliability
 Infinite life Infinite life
 Kt =1
First stage :
 Assumption
 Material of pinion & gear is hardened steel (Nickel- chromium 0.4% c)
 [BHN= 300 & Ses=830 Mpa & Sa= 275Mpa]
 Where:
 Np1= 20 teeth
 b1 = 10 m
 ϕt = 20 ̊ full depth
 ѱ = 20̊
 wear load Fw= 3*Ft
 Ft is tangential load
 Fw is allowable wear load
 Ѱ is helix angle (10̊ - 30̊ )
 ϕt is transverse pressure angle
 b is face width
First stage :
 From Buckingham Equation
 mt = 2.2 mm
 mn = mt *cos ѱ = 2.2 *cos 20 = 2.1 mm
 Take : mn = 3mm (standard )
 New mt = 3.19 mm
 ∴ b1 = 3.19 *10 = 32 mm
 dp1= 3.19 *20 = 64mm
 dg1 = Vr1*dp1= 7*44 = 448 mm
 Fr =Ft* tan ϕt = 217.91 N
 Fa =Ft*tan ѱ =217.91 N
First stage :
 Check for gear strength
Apply Modified Lewis Equation
 For proper design :
 σ ≤ Sd
 19 < 183.33 
 ∴ check is safe

 Check for surface durability :

Apply Modified Buckingham Equation
 For proper design :
 σc ≤ Sdc
 301.8 < 774
 ∴ check is safe
Second stage :
 Given :
 V =7
r
 n = n = 214.28 rpm
g1 p2
 O/P
power = 2.85 kW
 X= 0.5 * (d + d ) = 0.5 * (448 +64 ) = 256 mm
g2 p2

 Assumption:
 Material of pinion &gear is hardened steel
 Nickel – Chromium 0.4% C
 [BHN = 300 , Ses = 830 , Sa = 275 ]
 Np2 = 20 Teeth
 b2 = 10 * mt
 ϕt = 20̊ full depth
 Ѱ = 20̊
 Fw = 3 * Ft
Second stage :
 ∵ X = 256 = 0.5 (dg2 + dp2 )
 ∴ dp2 = 64 mm
 dg2 = 20 mm
 b2 = 10 * mt = 10 *3.2 = 32 mm
 Fw = 3* Ft = 3 * 3971.95 = 11913.136N
 Fr = Ft * tan ϕt = 1445.34 N
 Fa = Ft * tan ѱ = 1445.34 N
Second stage :
 Check for gear strength
 Apply Modified Lewis Equation
 For proper design :
 σ ≤ Sd
 113.91 < 183 .33
 ∴Check is safe

 Check for surface durability :

 Apply Modified Buckingham Equation
 For proper design :
 σc ≤ Sdc
 739.4 < 774
 ∴ check is safe
Shaft design (input) :
 Design of input shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 35 mm
Shaft design (intermediat) :
 Design of intermediate shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 40 mm
Shaft design (output):
 Design of output shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 60 mm
Bearing selection
 Fa & Fr
 C = Po*fs
o
 assume normal condition fs= 1
 ∵ C = Ks * P * (L10)1/ε
 ∴take Ks = 1 & ε = 3 ball bearing
 Assume :
 L10 = 104 hrs , 90% Reliability
Bearing selection :
Selection of bearing (A)
Take bearing FAG 6307
with C = 25.5KN
Co = 18KN

Selection of bearing (b)

Take bearing FAG 6207
with C = 19.6 KN
Co= 13.7 KN
Bearing selection :
Selection of bearing (C)
Take bearing FAG 7408N
with C = 49KN
Co = 36.5KN

 Selection of bearing (D)

Take bearing FAG 6408N
with C = 49KN
Co = 36.5KN
Bearing selection :
Selection of bearing (E)
Take bearing FAG 6412 N
with C =83KN
Co=69.5KN

Selection of bearing (F)

Take bearing FAG 6312 N
with C = 63KN
Co = 48 KN
BEARING TABLE
Bearing GRADE
A FAG 16307
B FAG 6207
C FAG 7408N
D FAG 6408N
E FAG 6412N
F FAG 6312
Side car brake design :
 Data:
 Ddrum = 120 mm θcotact = 100 ̊
 P = 3 KW b = width of band = 200 mm
 n = 30.6 rpm µ = 0.3
 FR = actuating force on right shoe
 FL = actuating force on left shoe

∑ FY = 0.0
 FR sinα = F

∑ FX = 0.0
 FR cosα = FL
 Power = Ttotal * n
 Ttotal =TL + TR
 TR = 296* 103 Pmax
 TL = 296* 103 Pmax
 Take Pmax L = Pmax R
Force required:
 F = FR sinα = 21.29 *103 *sin 18.4
 = 6720.6 N
Design of wheel of side car
 Consider two cylinders of length L and diameters d 1 &d2
 The area of contact is a rectangle of width 2b and length L

Data:
 Weight = 13 ton
 Select material o.95 % C HR plain carbon steel

 S = 750 Mpa
𝒚
 E = 200 Gpa
  
 Assume :
 L= 50 mm

 V = 15 m / min = o.25 m/s

1
 V = 0.0
2
 d =∞
2

 Take d1 = 150 mm
Trolly design
(2 stages helical gear)
 Data :
 Total load = 12.5 ton [ weight +drum + hook + wire rope]
 All gears are helical
 Assumptions:
 µ coefficient of rolling friction = 0.08
 φn normal pressure angle = 20̊
 φt =20̊ full depth
 ѱ helix angle = 20̊
 Np no of pinion teeth = 20
 ηover all for motor = 95%
 VR total velocity ratio = 36
 b face width
 Fw allowable wear load = 3 Ft
 Vr =49 total velocity ratio
Trolley design
(2 stages helical gear)
 Motor selection
 P =F*V
o/p wheel
 = µ *N * Vwheel
 Pi/p = Po/p / ηover all = 3.5 hp
 1500 rpm
Design of gears :first stage
 Assumption
 Material of pinion & gear is hardened steel (Nickel-

chromium 0.4% c)
 [BHN=300 & Ses=830 Mpa & Sa= 275Mpa]
Vr1 = 7
 From Buckingham Equation
 mt= 1.85 mm
 mn = mt1 cos ѱ = 1.76 mm
 ∴ Take mn1 = 2 mm
 ∴ New mt1 = = 2.1 mm
 ∴ b1 = 38 mm & dp1 = 42 mm
 ∴ dg1 = Vr1 * dp1 = 42 * 7 = 294 mm

 Forces acting on the first stage :

 Fw= = 2365.8 N
 Ft1 = = 788.6 N
 Fr1 = Ft1 *tan φt1 = 287.03 N
 Fa1 = Ft1 *tan ѱ = 287.03 N
 ng1 = 1500/ 7 = 214.285
 Check for strength :
275 Mpa > σ t
 ∴Check is safe

 Check on surface durability

For proper design :
 σ
c ≤ Sdc
 358.26 < 830
 ∴ check is safe
Design of gears :first stage
 Assume the material for both the pinion & gear are
Molybdenum 0.65% C
 Quenched and tempered
 BHN= 400 & Sa = 340Mpa & Ses = 1100 Mpa
 Vr2 = 7

 Forced acting on the second stage :

 Ft2 = 5520.18 N
 Fr2 = Ft2 * tan φt2 = 2009.18 N
 Fa2 = Ft2 * tan ѱ = 2009.18 N
 Check for strength :
340 Mpa > σ t
 ∴Check is safe

 Check on surface durability

For proper design :
 σ
c ≤ Sdc
 1019 < 1100
 ∴ check is safe
Design of shafts(input ):
 Design of input shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 25 mm
Design of shafts(intermediat):
 Design of intermediat shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 40 mm
Design of shafts(output ):
 Design of output shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 60 mm
Bearing selection :
BEARING GRADE
A FAG 6405
B FAG 6405
C FAG 6405
D FAG 6308
E FAG 6312
F FAG 6412
Trolley brake design :
 Data:
 Ddrum = 120 mm θcotact = 100 ̊
 P = 2.758 KW b = width of band = 200
mm
 .n = 30.6 rpm µ = 0.3
 F = actuating force on right shoe
R
 FL = actuating force on left shoe
Force required:
F = FR sinα = 19.78 *103 *sin 18.4
 = 6243.53 N
Design of wheel of Trolley
 Consider two cylinders of length L and diameters d 1 &d2
 The area of contact is a rectangle of width 2b and length L

 Data:
 Weight = 12.5 ton
 Select material o.95 % C HR plain carbon steel
 S𝒚= 750 Mpa
 E = 200 Gpa
 Assume :
 L= 50 mm
 V1 = 15 m / min = o.25 m/s
 V2 = 0.0
 d2 = ∞

Take d1 = 150 mm
Hoist design
(2 stages helical gear)
Design of gears: 1st stage
 Assumptions:
 Vr = 7
 Ѱ [ helix angle ] = 20̊
 Φn [normal pressure ] = 20̊
 Material of first stage (Ni-Cr 0.4% C quenched and tempered ) S a
= 275Mpa
 BHN = 300 Mpa , Ses =830 Mpa
 Load= 12.5 ton
 η ( efficiency of gearbox) = 0.95
 Np no of teeth of pinion =20
 np = 1500 rpm
 Buckingham Equation :
 From Buckingham Equation
 F =3F
w t
 = 2.31 mm
 Take = 2.5 mm

 .m = m cos ѱ = 2.34 mm
n t
 Take mn = 2.34mm
 ∴ d = *20 =50 mm
p1
 ∴ dg1 = Vr1 * dp1 = 42 * 7 = 294 mm
 Check for strength : 
 S = 183.33 Mpa > σ
d1 c1
 ∴ Check is safe

 Check on surface durability :

 For proper design :
 σ
c1 ≤ Sdc
 319.85 < 830
 ∴ check is safe
Design of the second stage :
 Assumptions:
 Material [ Ni-Cr 0.4% C quenched & tempered ]

BHN= 300 Mpa

 S = 830 Mpa , Sa = 275 Mpa
es
 Check on strength :
 Sd = 537.89 Mpa > σc2
 ∴Check is safe

 Check on surface durability :

 For proper design :
 σ
c2 ≤ Sdc
 808.97 < 830
 ∴ check is safe
Design of shafts : input shaft
 Design of input shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 25 mm
Design of the intermediate shaft
 Fa2= Ft2* tan ѱ2 = 10643.85 *tan 20 = 3874 N
 Fr2 = Ft2* tan ϕ2 = 10643.85 *tan 20 = 3874 N
 Design of intermediate shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 65 mm
Design of output shaft
 Design of output shaft
 Calculate forces vertical
 Calculate forces horizontal
 Max moment
 Torque

Apply ASME equation to get do

 do = 75 mm
Bearing design :
BEARING GRADE

A FAG 6405

B FAG 6405

C FAG 6413N

D FAG 6313N

E FAG 61810

F FAG 16010
Trolley brake design :
Data:
 Ddrum = 180mm θcotact = 100 ̊
 P = 5.968 KW b = width of band = 200 mm
 .n = 30.6 rpm µ = 0.3
 FR = actuating force on right shoe
 FL = actuating force on left shoe
 ∑ FY = 0.0
 FR sinα = F
 ∑ FX = 0.0
 FR cosα = FL
 Power = Ttotal * n
Force required :
 F = FR sinα = 25.469 *103 *sin 18.4
 = 8039.3 N