Software Development for Designing and

Analysis of Major Components of

EOT Crane

By

JITENDRAKUMAR PATEL
(10MMED10)

DEPARTMENT OF MECHANICAL ENGINEERING

INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
AHMEDABAD-382481
May 2012
Software Development for Designing and
Analysis of Major Components of
EOT Crane

Major Project

Submitted in partial fulfillment of the requirements

For the degree of

Master of Technology in Mechanical Engineering

(Design Engineering)

By

JITENDRAKUMAR PATEL
(10MMED10)

Guided by
Asst.Prof. V.M. Bhojawala
Asst. Prof. D.V. Patel

DEPARTMENT OF MECHANICAL ENGINEERING

INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
AHMEDABAD-382481
May 2012
 iii

Declaration

This is to certify that

• The thesis comprises my original work towards the degree of Master of Tech-
nology in Mechanical Engineering (Design Engg.) at Nirma University and has
not been submitted elsewhere for a degree.

• Due acknowledgement has been made in the text to all other material used.

Jitendrakumar Patel
10MMED10
 iv

Undertaking for Originality of the Work

I, Jitendrakumar K. Patel, Roll. No.10MMED10 , give undertaking that the

Major Project entitled “Software Development for Designing and Analysis
of Major Components of EOT Crane.” submitted by me, towards the partial
fulfillment of the requirements for the degree of Master of Technology in Mechanical
Engineering (Design Engineering) of Nirma University, Ahmedabad, is the original
work carried out by me and I give assurance that no attempt of plagiarism has been
made. I understand that in the event of any similarity found subsequently with any
published work or any dissertation work elsewhere; it will result in severe disciplinary
action.

Signature of Student

Date:

Place: NU, Ahmedabad

Endorsed by

(Signature of Guide) (Signature of Guide)

 v

Certificate

This is to certify that the Major Project entitled “Software Development for De-
signing and Analysis of Major Components of EOT Crane” submitted by
Jitendrakumar Patel (10MMED10), towards the partial fulfillment of the re-
quirements for the degree of Master of Technology in Mechanical Engineering
(Design Engg.) of Nirma University of Science and Technology, Ahmedabad is the
record of work carried out by him under my supervision and guidance. In my opinion,
the submitted work has reached a level required for being accepted for examination.
The results embodied in this major project, to the best of my knowledge, haven’t been
submitted to any other university or institution for award of any degree or diploma.

D. V. Patel,
Co-Guide, Assistant Professor,
Department of Mechanical Engineering,
Institute of Technology,
Nirma University, Ahmedabad
V.M.Bhojawala,
Guide, Assistant Professor,
Department of Mechanical Engineering,
Institute of Technology,
Nirma University, Ahmedabad

Dr. R N Patel Dr K Kotecha

Head and Professor, Director,
Department of Mechanical Engineering, Institute of Technology,
Institute of Technology, Nirma University, Ahmedabad
Nirma University, Ahmedabad
 vi

Acknowledgements

It is indeed a pleasure for me to express my sincere gratitude to those who have al-
ways helped me throughout my project work.

First of all I like to thank my internal project guide Ass. Prof.V.M.Bhojawala and
Ass. Prof. D.V. Patel (Mechanical Engineering Department, Institute of Technology,
Nirma University) who helped me selecting the project topic, understanding of the
subject, stimulating suggestions, encouragement and also for writing of this thesis. I
am sincerely thankful for his valuable guidance and help to enhance my presentation
skills. I would also like to thank our Head of the Department Prof. R.N.Patel for pro-
viding valuable guidance and also to the Nirma University of science and technology
for providing excellent infrastructure and facilities whenever and wherever required.

Finally, I am thankful to all the faculty members of Mechanical Engineering Depart-

ment, Laboratory assistants, Library staff and all my friends, colleagues who have
directly or indirectly helped me during this project work.

Last but not the least, I would like to thank Almighty, my parents, my family mem-
bers and friends for their love, support and excellent co-operation to build my moral
during the work.

- Jitendrakumar Patel
(10MMED10)
 vii

Abstract

Material handling equipments are an eminent part of the human life. Modern
technological era cannot be imagined without various material handling equipments.
Cranes are amongst one of the material handling equipment which finds wide appli-
cations in different fields of engineering.
The present work is an effort to develop software for carrying out automated design
and analysis of major parts of EOT crane using Visual Basic 6 as platform.The de-
velopment of software has been done in two phases, first which is the development
of the automated design software while the second is to perform the detailed design
analysis of the major components of EOT crane. For the development of the user in-
terface Visual Basic 6.0 has been used. The automated FEA of the components have
been carried out by developing interface between the software and Finite Element
Analysis package ANSYS 11 using Ansys parametric development language (APDL).
This method speeds up design and reliability.
Contents

Declaration iii

Certificate v

Acknowledgements vi

Abstract vii

List of Figures xi

List of Tables xii

Nomenclature 1

1 Introduction 4
1.1 Preliminary Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Material handling equipment . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Conventional equipment . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Computer aided material handling equipment . . . . . . . . . 5
1.3 Hoisting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1 Types of Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 Electric Overhead Travelling (EOT) Cranes . . . . . . . . . . 6
1.5 Problem Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Layout of Thesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Literature Survey 8

3 Components of EOT Crane 11

3.1 List of Components of EOT Crane . . . . . . . . . . . . . . . . . . . 11
3.1.1 Load Handling Attachment . . . . . . . . . . . . . . . . . . . 11
3.1.2 Flexible Hoisting Appliances . . . . . . . . . . . . . . . . . . . 12
3.1.3 Pulleys and Drum . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.4 Drives (Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . 14

viii
CONTENTS ix

3.1.5 Transmission Components . . . . . . . . . . . . . . . . . . . . 14

3.1.6 Rail and Traveling Wheels . . . . . . . . . . . . . . . . . . . . 15
3.1.7 Machine Structure (Crane Frames) . . . . . . . . . . . . . . . 16

4 Design of Crane Major Components 18

4.1 Priliminary remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Crane Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Loading to be considered in the design of mechanism . . . . . . . . . 20
4.4 Design of Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.1 Selection of Lifting Hooks . . . . . . . . . . . . . . . . . . . . 21
4.4.2 Design of Shank . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.3 Design of Hook Section . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Wire Rope Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.1 Stresses in Wire Ropes . . . . . . . . . . . . . . . . . . . . . . 23
4.5.2 Design of Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . 24
4.6 Sheave Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.7 Wire Rope Drum Design . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.8 Girder Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.8.1 Loads acting on gantry girders . . . . . . . . . . . . . . . . . . 26

5 Software Development Method and Process Flow 29

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Software Development . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.1 Development Tools . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Organization of ANSYS software . . . . . . . . . . . . . . . . . . . . 31
5.3.1 Levels of ANSYS Software . . . . . . . . . . . . . . . . . . . . 31
5.3.2 ANSYS Analysis Approach . . . . . . . . . . . . . . . . . . . 32
5.3.3 ANSYS Processors . . . . . . . . . . . . . . . . . . . . . . . . 33
5.4 Development Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4.1 Parameters File . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.2 Visual Basic to ANSYS Interaction . . . . . . . . . . . . . . . 35
5.5 Process Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.1 Parameter Design . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.2 Element and Material Parameter . . . . . . . . . . . . . . . . 37
5.5.3 FE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.5.4 Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5.5 ANSYS Solve . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6 Automated Crane Design Software Development 39

6.1 Software Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 User Interface Development . . . . . . . . . . . . . . . . . . . . . . . 39
6.2.1 Development of GUIs . . . . . . . . . . . . . . . . . . . . . . . 39
6.2.2 Parametric File Creation . . . . . . . . . . . . . . . . . . . . . 40
CONTENTS x

6.2.3 ANSYS Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.3 Flow Base of ANSYS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.1 ANSYS Files and Processors . . . . . . . . . . . . . . . . . . . 41
6.3.2 APDL Execution . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4 FEA Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.5 EOT Crane Software architecture . . . . . . . . . . . . . . . . . . . . 43
6.6 Automated Analysis Results . . . . . . . . . . . . . . . . . . . . . . . 45
6.6.1 Hook Parametric Modelling & Analysis . . . . . . . . . . . . . 45
6.6.2 Wire Rope Drum Parametric Modelling & Analysis . . . . . . 47
6.6.3 Sheave Parametric Modelling & Analysis . . . . . . . . . . . . 48
6.6.4 Girder Parametric Modelling & Analysis . . . . . . . . . . . . 51

7 Conclusion and Future Work 54

7.1 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2 Future Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

References 56
List of Figures

3.1 Structure of overhead crane . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Section of point hook . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.2 Loads on overhead crane . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Vertical loads for maximum bending moment . . . . . . . . . . . . . . 27

5.1 Architecture of ANSYS Software . . . . . . . . . . . . . . . . . . . . 32

5.2 Process Flow for Interaction . . . . . . . . . . . . . . . . . . . . . . . 37

6.1 Crane Design Software Structure . . . . . . . . . . . . . . . . . . . . 40

6.2 Steps Involved in Typical FEA . . . . . . . . . . . . . . . . . . . . . . 42
6.3 Main GUI of Crane Design Software . . . . . . . . . . . . . . . . . . 43
6.4 HooK Design GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.5 Keypoint generation for hook design . . . . . . . . . . . . . . . . . . 45
6.6 Hook Parametric Modeling and Analysis . . . . . . . . . . . . . . . . 46
6.7 Wire Rope Drum GUI for Keypoint Generation and Analysis . . . . . 47
6.8 Wire Rope Drum Parametric Modeling and Analysis . . . . . . . . . 48
6.9 Sheave Design GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.10 Keypoint Generation for Sheave Design . . . . . . . . . . . . . . . . . 49
6.11 Sheave Parametric Modeling and Analysis . . . . . . . . . . . . . . . 50
6.12 Girder Design GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.13 Keypoint Generation for Girder Design . . . . . . . . . . . . . . . . . 52
6.14 Girder Parametric Modeling and Analysis . . . . . . . . . . . . . . . 53

xi
List of Tables

4.1 Description of crane duty, examples and duty factor [14] . . . . . . . 19

4.2 Starting class, Impact factor & Recommended cyclic duration [14] . . 20

xii
Nomenclature

Rd Loads due to the dead weight of the mechanism or component and dead
weight of Those parts of the crane acting on the mechanism or the
component under consideration
Rh Loads due to weight of hook load and also it is defined as SWL of the hook
Rhi Loads due to the weight of the hook load increased by impact factor
Rm Dynamic loading arising from the acceleration or braking of the motion
Rf Load arising from the frictional forces
Rw1 Loads due to the service wind acting horizontally in any direction where
applicable to IS 875 (part-3)
Rw2 Loads due to the out of service wind acting horizontally in any direction
where applicable to IS 875 (part-3)
Fo Minimum breaking load
Zp Maximum rope tension considering inclination of the rope in the upper
most position
Cdf Duty factor for hoist for appropriate mechanism class
Ds Diameter if sheave measured at bottom of the groove
Dd Diameter of drum measured at the bottom of the groove
d Rope diameter
Crc Factor depend upon the construction of wire rope
Crr Co-efficient depending upon the type of receiving system
σs Unit tensile stress in the shank
Q Load on the hook
A Cross-section area of the shank
d1 Minor diameter of the thread
R1 Radius of section at intrados

1
NOMENCLATURE 2

R2 Radius of section at extrados

Lm Width of the point hook section
Hm Height of the point hook section
D Seat diameter of point hook
σt Direct tensile stress at the hook section
σRi Resultant stress at the inside fiber
σRo Resultant stress at the outside fiber
σBi Maximum bending stress at the inside fiber
σBo Maximum bending stress at the outside fiber
L Length of rope drum
s Pitch of groove in rope drum
l1 Space in the middle of the drum
W Wall thickness of drum
σb Maximum bending stress in drum
τ Maximum shear stress
σc Crushing stress
σn Total normal stress
σe Combined equivalent stress
σe Bending stress
A Minimum hook approach
B Span of crane girder
L Length of gantry girder
Wc Weight of crane excluding crab
RA Reaction at point A
RC Reaction at point C
W Static wheel load
Mx Bending Moment
Z section modulus
b Wheel base
NOMENCLATURE 3

w1 Self weight of girder

w2 Weight of rail
Chapter 1

Introduction

1.1 Preliminary Remarks

Material handling equipment is employed for moving loads in premises or areas, de-
partment, factories and plants, at construction sites, point of storage and reloading,
etc. As distinct from the so-called long distance transport (railway, automobile, wa-
ter, air) moves load over a considerable distance, material handling equipment moves
loads over comparatively short distances. In practice these distance are usually conned
to ten or hundreds of meters and reach thousands of meters only occasionally to en-
sure a constant load transfer between two or several points connected by common
production activities. Handling and loading operations in each enterprise depend on
the available external and intra-plant facilities. External transporting facilities sup-
ply the enterprise with raw materials, semi finished items, fuel, auxiliary materials,
etc. And the intra-plant transporting facilities distributes the load, which come in,
throughout the enterprise, move material between processing unit directly engaged
in production and bring finished products and waste to loading points to be loaded
and shipped from the enterprise by external transporting facilities.
The transporting facilities insides the plant is in turn subdivided into inter department
and intra-department facilities. Inter department transporting facilities move loads

4
CHAPTER 1. INTRODUCTION 5

between department, for example, at a mechanical engineering plant, between blank

manufacturing, machining and auxiliary departments, as well as between department
and warehouses, loading and unloading points, etc. Intra-department transporting
facilities move loads between sections, stores, machines, etc., within the limits of one
department.

1.2 Material handling equipment

1.2.1 Conventional equipment

1. Hoisting equipment
2. Conveying equipment
3. Surface and overhead equipment

1.2.2 Computer aided material handling equipment

1. Robotics
2. Computer controlled conveyor
3. AGV

1.3 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, various parts of machines and whole machines,
elements of metal structure, hopper and ladles, girders, building blocks and materials,
etc.
Types of Hoisting equipments are:
1. Hoisting machinery
2. Cranes
3. Elevators
CHAPTER 1. INTRODUCTION 6

1.4 Cranes

1.4.1 Types of Cranes

1. Electric Overhead Traveling Crane

• Single Girder Overhead Traveling Crane
• Double Girder Overhead Traveling Crane
• Under slung Cranes

2. Gantry Crane

3. Jib Crane

4. Tower Crane

5. Derrik Crane

6. Crawler Crane

7. Truck mounted Crane

1.4.2 Electric Overhead Travelling (EOT) Cranes

Overhead travelling cranes form a vital part of industrial plants where heavy objects
require moving. Overhead travelling cranes aid in production by allowing an unin-
terrupted work process on the ground while heavy loads are moved to their required
locations. There are various configurations for EOT cranes depending on their appli-
cation, the layout of the industrial building and the type of load to be hoisted. The
configurations are bridge cranes, portal cranes and semi-portal cranes. Portal cranes
are portal frame structures where the base of the frame legs is running on rails. Semi
portal cranes are semi-portal frames where one end of the crane bridge runs on an
elevated rail and the other end is connected to a column with the base of the column
running on a lower rail. Bridge cranes are cranes where both rails are at the same
elevated level.
CHAPTER 1. INTRODUCTION 7

1.5 Problem Definition

The aim of the project is to design the major components of the Electric Overhead
Travelling Crane and to setup generalized methodology to design Electric Overhead
Crane. To develop a software using Visual Basic 6 and Ansys and interfacing between
them for design and analysis of the Electric Overhead Crane components. To pre-
pare 3-D models of major components of Electric Overhead Crane and finite element
analysis of the same has to be carried out.

1.6 Layout of Thesis

Chapter 2, gives an overview of the existing literature review on various aspect of
crane design and software developed for the same.
Chapter 3, describes in detail the components of EOT crane.
Chapter 4, provides the detail design of EOT crane major components.
Chapter 5, describes the methodology for the software development and process flow.
Chapter 6,describes the software development in order to reduce the exhaustive calcu-
lation and analysis of the design for the Electric Overhead Crane major components
by interfacing between Visual Basic 6 and Ansys 11 package.
In Chapter 7, summary and future scope are given.
Chapter 2

Literature Survey

In the design of EOT(Electric Overhead Travelling) crane , it is necessary to have

knowledge of different components used in Electric Overhead Travelling crane and
the loads on the components.Material Handling Equipment by N Rudenko [1] is the
book for EOT crane design, which covers the main aspects of EOT crane.It covers
construction of wire ropes,design procedure of pulley and drum, guideline for selecting
the motor rating and gives the idea for hook section and sets of equation to calculate
stresses induced in different section of the hook.
Development of a crane load software application for electric driven overhead travel-
ling bridge cranes by Arthur William de Waal, Stellenbosch University[2] this thesis
presents an investigation into the procedure for determining the actions induced by
overhead travelling bridge cranes adopted in the SANS 10160-6:2010 code of prac-
tice.It is conducted by developing a software application to automatically determine
the necessary crane actions needed for the design of the crane support structure, given
certain input parameters.
Solid Modeling and Finite Element Analysis of an Overhead Crane Bridge by C.
Alkin, C. E. Imrak, H. Kocabas [3] gives the finite element analysis of an overhead
crane bridge.
Failure Modes and Effects Analysis For 5 ton Acco Wright Series 32 Electric Wire
Rope Hoist by Phillip Ezzell, Crane Safety Associates of America, Inc.[4] gives the

8
CHAPTER 2. LITERATURE SURVEY 9

modes of failure of wire rope and analysis.

Automated Design Analysis of Anti-Roll Bars by Kemal Caliskan,The Middle East
Technical University[5] gives the idea about interfacing between ansys and Visual
Basic 6 from the design and analysis of Anti-Roll Bars.
Ansys Second Development Method and Application in Computer Aided Engineering
Sun Yuantao, Wang Shaomei Department of Logistics Engineering, Wuhan Univer-
sity of Technology, China[6] shows that the Visual Basic and APDL are important
development tools and are applied in the product design at the same time and the
parameter design and analysis process of the bridge girder erecting equipment is car-
ried on with Ansys software and its secondary development tools-APDL and Visual
Basics, including the interact between the mode of Ansys batch solving and Visual
Basic. The method speeds up design and enhances the product the quality and the
performance.
Design of steel structures, Prof. S.R.Satish Kumar and Prof. A.R.Santha Kumar,
IIT Madras. [7] covers steel structure design, types crane girders and loads on the
crane girders and the effect of the load on the girder.
Mechanics of Wire Rope by George A. Costello[8] Department of Theoretical and Ap-
plied Mechanics University of Illinois at Urbana-Champaign gives the loads on wire
rope pulled and bent over a sheave and stresses in wire rope.
Machine Design by Jindal U.C. [9] in this book the design of section and the stresses
in the hook are given.
The Redevelopment of Stirrer Based on ANSYS and Integration with VB Zheng Bin ,
Ying guofu October 2011, Singapore[10] The stirrer parametric model was established
by using the APDL command stream of ANSYS, and the graphical user interface was
developed by using Visual Basic programming language.
An ANSYS-Based Turbine Blade Analysis System Avinash V. Sarlashkar Girish A.
Modgil Mark L. Redding ,Impact Technologies, LLC, Rochester, NY 14623, U.S.A.[11]
BladePro is a cutting-edge example for vertical applications built on the core ANSYS
engine using ANSYS APDL and Tcl/Tk. Examples of how the program makes effec-
CHAPTER 2. LITERATURE SURVEY 10

tive use of the ANSYS preprocessor to mesh complex turbine blade geometries and
apply boundary conditions are presented using specific examples.
Implementation of Ansys Parametric Design Language for the Determination of Crit-
ical Speeds of a Fluid Film Bearing-Supported Multi-Sectioned Rotor with Residual
Unbalance Through Modal and Out-Of-Balance Response Analysis ,B. Gurudatt, S.
Seetharamu, P. S. Sampathkumaran and Vikram Krishna, London, U.K.[12] The
unbalance that exists in any rotor due to eccentricity has been used as excitation
to perform harmonic analysis to identify frequency of a system through amplitude
and phase angle plots. ANSYS parametric design language has been implemented
to achieve the results harmonic analysis to identify frequency of a system through
amplitude and phase angle plots.
Ansys Second Development Method and Application in Transient Thermal Simula-
tion, Tao Zhang School of Civiling Engineering, Dalian Jiaotong University Dalian,
China,2008[13].This paper proposes a method to enhance the computational perfor-
mance for ANSYS software. In this process, FORTRAN program is developed to
generate the input thermal parameter. Taking APDL (ANSYS Parametric Design
Language) as the secondary development for ANSYS (bridge girder), the thermal
simulation is executed though the pre-processor, solution and postprocessor modules
automatically.
Chapter 3

Components of EOT Crane

3.1 List of Components of EOT Crane

1. Load handling attachment

2. Flexible hoisting appliances
3. Pulleys and drum
4. Drives(motors)
5. Transmissions
6. Transmission components
7. Rail and traveling wheels
8. Machine structure
9. Control device

3.1.1 Load Handling Attachment

Overhead Crane which carries loads of various shapes and the load is handled by
means of chain or rope slings attached to the hook. Single point hook and Ramshorn
hooks are the two most popular designs used for this purpose and sometimes build-up
triangular hooks also used. Single point hook and Ramshorn hooks may be at-die or
closed-die forged or else made of series of shaped plates. One-piece forged hook are

11
CHAPTER 3. COMPONENTS OF EOT CRANE 12

used for lifting loads weighting up to 100 tonnes (single point hook-up to 50 tonnes
and Ramshorn hook beginning from 25 tonnes and upwards), while triangular and
laminated hooks can be employed to carry over 100 tonnes. After the forging and
machining operation hooks are carefully annealed and cleaned from scale. The inner
diameter of hooks should be sufficient to accommodate two strands of chain or rope
which carry the load. Lifting Hooks shall comply with IS 15560:2005 Point hooks
with shank up to 160 tonnes.

3.1.2 Flexible Hoisting Appliances

Steel wire ropes extensively used in hoisting machinery as flexible lifting appliance.
As compared to chains they have the following advantages
1. Lesser weight
2. Less susceptible to damage from jerk
3. Silent operation even at high working speeds
4. Greater reliability in operation

Failure in chain occurs suddenly while in wire ropes the outer wires are subjected
to more intensive wear and break before the inner wires. As a result, the wire ropes
become a fuzzy long before a rupture and should be immediately replaced. Wire ropes
cost less than chains but they require larger drums which makes the entire hoisting
mechanism heavier and more cumbersome.
Wire ropes are manufactured from steel wire with an ultimate strength of 130 to 200
kg/mm2 . In the process of manufacture the wire is subjected to special heat treat-
ment which, combined with cold drawing, imparts high mechanical property to wire
ropes. Cranes operating in dry premise utilize ropes made of bright (uncoated) wire.
Ropes intended for operation in damp premise are galvanized (zinc-coated) to protect
them against corrosion. However, the load lifting capacity of a rope with galvanized
wires is about 10 percent lower due to tempering effect of hot zinc coating. Hosting
CHAPTER 3. COMPONENTS OF EOT CRANE 13

Ropes shall conform to IS 2266:2002

3.1.3 Pulleys and Drum

Pulleys are manufactured in fixed and movable designs. Pulleys with fixed axles
are called as fixed pulley and also known as guiding pulley because they change the
direction of the hoisting appliance. Pulleys with movable axles are called as movable
pulley to which either a load or force is applied. The following shortcomings due to
direct suspension of loads from the rope end or from employing simple pulley for a
gain in force in hoisting appliances can be pointed out:

1. The rope parts are in one plane and this may cause the load to sway.

2. Larger diameter of ropes and pulley.

3. The load being lifted moves in a horizontal direction because a rope coiling on
drum moves along its length.

These shortcomings can be avoided by using multiple pulley system which rise the
load in a strictly vertical direction keeps it more stable. Moreover, one of the reasons
for the use of multiple pulley is dictated by the necessarily to reduce the load acting
on the ropes enabling thinner, less expensive ropes and pulley and drum with smaller
diameter to be employed. This reduces the size and weight of the entire mechanism.
Drum shall be made of seamless pipe as per ASTM A 106 GR A and B, cast iron
of minimum Grade 25, cast steel, rolled steel of welded construction and in case of
welded drum this should be stress relieved. Drum shall be designed to withstand the
compressive stress caused by wound of wire rope, bending stress due to beam action
and torsional stress.
CHAPTER 3. COMPONENTS OF EOT CRANE 14

3.1.4 Drives (Motor)

Various design of power drives are employed in regularly operating the cranes. Electric
drives have leadership among the various power drives available today. Electrically
driven cranes are designed to handle up to 2000 tonnes and other types of power drive
(such as hydraulic drive, pneumatic drive, steam drive, Internal Combustion Engine
drive) have more or less application. Advantages of Electric drives are:

1. Simple and cheap power supply.

2. Power used is always in proportion to the load, i.e., light loads can be handled
faster than heavy loads and motor can withstand considerable overloads.

3. Large initial torque at a relatively low power consumption.

4. Simple switchings operation.

5. Power can be stored in batteries.

The motors shall be selected to take care of loading condition and to suit the duty of
the mechanism in which it used. The motor shall be suitable for frequent reversing,
frequent acceleration and breaking.
Power is transmitted from the electric motor through the gear box to the drum on
which the hoisting rope is being wound.

3.1.5 Transmission Components

Power is transmitted from the electric motor through the gear box to the drum on
which the hoisting rope is being wound.
All the axle and shafts shall be made of steel. Shafts and axles shall have ample
strength, rigidity and adequate bearing surfaces. Suitable surface finish for stressed
portions of the shafts shall be selected having regard to sizes, stress level, severity
of stress raising fasteners and needs of bearing and seas, etc. each part of drive
shaft shall be designed to transmit torque due to the most unfavorable load position.
CHAPTER 3. COMPONENTS OF EOT CRANE 15

Bearing pedestal and mounting shall be capable of transporting the load from the
bearing to the supporting structure. Suitable provision shall be made for those cases
where the resultant load is not acting as a compression load on a bed plate. Suitable
antifriction bearing shall be used for live or fixed axles for wheels, for the shaft used
for sheaves and drums and for the shafts supporting gears. Suitable steel bushings as
used in bogie and steel bush bearing made out of phosphor bronze, cast iron or nylon
can be used for hinges or balances of crane bridge or trolley, magnet suspension, links
and grab bucket and at places where rotation is not powered.

3.1.6 Rail and Traveling Wheels

Track wheels shall have cylindrical or tapered treads. With flanges or with the help
of horizontal guide rollers they shall guide the crab or the crane effectively to prevent
derailment. The wheels shall be mounted in such a manner as to facilitate removal
and replacement.
The material for the track wheels should be of C-55 Mn 75 and also can be of steel or
wrought or shall have steel tyre shrunk on and registered with minimum hardness of
300 to 350 BHN. The steel shall not contain more than 0.06 percent either of sulphur
or phosphorus. For the light duty cranes, cast iron wheels should be prohibited. To
eliminate slipping of the drive wheels of the traveling mechanism of the crane or crab,
the design shall be checked for adhesion under the most unfavorable combination of
loads producing maximum and minimum loads on the drive wheels. The co-efficient of
adhesion shall be taken as 0.15 for dry rails and 0.1for damp rails. Traveling wheels
are checked for strength and wear, according to the theory of contact stress. The
following values of Brinell hardness for the surfaces of the traveling wheels can be
recommended depending on the operational duty of cranes: a) for light duty cranes-
170 to 200 BHN; b) for medium and heavy duty cranes - 240 to 350 BHN. Operational
practice has shown that wheels with parallel treads are subjected to rapid wear when
used in heavy duty cranes. Best performance is obtained with tapered traveling
CHAPTER 3. COMPONENTS OF EOT CRANE 16

wheels.

3.1.7 Machine Structure (Crane Frames)

Crane Girder- This is the main girder on which crab or trolley is moved from one end
to other end.
Gantry girder-Crane girder travels along the Gantry girder.
Crane girder and gantry girder are the example of laterally unsupported beams.
When the beams are not adequately supported in the lateral direction at all points,
the critical stress in lateral buckling may become less than the yield stress and the
permissible stress is correspondingly reduced. When the compression flange of the
beam is laterally unsupported the compression flange may buckle sideways, leading to
failure at or even below the elastic limit. Depending upon the load carrying Capacity
and span there two type of Crane girder generally used.

1. Plate or Box girder

2. Truss girder

Plate girder is built-up beams comprising of plate section for web and flanges when
welded connection are used. Plate girders have a moment resisting capacity between
rolled I- section and truss girders. The disadvantages of truss girder are higher vertical
clearance and costly maintenance. For light loads and short spans (¡10 meter) plate
girder are uneconomical due to increase in the connection cost and rolled I-section
are preferably provided.
CHAPTER 3. COMPONENTS OF EOT CRANE 17

Figure 3.1: Structure of overhead crane

Chapter 4

Design of Crane Major

Components

4.1 Priliminary remarks

In this chapter design of following major components of EOT carne are explained.
1. Hook
2. Wire rope
3. Sheave
4. Wire rope drum
5. Girder

4.2 Crane Classification

Cranes have been broadly classified into M1 , M2 . . . to M8 depending upon their
duty and numbers of hours in service per year.
The design of the component parts of the mechanism relating to each crane motion
shall be included with due allowance for the effects of the duty which the mechanism
will perform in service. The impact factor applied to the motion of the hook in a

18
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 19

vertical direction covers inertia forces including shock. In calculating the live loads
in the components of the mechanism, the rated hook load shall be multiplied by the
impact factor. For various classes of mechanism value of impact factor is given in
Table 4.1

Table 4.1: Description of crane duty, examples and duty factor [14]

Mechanism Description of Duty & Examples Duty Fac-

Class tor
M1 Crane or occasional use only, such as hand 1.18
and light power operated cranes
M2 Crane for occasional use only, such as en- 1.25
gine and power house crane
M3 Medium-duty industrial cranes for inter- 1.32
mittent use in maintenance shop
M4 Medium-duty industrial cranes for inter- 1.40
mittent use in stores and light machine
shop
M5 For general use in factories, workshops, 1.50
and warehouses, such as heavy duty in-
dustrial crane for non-ferrous foundries,
stockyards, railway goods yards, light iron
foundries
M6 Steelworks service and light process cranes, 1.60
heavy duty foundry works, light magnet
and grabbing duty
M7 Steelworks service and light process cranes, 1.60
heavy duty foundry works, light magnet
and grabbing duty
M8 Continuous process cranes for steel works, 1.70
such as continuous magnet work, continu-
ous grabbing duty
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 20

Table 4.2: Starting class, Impact factor & Recommended cyclic duration [14]

Mechanism Number Starting Impact Recommended

Class of hrs in Class, Factor Cyclic Duration
Service/yr Starts/hr
M1 Up to 1000 90 1.06 25
M2 Up to 1000 90 1.12 25
M3 Up to 1000 150 1.18 25
M4 Up to 2000 150 1.25 25
M5 Up to 2000 150-300 1.32 25-40
M6 2000 to 3000 150-300 1.40 40
M7 Up to 3000 300 1.50 60
M8 Up to 4000 300-600 1.50 60

4.3 Loading to be considered in the design of mech-

anism

The following load shall be taken into account when designing a crane mechanism
and its component.
Different Loading Conditions
Case 1: Normal service without wind where crane capacity equal to Rh
Vertical motion: hoisting or lowering
1. Rd + Rh + Rm + Rf
2. Rd + Rhi
Case 2: Normal service with wind
Vertical motion: hoisting or lowering
1. Rd + Rh + Rm + Rf + Rw1
2. Rd + Rhi + Rw1
Horizontal motion: traverse or travel 1. Rd + Rh + Rm + Rf + Rw1
Case 3: Crane out of service
Vertical motion: hoisting or lowering not applicable. Horizontal motion: traverse or
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 21

travel
1. Rd + Rw2
Mechanism component shall be proportioned by checking that they have adequate
safety against becoming unserviceable as a result of a single combination extreme
loading condition causing fracture, bending or other type of failures. They shall also
be checked whenever appropriate against fatigue, detection or overheating. Mecha-
nism Component are checked depending on the ultimate strength by verifying that
the calculated stress does not exceed a permissible stress dependent on the breaking
strength of the material used.

4.4 Design of Hook

4.4.1 Selection of Lifting Hooks

Single Point lifting hook is selected from IS 15560:2005 Point hooks with shank up
to 160 tonnes according to given crane capacity. Ramshorn hook is selected from IS
5749:1970 hooks according to given crane capacity.

4.4.2 Design of Shank

Design of the shank is done based on direct tensile load ,as per the formulas given in
N Rudenko for determining the diameter of the shank.

Q
σs =
A

Q = Load on the hook

A = Cross section area of the shank = π
4
× d1 2
d1 = Minor diameter of the thread
σs = Unit tensile stress in the shannk
Diameter of the shank has been found from the formulas for 5 tonnes crane capacity
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 22

is 56.5 mm

4.4.3 Design of Hook Section

Design of the hook section is shown in Figure 4.2. The various proportions for the
dimension of the hook are [9]:
R1 = Radius of section at intrados = 0.75 Hm
R2 = Radius of section at extrados = 0.125 Hm
Lm = Width of the section = 0.65 Hm
Hm = Height of the section
D = Seat diameter of hook

Figure 4.1: Section of point hook

Material of hook is Forged steel.

For 5 tonnes :
D = 84 mm
Hm = 80 mm
Lm = 52 mm
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 23

R1 = 60 mm
R2 = 10 mm
Stresses in the section of hook has been found according to Bending Stress in Curved
Beams theory for trapezoidal sections.
σt = Direct tensile stress at the hook section
σbi = Resultant stress at the inside fiber
σbo = Resultant stress at the outside fiber
σRi = Maximum bending stress at the inside fiber
σRo = Maximum bending stress at the outside fiber

σRi = σt +σbi
σRo = σt +σbo

For 5 Tonnes crane capacity stresses in the hook has been calculated are :
σt = 19.6N/mm2
σbi = 148.3N/mm2
σbo = 92.0N/mm2
σRi = 167.9N/mm2
σRo = 72.3N/mm2
Shank diameter = 56.5 mm

4.5 Wire Rope Design

4.5.1 Stresses in Wire Ropes

1. Direct stress due to axial load lifted and weight of the rope
2. Bending stress when the wire rope winds round the sheave and drum
3. Stress during operation ( starting , stopping and change in speed )
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 24

4.5.2 Design of Wire Ropes

Wire rope, unless otherwise specified or agreed by the purchaser, shall conform to
”IS 2266:2002 Steel wire rope for general engineering purpose- Specification”. Steel
core ropes with tensile designation of wires as ‘1960’ shall be used for the application
under water or in the corrosive atmosphere or while handling the hot metal. Rope
working under water and in corrosive atmosphere should be galvanized. The selection
of rope diameter shall be based on the following:
1. Group classification of the mechanism.
2. The rope receiving system employed and its efficiency.
3. Rope inclination at the upper extreme position of the hook, if the rope inclination
with respect to hoist axis exceeds 22.5 degree.
The minimum breaking load for of the rope intended for a particular duty shall be
determined from formula given below:

Fo = S × Zp × Cdf

For 60 tonnes Capacity, M5 class of mechanism minimum breaking load calculated

from the above formula is 300 KN. We can select a wire rope of 24 mm diameter of
6X24 SW construction , 1770 tensile designation.

4.6 Sheave Design

Diameter of sheave measured at the bottom of the groove shall not be less than the
value calculated with following formula:

Ds = 12 × d × Cdf × Crc × Crr

For equalizing pulley diameter measured at the bottom of the groove shall not be less
than the value calculated with following formula:
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 25

Ds = 8 × d × Cdf × Crc

Material used for the sheave is Steel Cast.

Dimensions of the sheave are found for the crane capacity of 50 Tonnes.
Diameter of the sheave measured at the bottom of the groove shall be 483 mm.
Diameter of the equalizing pulley measured at the bottom of the groove shall be 290
mm.
Radius of groove shall be 13.45 in mm
Depth of groove shall not be less than 36 mm.

4.7 Wire Rope Drum Design

The diameter of the drum measured at the bottom of the groove shall be not less
than the calculated value according to the formula given in IS 3177:1999.

Dd = 12 × d × Cdf × Crc

For 50 ton capacity Dd = 475 mm

The length of the drum,
2Hi


For one rope L = πD
+ 7 × S = 719 mm
For two ropes L = 2H


πD
i
+ 12 × S + l1
Where S = pitch and l1 is space in the middle of the drum
The wall thickness of drum w = 0.02D + (6 to 10) mm = 19.5 mm

Stresses induced in the drum are as follows :

8Fr LD
Maximum bending stress, σb = π (D4 −D1 4 )
= 3.24 N/mm2
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 26

16Mt D
Maximum shear stress, τ = π (D4 −D1 4 )
= 2.30 N/mm2
Fr
Crushing stress, σc = = 67.08 N/mm2
w×S
√
Total normal stress, σn = σb 2 + σc 2 = 67.15 N/mm2
p
Combined Equivalent stress, σe = σn 2 + 4τ 2 = 67.30 N/mm2

4.8 Girder Design

Gantry girders or crane girders carry hand operated or electric overhead cranes in
industrial buildings such as factories, steel works etc., to lift heavy materials, equip-
ment etc. and to carry them from one location to the other , within the building.
Various forces acting on gantry girder are given below:

4.8.1 Loads acting on gantry girders

Gantry girder having no lateral support in its length, has to withstand vertical loads
from the weight of the cranes, hook load and impact loads from the crane surge.
Vertical loads:
1. Weight of crane girders
2. Weight of trolly
3. Self weight of girder and rails
Lateral forces:
Lateral forces are caused due to sudden stopping and starting of the crab load when
moving over the crane bridge. The intensity of lateral load is the function of weight
of the trolly, lifting load and the acceleration of the trolly. Lateral forces are also
caused when the crane is dragging weights across the floor of the shop.
Longitudinal force(Drag force):
This is caused due to starting and stopping of the cane bridge moving over the carne
rails, as the carne moves longitudinally, i.e. in the direction of gantry girders.
Design of gantry girder for crane capacity of 25 tonnes.[20]
The loads are shown in 4.2 diagrammatically.
CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 27

Figure 4.2: Loads on overhead crane

Figure 4.3: Vertical loads for maximum bending moment

CHAPTER 4. DESIGN OF CRANE MAJOR COMPONENTS 28

Wc = weight of crane excluding crab = 200 KN

Wt = weight of crab + crane capacity = 310 KN
Maximum wheel load at A will occur when the crane hook is at a minimum distance
of a = minimum hook approach.
Wc Wt (B−a)
RA = 2
+ B
= 392.95 KN
There are two wheel loads at A ,
W = 21 RA = 196.48 KN
Static wheel load = 196.48 KN
Add impact allowance 25 % = 49.12 KN
Total W = 245.6 KN
There are two types of loading are possible based on one condition for the maximum
bending moment.
If b < 0.587(L), then distance of one wheel , from Centre of span = 14 b
If b > 0.587 (L), then one of the wheel will be at the mid span.
Self weight of girder = w1 = 1.96 KN/m
Weight of rail = w1 = 0.28 KN/m
w = w1 + w2 = 2.25 KN/m
The positions of wheel loads for maximum bending moment are shown in 4.3

RD = 193.8 KN

RC = 313.11 KN

Total = 506.94 KN
Mx (at F ) = 505.75 KN-m
Mx
Z= σbt
= 3525 × 103 mm3
Based on the obtained Z selecting the standard section of ISWB 600@133.7 kg/m
Bending stress = σbt = 134.3 N/mm2
Chapter 5

Software Development Method and

Process Flow

5.1 Introduction

The engineering environment has been revolutionized by the advent of computer tech-
nology. Computers not only enabled the engineers to perform the previously applied
design methods easier and faster, with higher precision, but also changed the methods
of design process. As an example, recent advantages in computer hardware technol-
ogy coupled with increased availability of sophisticated, user friendly Computer Aided
Engineering software, has lead to a significantly increase in the role of analysis in the
product development process. Today, various Computer Aided Design and Analysis
methods are being used, which improve the speed and quality of design.
The FEM is a numerical technique to obtain approximate solutions to a wide variety
of engineering problems where the variables are related by means of algebraic, differ-
ential and integral equations. Because of its diversity and flexibility as an analysis
tool, it is receiving much attention in industry. The number of equations is usually
rather large for most real-world applications of the FEM, and requires the computa-
tional power of the digital computer. Advances in and ready availability of computers

29
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW30

and software has brought the FEM within reach of engineers. Today, FEM is widely
used for detailed analysis step of the design process and it’s well known that, use of
Finite Element Analysis (FEA) in product development will significantly reduce cycle
time and improve product quality. However, the competitive market conditions give
rise to a new problem: Most of the companies use Finite Element Method, thus take
the advantage of using it. Therefore, a company has to use it more efficiently than
others do in order to gain a competitive advantage. Design automation with finite
element as a simulation tool is becoming more and more desired. The automation
and customization have constantly been a popular research and engineering topic.
The development of crane design software is to present a method for effective use of
general purpose FEA package programs in the design analysis, which is a requirement
in the current competitive market conditions.

5.2 Software Development

The software has been developed based on certain design parameters from the user
end via user interface. The FE Analysis for the same is performed at the back end
of the interface and the obtained results are displayed at the end of the process. The
user will not be aware about the solution process performed at the back end and hence
the knowledge regarding the FEA is not essential at the user end. The development
of software includes two phases, first of which is the development of the automated
design software while the second is to perform the detailed design analysis of the
major components of EOT crane. For the development of the user interface Visual
Basic 6.0 has been used. The FEA of the components are performed in ANSYS 11
for which the interfacing has been done with the Visual Basics 6.0 using ANSYS
Parametric Design Language (APDL).
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW31

5.2.1 Development Tools

Visual Basic 6

The user interface of the crane design software is developed in Visual Basic 6 which
is the powerful tool to create graphical user interface applications. A well designed
user interface insulates the user from the underlying technology, making it easy to
perform the task. The forms are designed in the Visual Basic 6 for the components
of the EOT crane and required for the usability of the application. The composition
of the form not only influences its aesthetic appeal, it also has a tremendous impact
on the usability of the application. Composition includes factors as positioning of
controls, consistency of elements, affordances, use of space, and simplicity of design.

ANSYS

The ANSYS program is a powerful tool which is capable of simulating problems and
used in a wide variety of engineering disciplines.
ANSYS is a widely-used software tool for structural, thermal, and fluid flow analysis.
It seems with the ANSYS macro capability, based on the versatile ANSYS Parametric
Design Language (APDL), there could likely be some benefit of developing a wide
range of flexible “canned” macros that instructors could use in many mechanical
engineering classes, which would require extremely small time and effort on the part
of the students and instructors in the classes. The results, including high level graphics
generated within the software, would supplement standard course materials.

5.3 Organization of ANSYS software

5.3.1 Levels of ANSYS Software

1.Begin Level : Gateway into and out of ANSYS and platform to utilize some global
controls such as changing the job name, etc.
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW32

Figure 5.1: Architecture of ANSYS Software

2.Processor Level: This level contains the processors that are used to conduct finite
element analysis.

5.3.2 ANSYS Analysis Approach

There are three main steps in a typical ANSYS analysis:

Model Generation

1.Simplifications, idealizations
2.Define materials/material properties
3.Generate finite element model (mesh).
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW33

Solution

1.Specify boundary conditions.

2.Obtain the solution.

Review Results

1.Plot/list results
2.Check for validity

Each of these steps corresponds to a specific processor or processors within the Proces-
sor Level in ANSYS. In particular, model generation is done in the Preprocessor and
application of loads and the solution is performed in the Solution Processor. Finally,
the results are viewed in the General Postprocessor and Time History Postprocessor
for steady-state (static) and transient (time-dependent) problems, respectively. There
are several other processors within the ANSYS program. These mostly concern op-
timization and probabilistic-type problems. The most commonly used processors are
described in the following subsections.

5.3.3 ANSYS Processors

ANSYS Preprocessor

Model generation is conducted in this processor, which involves material definition,

creation of a solid model, and, finally, meshing. Important tasks within this processor
are:
1.Specify element type
2.Define real constants (if required by the element type)
3.Define material properties
4.Create the model geometry
5.Generate the mesh
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW34

Although the boundary conditions can also be specified in this processor, it is usually
done in the Solution Processor.

ANSYS Solution Processor

This processor is used for obtaining the solution for the finite element model that is
generated within the Preprocessor, Important tasks within this processor are:
1.Define analysis type and analysis options
2.Specify boundary conditions.
3.Obtain solution.

ANSYS General Postprocessor

In this processor, the results at a specific time (if the analysis type is transient)
over the entire or a portion of the model are reviewed. This includes the plotting
of contours, vector displays, deformed shapes, and listings of the results in tabular
format.

ANSYS Time History Postprocessor

This processor is used to review results at specific points in time (if the analysis type
is transient). Similar to the General Postprocessor, it provides graphical variations
and tabular listings of results data as functions of time.

5.4 Development Method

The software interface has been developed in Visual Basic 6 by creating forms for the
design of all the major components of the EOT crane which will generate parametric
files for analysis. The interface provides data input forms to the user for specific
inputs which will be utilized for modeling and analysis of the crane components. For
execution of APDL files certain commands must be added to the “.ans” extension file
in the ANSYS setup directory. The geometry parameters are automatically created
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW35

using the formulations by specific user data input. After completing the procedure for
generation of parameter file, solution is performed by clicking the “ANSYS” button
on the interface. The interface prompts the user to wait for ANSYS to complete the
analysis. Finally the results are viewed inside the ANSYS software for the stress and
the displacements.

5.4.1 Parameters File

The parameters file is created by the user and includes the necessary analysis param-
eters of the components of the crane components. The file contains both numerical
parameters input by the user and selections among different options. Parametric file
includes all the steps from beginning to the end of the solution. The parametric file
prepared for the analysis purpose is composed in ANSYS Parametric Design Language
(APDL).The APDL file capability of the ANSYS program is used for automating the
design analysis. Using APDL information created from the software forms can be
read in for ANSYS.
APDL is a scripting language that you can use to automate common tasks or even
build the model in terms of parameters or variables. APDL commands are the script-
ing commands and encompass a wide range of other feature such as repeating a
command, macros, if-then-else branching do-loops, and scalar, vector and matrix
operations.

5.4.2 Visual Basic to ANSYS Interaction

The user interface created in the Visual Basic 6 provides data input forms for the
modeling and analysis of the crane components .The APDL file will be generated from
the Visual Basic 6, from the developed codes for generating the required parameters
in the database for the execution.
The interact code between the mode of Ansys batch solving and Visual Basic is:
“Shell C:/Program Files(x86)/ANSYSInc/v110/ANSYS/bin/intel/ansys.exe
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW36

-g -p -ansysul -i input.txt -o out.txt”

In the code, the input.txt is input APDL command file and out.txt is out file.
To solve the Finite Element model, the APDL commands file which has already been
created for the interaction between the mode of ANSYS batch solving and Visual
Basic 6 will be executed. Then the APDL command file can be solved by the mode
of ANSYS batch solving that is run by the Visual Basic command.

5.5 Process Flow

Visual Basic is a good object oriented tool. It is convenient for programmers making
the user interface to users can input various parameters. The command flows file
of APDL also will be created. So the Visual basic 6 will be the APDL translator.
Then APDL can work in the way of ANSYS batch to build FE model and analyze
the structure.
At the click event of the ANSYS button of the developed software the interaction
code for calling the ANSYS from the specified location of the database runs. After
finding the ANSYS application file, the application file of the specified”.ans” extension
from the ANSYS setup directory and the commands written in the setup file executes.
After the execution of the commands developed in the setup file the APDL file which
has been created from the outputs of user interfaces of the software executes. The
commands in the APDL file executes according to the given sequence. The user
is prompted for waiting the ANSYS to complete the process. Finally the ANSYS
window appears to the user with the desired solution of the component.

5.5.1 Parameter Design

According to the design requirement of the component the parameters are determined.
Parameters are created from the design procedure involved in the background process
of the crane design software. Some parameters are called from the IS standards which
has already been stored in the database of the M.S. Access files.
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW37

Figure 5.2: Process Flow for Interaction

5.5.2 Element and Material Parameter

The element type for the component to be modeled and analyzed is defined. The
properties of the material are defined in the material parameters. In the analysis the
material is linear and isotropic. The modulus of elasticity and the poisons ratio for
the material are defined.

5.5.3 FE Model

After defining the element and material parameters the meshing of the model created
for the analysis is created. The type of the element for the meshing and the size of
the meshed element are defined. The refinement of the mesh is done according to the
user requirements.
CHAPTER 5. SOFTWARE DEVELOPMENT METHOD AND PROCESS FLOW38

5.5.4 Work Conditions

The constraints and the loads at the specific points and surfaces are determined. The
degree of freedom of the points is defined from the codes in the APDL file. The
loads are calculated from the user interface and applied to the specified areas of the
component for the desired solution.

5.5.5 ANSYS Solve

The necessary contend of APDL is input by Visual Basic by a format. Then the
APDL command is solved by the mode of ANSYS batch solving that is run by the
Visual Basic command. The post process is aiming at the getting the results such as
the stress and the displacement of the completed analysis.
Chapter 6

Automated Crane Design Software

Development

6.1 Software Structure

Procedural design involves exhaustive calculations hence for the software has been
developed for design and analysis of the major parts of EOT crane using Visual Baisc
6 and Ansys to avoid the cumbersome calculations and analysis procedure of the
components.
In Crane Design Software there are individual GUIs for design and analysis of each
component after selecting the capacity of the EOT crane.

6.2 User Interface Development

6.2.1 Development of GUIs

The user interfaces for the different components of the crane components are designed
in the Visual Basic 6. Its includes the figures, text boxes, labels and buttons for every
component.
Crane Design Software GUIs : Log in, Design Selection, hook design, wire rope

39
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT40

Figure 6.1: Crane Design Software Structure

selection, sheave design , wire rope drum design, and girder design.

6.2.2 Parametric File Creation

Certain commands are added on the click events of the buttons for the creation of
the APDL format file in the database for the execution in ANSYS. From Visual Basic
required parameters and sequence of the commands are written in the file and the
files are generated.

6.2.3 ANSYS Run

On the click event of the ANSYS button created on the GUI of the crane design soft-
ware the interaction code between the Visual Basic and ANSYS executes. According
to the commands in the generated APDL file sequence of the commands executes and
shows the ANSYS window with the desired results.
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT41

6.3 Flow Base of ANSYS

6.3.1 ANSYS Files and Processors

ANSYS Files

Input and output are two main files for the analysis procedure which has been gen-
erated before and after the analysis process based on the developed software.
The other files created with the analysis run are,
Log file, Results file , Error file, Database file, etc.

ANSYS Processors

1.PREP7 (Build Model)

2.SOLUTION (Apply loads and obtain finite element solution)
3.POST1 (Review results over the entire model at specific time points)
4.POST26 (Review results at specific points in the model as a function of time)

6.3.2 APDL Execution

The following operations are accomplished by the commands in the APDL file:
1. /PREP7 starts pre-processor at the beginning of the file execution.
2. Element type is defined for the component.
3. Defining the material properties.
4. The keypoints are created with the coordinates written in the parameters file.
5. Keypoints are connected with straight lines.
6. By connecting close loops of lines are created for generating the desired section for
the component.
7. Areas are generated passing though the lines.
8. Volumes are generated from the existing areas.
9. Meshing of the generated volume of the component.
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT42

10. Refine the mesh.

11. Solution processor is started.
12. Analysis type is selected.
13. Applying the loading conditions
14. Solution is performed.
15. Post - processor is started.
16. Contour plots of stresses and deformed shape from different views are viewed.
17. Post - processor ends with finish command.

6.4 FEA Flow

Figure 6.2: Steps Involved in Typical FEA

CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT43

6.5 EOT Crane Software architecture

The following figure shows the home screen for the EOT crane software.
The software architecture has been developed in such a way that various component

Figure 6.3: Main GUI of Crane Design Software

designs can be performed based on individual independent design modules created

inside the software. The methodology for operation of the software has been explained
as follows for one of the component of EOT crane hook.The separate forms and
buttons have been created and the following GUI window will appear after clicking
and respective codes will run according to the given commands . This module of hook
design has been developed in such a way that the user will decide weather user wants
to perform a detailed FEA or the user is only interested in finding out the critical
dimensions of the hook only.The input parameters required for this design is the
capacity of the hook.For example if the user enters capacity 10 tonnes, the user will
input the value in crane capacity text box.Upon clicking “Calculate hook dimensions”
button, the software will calculate the basic dimensions of hook to be used is shown
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT44

Figure 6.4: HooK Design GUI

in fig.6.4. The software is also having capability of performing automatic FE analysis.

A separate button of “Update Dimensions” has been created which takes care about
this aspect.Upon clicking on this button , the GUI shown in fig.6.5 opens. Upon
clicking “Update Dimensions”, the required keypoint co-ordinate for modelling of the
crane hook will be generated as shown in fig.6.5. After kepoints generation process,
upon clicking on “Execute” button in the same GUI, an ansys parametric file will be
generated which contains the geometry details,material details as well as the loading
and boundary conditions. For the static analysis the hook geometry is constrained at
shank and the load is applied at the bottom portion of of the hook in the downward
direction. Also at the same time the static structural analysis is carried out at the back
end of the software using analysis as platform . After the completion of the execution
part, the Ansys window with the solid model of hook is displayed. Ansys window
is also customized by adding “Stress-Vonmises” and “Deformation” buttons which
provide user an easier way to visualize the stress and deformation results without
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT45

Figure 6.5: Keypoint generation for hook design

exploring the Ansys GUI as shown in fig.6.6.

6.6 Automated Analysis Results

6.6.1 Hook Parametric Modelling & Analysis

The sample analysis is performed for hook with the capacity of 5 tonnes and the com-
parison between the theoretical and automated analysis of the crane software design
has been done.
Input: Crane capacity in tonnes
Output: Model of hook for the required crane capacity, Stress and Displacement
plots
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT46

Figure 6.6: Hook Parametric Modeling and Analysis

Process flow:
1. Enter crane capacity and after that the basic dimensions will be shown on the
hook design GUI.
2. Proceeding to the update parameters GUI, the parameters will be updated with
the execute button command.
3. Analysis will be started on the single click event of ANSYS button and within some
time the analyzed result for the required hook will be displayed on ANSYS window.
Comparison : For 5 tonnes crane capacity :
Theoretical maximum stress : 167.9 N/mm2
Automated software analysis maximum stress : 146.3 N/mm2
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT47

6.6.2 Wire Rope Drum Parametric Modelling & Analysis

The sample analysis is performed for Wire rope drum with the capacity of 50 tonnes
and the comparison between the theoretical and automated analysis of the crane
software design has been done.
Input: Crane capacity in tonnes, hoist height, wire rope diameter

Figure 6.7: Wire Rope Drum GUI for Keypoint Generation and Analysis

Output: Model of wire rope Stress and Displacement plots

After selection of design for wire rope drum from the main GUI of the developed
software user have two options, for the basic dimensions of wire rope drum and for
keypoint generation, both the options are available in the Wire Rope Drum GUI
fig.6.7.
Process flow:
1. Enter crane capacity and based on that selection of the wire rope will be done on
the wire rope selection GUI.
2. Proceeding to wire rope drum design GUI and entering the hoist height the basic
dimensions of wire rope drum will be displayed and then the parameters will be
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT48

Figure 6.8: Wire Rope Drum Parametric Modeling and Analysis

updated with the execute button command.

3. Analysis will be started on the single click event of ANSYS button and within
some time the analyzed result for the required wire rope drum will be displayed on
ANSYS window fig.6.8.
Comparison : For 50 tonnes crane capacity :
Theoretical maximum stress : 67.3 N/mm2
Automated software analysis maximum stress : 72.24 N/mm2

6.6.3 Sheave Parametric Modelling & Analysis

The sample analysis is performed for sheave with the capacity of 10 tonnes and au-
tomated modelling and analysis results are obtained from the crane design software.
Input: Crane capacity in tonnes, diameter of wire rope
Output: Model of sheave, Stress and Displacement plots
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT49

Figure 6.9: Sheave Design GUI

Figure 6.10: Keypoint Generation for Sheave Design

CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT50

After selection of design for sheave from the main GUI of the developed software
user have two options, for the basic dimensions of sheave fig.6.9 and for keypoint
generation fig.6.10.
Process flow:
1. Enter crane capacity and based on that selection of the wire rope will be done on
the wire rope selection GUI.
2. Proceeding to sheave design GUI basic dimensions of sheave will be displayed and
then the parameters will be updated with the execute button command on the sheave
update parameters GUI.
3. Analysis will be started on the single click event of ANSYS button and within
some time the analyzed result for the required sheave will be displayed on ANSYS
window fig.6.11.

Figure 6.11: Sheave Parametric Modeling and Analysis

CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT51

6.6.4 Girder Parametric Modelling & Analysis

The sample analysis is performed for girder with the capacity of 10 tonnes and auto-
mated modelling and analysis results are obtained from the crane design software.
Input: Crane capacity in tonnes, weight of crab, span of crane between rails, mini-
mum hook approach, wheel base, span of gantry girder, mass of rail section.
Output: Model of girder for the required crane capacity, Stress and Displacement
plots
Process flow:

Figure 6.12: Girder Design GUI

1. Enter crane capacity and parameters according to the user requirement for the
girder design.
2. Proceeding to girder design GUI basic dimensions of girder will be displayed and
then the parameters will be updated with the execute button command on the girder
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT52

Figure 6.13: Keypoint Generation for Girder Design

update parameters. GUI.

3. Analysis will be started on the single click event of ANSYS button and within
some time the analyzed result for the required girder will be displayed on ANSYS
window fig.6.14.
After selection of design for girder from the main GUI of the developed software user
have two options, for the basic dimensions of girder as shown in fig.6.12 and for key-
point generation and FE analysis as shown fig.6.13.

Comparison : For 25 tonnes crane capacity :

Theoretical maximum stress : 134.6 N/mm2
Automated software analysis maximum stress : 96.27 N/mm2
CHAPTER 6. AUTOMATED CRANE DESIGN SOFTWARE DEVELOPMENT53

Figure 6.14: Girder Parametric Modeling and Analysis

Chapter 7

Conclusion and Future Work

7.1 Conclusion

Design of EOT crane major components has been carried out.On the basis of the
adopted design methodology,the Crane Design Software has been developed with Vi-
sual Basic 6. for carrying out automated Finite Element Analysis, the interfacing
has been developed using Ansys Parametric Development Language (APDL) with
ANSYS 11. The interaction between these two development tools has been done to
avoid the exhaustive design calculations and the whole analysis procedure of the crane
components for the required capacity.The automated analysis results from the devel-
oped software are found within permissible stress limits and closer to the theoretically
calculated stress values. This method of interaction between the user interface design
software and FEA software speeds up design and enhance the reliability of the design
procedure. The development of crane design software proposes the methodology for
effective use of general purpose FEA package programs in the design analysis, which
can prove an innovative methodology in the current competitive market conditions.

54
CHAPTER 7. CONCLUSION AND FUTURE WORK 55

7.2 Future Work

1. Automated design and analysis can be done for the all the components of the EOT
crane as well as other machine components also.
2. Optimization of the results obtained from the developed software can be done by
refining the design of the components.
3. Dynamic analysis of the EOT crane can be automated by this method of interaction
from these development tools.
References

[1] N Rudenko, Material Handling Equipment

[2] Arthur William de Waal ,Development of a crane load software application for
electric driven overhead travelling bridge cranes, Stellenbosch University,2011

[3] C. Alkin, C. E. Imrak, H. Kocabas, Solid Modeling and Finite Element Analysis
of an Overhead Crane Bridge,2005

[4] Phillip Ezzell, Failure Modes and Effects Analysis For 5 ton Acco Wright Series
32 Electric Wire Rope Hoist,Crane Safety Associates of America, Inc.,2010

[5] Kemal Caliskan, Automated Design Analysis of Anti-Roll BarsThe Middle East
Technical University,2003

[6] Sun Yuantao, Wang Shaomei, Ansys Second Development Method and Application
in Computer Aided Engineering, Wuhan University of Technology, China

[7] Prof. S.R.Satish Kumar and Prof. A.R.Santha Kumar, Design of steel structures,
IIT Madras

[8] George A. Costello, Mechanics of Wire Rope”,Department of Theoretical and

Applied Mechanics University of Illinois at Urbana,2003

[9] Jindal U.C,Machine Design.

[10] Zheng Bin , Yin guofu,The Redevelopment of Stirrer Based on ANSYS and In-
tegration with VB,Singapore,2011

56
REFERENCES 57

[11] Avinash V. Sarlashkar Girish A. Modgil Mark L. Redding,An ANSYS-Based

Turbine Blade Analysis System,U.S.A

[12] B. Gurudatt, S. Seetharamu, P. S. Sampathkumaran and Vikram Kr-

ishna,Implementation of Ansys Parametric Design Language for the Determina-
tion of Critical Speeds of a Fluid Film Bearing-Supported Multi-Sectioned Rotor
with Residual Unbalance Through Modal and Out-Of-Balance Response Analy-
sis,London,2010

[13] Dalian Jiaotong University Dalian,Ansys Second Development Method and Ap-
plication in Transient Thermal Simulation”Tao Zhang School of Civiling Engi-
neering,China,2008

[14] EOT crane are designed as per IS 3177 : 1999 Code of practice for electric
overhead travelling cranes and gantry cranes other than steel work cranes (second
revision)

[15] IS 2266 : 2002 Steel wire rope for general engineering purpose Specification

[16] IS 15560 : 2005 Point hooks with shank up to 160 tonnes Specification (Merging
of IS 3815, 6294 and 8610)

[17] IS 5749 : 1970 Specification for Forged ram shorn hooks are used in selection
hook.

[18] Design of crane girder is satisfies the IS 807:2006 Design, Erection, and Testing
(structural portion) of Crane and also IS 800:1984 Code of practice for general
construction in steel

[19] IS : 3443 1980, Indian Standard Specification for Crane Rail Sections.

[20] Dr B.C Punmia,Compreshensive Design of Steel Structures, 2006.