ADAMA AGRICULTURUL MACHINARY

MANUFACTURING INDUSTRIES

Design &fabrication of hydraulic floor crane

HARAMAYA UNIVERSITY

PROPOSED BY BIRUK TESHOME

5/24/2021

SUBMITED TO MR. YARED

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page
 Design &fabrication of hydraulic floor crane
2021

Acknowledgement

Firstly, we would like to thank the almighty God for giving us strength, endurance and
knowledge to complete this research Proposal work successfully. After the completion of this
work, we would like to give our sincere thanks to all those who helped us to reach our goal.
We would like to express our heartfelt appreciation and thanks to our advisor Mr. Biruk Hailu
and also our company adviser Mr.Yared. in addition to these Mr Getenet who advised us
during our works I would thanks him for his help. And also We would like to thank to all
mechanical Engineering staff members.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page i

 Design &fabrication of hydraulic floor crane
2021

Abstract

Our project is concerns about design and manufacture of hydraulic floor crane .this machine
is used in many industries .hydraulic floor crane is small lifting and material handling
equipment used in engineering work shops as well as in god owns and Warehouses .this
crane is used for lifting various style of materials with in the segment were ever frequently
lifting and handling of material activity needed this material handling crane manually
operated however ,electrical power is usually needed for lifting operation according to the
needed .special kind of crane are utilized in positioning the cameras in shootings .hydraulic
jib crane works on the principles Pascal’s law. when the handle is operated, the plunger is
reciprocating then the oil from the reservoir is sacked into the hydraulic cylinder during
upward stroke of the plunger .this pressurized oil lifts the load up, which is placed on the
crane arm .After the work is completed the pressure within the cylinder is discharged by
unscrewing the lowering screw therefore the pressure release and also the ram is lowered,
then the oil is rushed into the reservoir.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page ii

 Design &fabrication of hydraulic floor crane
2021

List Of Figure

FIG 1.1 A TYPE OF HYDRAULIC FLOOR CRANE ..................................................................................................................... 1

FIG 2.1 A BALL BEARING (6400)
SOURCE: HTTPS://WWW.BIZSEARCH.COM/IMAGSPRODUCTS/01/53/15364.JPG) ........................................................ 7
FIG 2.3 A HYDRAULIC JACK (3 TON) ................................................................................................................................ 8
FIG 7.1 DIMENSIONS ................................................................................................................................................. 20
FIG 7.2 DIMENSIONS ................................................................................................................................................. 21
FIG 7.3 REACTION ON HORIZONTAL ARM ........................................................................................................................ 22
FIG 7.4 VIEWS .......................................................................................................................................................... 27
FIG 7.5 VIEWS ......................................................................................................................................................... 27
FIG 7.6 VIEW ......................................................................................................................................................... 27
FIG 7.7 VIEWS ......................................................................................................................................................... 28

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page iii

 Design &fabrication of hydraulic floor crane
2021

List Of Table

TABLE 7.1 LIST OF SYMBOLS......................................................................................................................................... 18

TABLE 7.2 SPECIFICATION OF THE PROJECT...................................................................................................................... 19
TABLE 7.3 MATERIAL PROPERTIES ................................................................................................................................. 26
TABLE 7.4 WORKING PLAN .......................................................................................................................................... 29
TABLE 7.5 COST ANALYSIS ........................................................................................................................................... 31

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page iv

 Design &fabrication of hydraulic floor crane
2021

Table of Contents
Acknowledgement…………………………………………………………………………. i

Abstract…………………………………………………………………………………...…ii

List of figure …………………………………………………………………… ………… iii

List of Table ………………………………………………………………………….......... iv

1 Introduction ............................................................................................................................. 1
1.1 Objective .......................................................................................................................... 2
1.1.2 General objective ...................................................................................................... 2
CHAPTER 2 .............................................................................................................................. 6
Literature Review....................................................................................................................... 6
CHAPTER 3 .............................................................................................................................. 9
Types of hydraulic crane ............................................................................................................ 9
CHAPTER 4 ............................................................................................................................ 13
Application & merits of hydraulic floor crane ......................................................................... 13
4.1 Application of crane ................................................................................................... 13
4.2 merits:- ............................................................................................................................... 13
Chapter-5.................................................................................................................................. 15
Relevant Theory ....................................................................................................................... 15
5.1 Design work:-................................................................................................................. 15
5.2 Design Criteria:-............................................................................................................. 15
5.3 Design Capacity ............................................................................................................. 15
5.4 STABILITY:- ................................................................................................................ 16
Chapter-6.................................................................................................................................. 17
Manufacturing process ............................................................................................................. 17
6.1 Manufacturing: - ............................................................................................................ 17
6.2 Assembly:- ..................................................................................................................... 17
CHAPTER 7 ............................................................................................................................ 18
Design and calculation ............................................................................................................. 18
WORK PLAN .......................................................................................................................... 29
COST ANALYSIS................................................................................................................... 30

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page v

 Design &fabrication of hydraulic floor crane
2021

CHAPTER 8 ............................................................................................................................ 31
Instruction for use .................................................................................................................... 31
CHAPTER ............................................................................................................................... 33
CONCULUSION ..................................................................................................................... 33
REFERENCES ........................................................................................................................ 34

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page vi

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page i
 CHAPTER 1

1 Introduction
These hydraulic floor cranes provide an efficient, low cost alternative to other material
handling equipment. Strong, robust, sturdy and built to very standard these cranes are
manoeuvrable in loading, unloading and shifting of heavy loads. Crane structure consist of
chassis, vertical column, horizontal arm and hydraulic with cylinder assembly .the box crane
can take heavy loads effectively, avoids damage under rough and unskilled handling.

The hydraulic cranes used in the industry are efficient but they only have the ability to lift the
load and put it down at some other position. In this general design, the arm of crane moves in
the vertical plane only.ie it has constrained motion. The aim of our project to re-design the
hydraulic crane and gives its arm the rotational ability. The ball bearing provides rotational to
column. The hydraulic crane was inverted in Newcastle by William Armstrong in about 1845
to help load coal into barges at the quayside.

Fig 1.1 a Type of hydraulic floor crane

(source:http//www.clcall.co.uk/asset/product/materialhandling_heavyduty.jpg)

The main aim of the project is the design, analysis and production of a hydraulic floor crane
having vertical arm motion of 360 degree, horizontal motion up and down as well as
movement of carrying hook using pulleys.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 1

 Design &fabrication of hydraulic floor crane
2021

The project involves designing and assembling of hand operated jib crane .the advantages of
this jib crane in this Adama agricultural machinery manufacturing industry in order to reduce
time and labour force of the industries worker .and also more efficient without any damage of
the materials, more suitable for labour

This jib crane material handling equipment is operated manually by hydraulic force of piston
and worked by Pascal’s law principles.

1.1 Objective

1.1.2 General objective

To design hand operated hydraulic floor crane which is material handling equipment.

1.1.3 Specific objective

To design base

To design vertical arm

To design horizontal arms

To design ball bearing

To design wheels

To design handle

To design bolt and nut

To design hook

To design pulley

To design hydraulic jack

To design jack holder

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 2

 Design &fabrication of hydraulic floor crane
2021

1.2 Problem statement

During our internship when the company workers (labour) works putting the heavy materials
on their shoulder by Appling human force to connect it .so I think something why this human
power can be changed to machine .to reduce the wastage of this labour force and time and
also to increase accuracy with more efficient.in addition this crane are multipurpose for
lifting materials up to 150 kg weight. it also reduce the costs because of, for example to caries
90 kg and for assemble it at list three labour needed but when use this machine only one
person or labour can do it. So it reduce the two person budget can be replaced only by one so
the cost is reduced.

1.3 Scope of project

This project is focus on the material handling during working in the industries. In addition
increasing accuracy during assembly and reduce the labour effort. In this project we design
all parts of hydraulic floor crane for material handling in the system.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 3

 Design &fabrication of hydraulic floor crane
2021

1.4 Morphology of design

In designing a machine component, there is no rigid rule. The problem may be attempted in
several ways .however the general procedure to solve a design problem is as follows:

Recognition of need: First of all, make a complete statement of the problem, indicating the
need, aim or purpose for which the machine is to be designed.

Synthesis (mechanisms): select the possible mechanism or group of mechanism, which will
give the desired motion.

Analysis of force: Find the force acting on each member of the machine and the energy
transmitted by each member.

Design of element (size and stresses): Find the size of each member of the machine by
considering the force acting on the member and the permissible stresses for the material used.
It should not deflector deform than the permissible limit.

Modification: Modify the size of the member to agree with the past experience and judgment
to facilitate manufacture. The modification may also be necessary by considering of
manufacturing to reduce overall cost.

Detail drawing: Draw the detail of each component and assembly of the machine with
complete specification for the manufacturing process suggested.

Production: The component, as per the drawing, is manufactured in the workshop.

1.4 need analysis

The primary goal for a manufacturing this crane is to solve the dexterity versus strength trade
off in the context of machine tools and flexible manufacturing assembly systems.

Synthesis

We have selected group of mechanism, which will give the desired motion. We have used
revolute configuration to give motion to the column. Column will revolve over the base (360)
and in between arm and column. Arm will revolve 360 (vertical) about the column for
picking and placing of object. This configuration will help in searching the object.

Material selection

We have chosen the cheap and best material which is very commercial available i.e iron due
to its good strength.

Design of elements

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 4

 Design &fabrication of hydraulic floor crane
2021

We have calculates the specification of arm, column, and base after considering the force and
permissible stresses of individual component.

Modification

We can further modify our crane by employing other configuration, for this we do not need
have to change the whole mechanical design.

Detail drawing

We have made isometric drawing of our robotic with the help of AUTO-CAD 3D software
labelling all the necessary part with complete dimensions.

Production

All the manufactured and fabricated part of our project is accomplished in workshop itself.
We have drawn AUTO-CAD drawing in our private computer provided by our home.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 5

 Design &fabrication of hydraulic floor crane
2021

CHAPTER 2

Literature Review
Material handling is the movement, control and protection of material, goods and products
throughout the process of manufacturing, distribution, consumption, and disposal. The focus
is on the method, mechanical equipment, system and related control used to achieve these
functions. Hydraulic cranes are important part of the material handling equipment. The
hydraulic cranes that are being used work on manual power.

A crane is a type of machine, generally equipped with a hoist, wire ropes or chain, and
sheaves, that can be used both to lift and lower material and to move them horizontally. It is
mainly used for lifting heavy material and transporting them to other place. It uses one or
more simple machine to create mechanical advantage and this move loads beyond the normal
capability of man.

Cranes are commonly employed in the transport industry for the loading and unloading of
freight, in the construction industry for the movement of material and in the manufacturing
industry for the assembling of heavy equipment.

1.2.1 Parts and description of hydraulic floor crane

1. Base plate/ Truck/Pallet

2. Vertical column

3. Ball bearings

4. Horizontal arm

5. Hook

6. Nuts and bolts

7. Wheels

8. Pulleys

9. Hydraulic jack

1. Base plate/Truck /Pallet:-

It is a plate that serves as a base or support. It is used for carrying the overall weight of the
project. It is made of mild steel. In this 4 bars are welded by using electric arc welding to give
it a rectangular shape. It is made up of cast iron.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 6

 Design &fabrication of hydraulic floor crane
2021

2. Pulleys:-
A pulley is a wheel on an axle that is designed to support movement and change of direction
of a cable or belt along its circumference. Pulleys are used in a variety of ways to lift loads.
Apply force, and to transmit power. A pulley is also called a sheave or drum and may have a
groove between two flange around its circumference. the drive element of a pulley system
can be a rope, cable, belt, or chain that runs over the pulley inside the groove.
3. vertical column:-
his is mounted on the pl te se pl te truck in longitudin l or y-direction. t is consist of
short h ndle which is welded to the vertic l column for 3 rot tion of the column so th t
the load can be dropped at the required position. It consists of roller bearing at the base in the
circumference manner to reduce friction at the time of rotating the vertical column.
4. Thrust ball bearings:-
B ll e rings re c lled s “anti-friction e rings”. his is misnomer because friction is
always present in such bearings, mainly owing to rolling resistance between the balls or
rollers and the race. It carries the vertical thrust and axial load.

Fig 2.1 A Ball Bearing (6400)

Source: https://www.bizsearch.com/imagsproducts/01/53/15364.jpg)

5. Horizontal arm:-
It is fixed horizontal arm on which our hydraulic piston and cylinder is mounted. It is fixed
with the vertical column with welded joint which can rotate with the rotating vertical column
to 360 rotation.

6. Hook:-
Hook is fixed with the cable moving on pulleys. Hook is used for attaching the load to
horizontal arm which moves up and down due which the connected loads are lifted and
rotates.
7. Nuts and Bolts:-
Nuts and bolts are the hardware fasteners which are used to fasten the various different parts.
In our project we have used around 20 nuts and bolts.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 7

 Design &fabrication of hydraulic floor crane
2021

8. Wheels:-
A wheel is a circular component that is intended to rotate on an axial bearing. The wheel is
one of the main components of the wheel and axle which is one of the six simple machines.
Wheel is conjunction with axles. Allow heavy objects to be moved easily facilitating
movement or transporting while supporting a load or performing labor in machines. I our
project we are using four wheels of diameter 7cm.
9. Hydraulic jack:-
A hydraulic jack is a jack that uses a liquid to push against a piston. This is based on P sc l’s
principle. The principle states that pressure in a closed container is the sane at all points. If
there are two cylinders connected, Applying force to the smaller cylinder will result in the
same amount of pressure in the large cylinder. However, since the larger cylinder has more
area. The resulting force will be greater. In other words, an increase in area leads to increase
in force. The greater the difference in size between the two cylinders the greater the increase
in the force will be. A hydraulic jack operates based on this two cylinder system.

Fig 2.3 A Hydraulic Jack (3 ton)

Source: http://www.pappumarine.com/images/hydraulic_bottle_jack.jpg

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 8

 Design &fabrication of hydraulic floor crane
2021

CHAPTER 3

Types of hydraulic crane

a. Truck cranes

b. Crawler –mounted cranes

c. Overhead cranes

d. Tower crane

a. Truck cranes

A crane mounted on a truck carrier provides the mobility for these types of crane. This cranes
has two parts: the carrier, often referred to as lower, and the lifting component which includes
the boom referred to as the upper. These modern hydraulic truck cranes are usually single –
engine machines, with the same engine powering the undercarriage and the crane.

The upper is usually powered via hydraulic run through the turntable from the pump mounted
on the lower. In older model design of hydraulic truck cranes, they are two engines. One in
the lower pulled the crane down the road and ran a hydraulic pump of its own. Many older
operator favor the two –engine system due to leaking seals in the turntable of aging newer
design cranes.

Generally, these cranes are able to travel on highways, eliminating the need for special
equipment to transport the crane unless weight or other size constrictions are in place such
local laws. If this is the case, mostly larger cranes are equipped with either special trailer to
help spread the load over more axles or are able to disassemble to meet requirements. An
example is counter weights. Often a crane will be followed by another truck hauling the
counterweights that are removed for travel. In addition some cranes are able to remove the
entire upper. However, this is usually only an issue in a large crane and mostly done with a
convectional crane such as a link –belt HC-238. When working on the job site, outriggers are
extended horizontally from the chassis then vertically to level and (a few miles per hour)
while suspending a load. Great care must be taken not to swing the load sideways from the
direction of travel, as most anti-tipping stability then lies in the stiffness of the chassis
suspension.

Most cranes of this type also have moving counterweights for stabilization beyond that
provided by the outriggers. Loads suspended directly aft are the most stable, since most of the
weight of the crane acts as a counterweight. Factory calculated charts (or electronic
safeguards) are used by cranes operator to determine the maximum safe loads for stationary
(outrigger) work as well as (on –rubber) loads and travelling speeds.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 9

 Design &fabrication of hydraulic floor crane
2021

b. crawler –mounted cranes

A crawler is a crane mounted on undercarriage with a set of trucks (also called crawler) that
provide stability and mobility. Crawler cranes range in lifting capacity from about 40 to 3500
short tons (35.7 to 3125 long tons; 36.3 to 3175.1ton).

Crawler cranes have both advantages and disadvantages depending on their use. Their main
advantages is that they can move around on site and perform each lift with little set up, since
the crane is stable on its tracks with no outrigger. In addition, a crawler crane is capable of
traveling with a load. The main advantages are that they are very heavy, and cannot easily be
moved from one job site to other without significant expense. Typically a large crawler must
be disassembled and moved by trucks, rail cars or ships to its next location.

c. Overhead crane

Overhead cranes being used in typically machine shop. The hoist is operated via a wired
pushbutton station to move system and the load in any direction. An overhead crane, also
known as bridge crane, is a type of crane where the hook and line mechanism runs along a
horizontal beam that itself runs two widely separated rails. Often it is in a long factory
building and runs along rails along the building two long walls. It is similar to gantry crane.
Overhead cranes typically consist of either a single beam or a double beam construction.

These can be built using typical steel beams or more complex box girder type. Pictured on the
right is a single bridge box girder crane with the hoist and system operated with a control
pendant.

Double grinder bridges are more typical when needing heavier capacity systems from 10
tones and above. The advantages of the box girder type configuration results in a system that
has a lower dead weight yet stronger overall system integrity. Also include would be hoist to
lift the items, the bridge, which spans the area covered by the crane, and a trolley to move
along the bridge.

The most common overhead crane use is in the steel industry. At every step of the
manufacturing process, until it leaves a factory as a finished product, steel is handled by an
overhead crane. Raw materials are poured into a furnace by crane, hot steel is stored for
cooling by an overhead crane, the finished coils are lifted and loaded on to tracks and trails
by an overhead crane, and fabrication or stamper uses an overhead crane for handling of raw
materials. Smaller workstation cranes handle lighter loads in a work area such as CNC mill or
saw.

Almost all paper mills use bridge cranes for regular maintenance requiring removal of heavy
press rolls and other equipment. The bridge cranes are used in the initial construction of paper
machines because they facilitate installation of the heavy cast iron paper drying drums and
other massive equipment, some weighing as much as 70 tons.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 10

 Design &fabrication of hydraulic floor crane
2021

d. Tower cranes

Tower cranes are modern form of balance crane that consist of the same basic parts. Fixed to
the ground on a concrete slab (and sometimes attached to the side of structures as well),
tower cranes often give the best combination of height and lifting capacity and are used in the
construction of tall buildings. The base is then attached to the mast which gives the crane its
height. Further the mast is attached to the slewing until (gear and motion) that allows the
cranes to rotate. On top of the slewing until there are three main parts; the long horizontal jib
(working arm), shorter counter jib, and the operator cap, tower crane cabin.

The long horizontal jib is the part of crane that carries the load. The counter- jib carries a
counterweight, usually of concrete blocks, while the jib suspends the load to and from the
center of the crane. The crane operator either sits in a cab at the top of the tower or controls
the cranes by the radio remote control from the ground. In the first case operator cab is most
usually located at the top of the tower attached to the turntable, but can mounted on the jib, or
part way down the tower. The lifting hook is operated by the crane operator using electric
motor to manipulate wire rope cable through a system of sheaves. The hook is located on the
long horizontal arm to lift the load which also contains its motor.

A tower crane routes on its axis before lowering the lifting hook. In order to hook and unhook
the loads the loads, the operator usually works in conjunction with a signaler (known as a
dagger ,rigger or swampier). They are most often in radio contact, and always use hand
signals. The rigger or dagger directs the schedule of lift for the crane, and is responsible for
the safety of the rigging and loads.

The components of Tower Crane

Tower cranes are used extensively in consistence and other industries to hoist and move
materials. There are many types of tower cranes. Although they are different in type, the main
parts are the same, as follows;

1. Mast

The mast is the main supporting tower of the crane. It is made of steel trussed section that are
connected together during installation.

2. Slewing Unit

The slewing units sit at the top of the mast. This is the engine that enables the crane to rotate

3. Operating Cabin

The operating cabin sits just above the slewing unit. It contains the operating controls.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 11

 Design &fabrication of hydraulic floor crane
2021

4. jib

he ji , or oper ting rm, extends horizont lly from the cr ne. A “luffing “ ji is le to
move up and down a fixed jib has a rolling trolley that runs along the underside to move
goods horizontally.

5. Hook

The hook (or hooks) is used to connect the material to the crane. It hangs at the end of thick
steel cables that run along the jib to the motor.

6. Weights

Large concrete counterweights are mounted toward the rear of the mast, to compensate for
the weight of the goods lifted.

A tower cane is usually assembled by a telescopic jib (mobile) crane of greater reach (also
see “self –erecting cr ne” below) and in the case of tower cranes that have risen while
constructing very tall skyscraper, a smaller crane (or derrick) will often be lifted to the roof of
the completed tower to dismantle the tower crane afterwards, which may be more difficult
than the installation.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 12

 Design &fabrication of hydraulic floor crane
2021

CHAPTER 4

Application & merits of hydraulic floor crane

4.1 Application of crane
Crane exist in an enormous variety of forms – each tailored to a specific use. Sometimes size
range from the smallest jib cranes, used inside workshop, to the tallest tower cranes, used for
constructing high buildings. For a while, mini – cranes are also used for constructing high
buildings. In order to facilitate construction by reaching tight space. Finally. We can find
larger floating cranes, generally used to build oil rigs and salvage sunken ships.
These days hydraulic principle is being used extensively in material handling process through
cranes. Depending on the load to be handled and the operation to be performed there are
different types of crane like crawler Crane, Truck Crane, Floor Cranes.
Hydraulic Crawler cranes are used for picking and moving huge amount of loads. Generally
loads are kept in containers for Bulk loading.
Hydraulic truck crane have good flexibility with high load carrying capacities.
Hydraulic Workshop foldable crane used in industries for moving small to medium sized
materials from one place to other. The load carrying can vary from 80 kg to half ton or more.

4.2 merits:-
1. Most powerful means of lifting objects:-
It is one of the most powerful means of lifting objects is with the strength of a hydraulic
crane. By harnessing the strength that liquid under the pressure gives, and the case with
which it can be used, it is possible to transfer a relatively small amount of effort from one
place to another, and hydraulic crane are amongst the most efficient lifting systems available
in the modern workplace.
2. Extremely stable in use:-
Because hydraulic cranes used a fixed system of ropes, constant pressure can be maintained
once a part of the system has been moved into place, and this makes them extremely stable in
use, and able to support relatively large weights.
3.Very easy to maintain :-
Hydraulic crane are amongst the simplest system that you can use within any industrial
process, and are very easy to maintain. Provided that all the pumps and piston are regularly
checked for any leaks. and potential stress points where the levers are supported are inspected
for damage. The crane will continue to operate completely reliable for long periods of time

4. A very versatile tool:-

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 13

 Design &fabrication of hydraulic floor crane
2021

Most hydraulic crane are comparatively light weight , and the case with which they can be
moved from one area to another within the factory or distribution center, make them a very
versatile tool with lots of uses on a day to day basis. From simple loading jobs in your
loading bay area where the portable hydraulic crane can be used to lift objects in to a waiting
truck to more complex job within the main factory, the lifts will come in very useful.
5, quite simple design
A hydraulic system works with a system of pumps and pistons that are filled with a liquid,
usually a light oil or water. By moving the liquid under pressure from the pumps, piston can
be extended or reduced. And when these piston are connected to a system of levers. The
pistons can be used to lift surprisingly heavy weights.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 14

 Design &fabrication of hydraulic floor crane
2021

Chapter-5

Relevant Theory
5.1 Design work:-
The designing work was carried out using pro E software. The required dimension of the
driver and the driven wheels where taken as per the design equation. Pro E is the most widely
used design software which help in designing 2 as well as 3 dimensional models using
simplified alphabetical and numerical commands. A slot was cut on the Geneva wheel using
the trim tool. It was then edited using polyline command and the remaining slots were
constructed using the array tool. The crank pin and the driving wheel were drawn to the
required dimension.

5.2 Design Criteria:-

There are three major considerations in the design of cranes.
1. The crane must be able to lift the weight of the load:
2. The crane must not topple:
3. The must not rupture.

5.3 Design Capacity

The lifting capacity of hydraulic crane mainly depends on following.
1. The Lever:-
A balance crane contain a horizontal beam (the lever) pivoted about a point called the
fulcrum. The principle of the lever allows the heavy load attached to the shorter end of the
beam to be lifted by the smaller force applied in the opposite direction to the longer end of
the e m. he r tio of the lo d’s weight to the pplied force is equ l to the r tio of the lengths
of the longer arm and the shorter arm. And is called the mechanical advantage.
2. The Pulleys:-
A jib crane contains a tilted strut (the jib) that support a fixed pulleys block. Cables are
wrapped multiple times round the fixed block and round another block attached to the load.
When the free end of the cable is pulled by hand or by a winding machine. The pulleys
system delivers a force to the load that is equal to the applied force multiplied by the number
of length of cable passing between the two blocks. This number is the mechanical advantage.
3. The Hydraulic:-
This can be used directly to lift the load or directly to move the jib or beam that carries
another lifting device. Cranes, like all machine, obey the principle of conversation of energy.
This means that the energy delivered to the load cannot exceed the energy put into the
machine. For example, if the pulleys system multiplies force by ten, then the load moves only
one tenth as far as the applied force. Since energy is proportional to the force multiplied by

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 15

 Design &fabrication of hydraulic floor crane
2021

distance, the output energy is kept roughly equal to the input energy (in practice slightly less.
because some energy is lost to friction and other inefficiencies)
The same principle can operate in reverse. In case of some problem, the combination of
heavy load and great height can accelerate small objects to tremendous speed. Such
projectiles can result In severe damage to nearly structure and people. Crane can also get in
chain reactions: the rupture of one crane may in turn take out nearby cranes. Cranes need to
be watched carefully.

5.4 STABILITY:-
For stability, the sum of all moment about any point such as the base of the crane must equate
to zero. In practice, the magnitude of load that is permitted to be lifted (called the “rated
load” in the US) is some value less than the load that will cause the crane to tip ( providing a
safety margin).
Standard for cranes mounted on ships or offshore platforms are somewhat stricter because of
the dynamic load on the crane due to vessel motion. Additionally, the stability of the vessel
or platforms must be considered.
For stationary pedestal or kingpost mounted cranes. The moment created by the boom, jib,
and load is resisted by the pedestal base or kingpost. Stress within the base must be less than
the yield stress of the material or the crane will fail.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 16

 Design &fabrication of hydraulic floor crane
2021

Chapter-6

Manufacturing process
6.1 Manufacturing: -
The hydraulic crane which was manufactured has 12 parts. They are base plate/ truck/ pallet,
hydraulic jack, hydraulic hose, vertical column, ball bearing, horizontal arm, roller, hook,
nuts and bolts, wheels, pulleys, cable, handle. Base plates are made of caste iron metal rod.
The road are cut according to the dimension and they are welded using metal are welding.
Then bearing was selected according to the thrust and axial load and vertic l column re
fitted on the e ring so th t it c n rot te to 3 . he horizont l rm is hinged nd cont ins
pulley in it so that hook can travel up and down. Hydraulic system is selected according to
the power required.

6.2 Assembly:-
1. Arrangement of four wheel on the four the base plate.
2. Assembly of fixture for holding the bearing and the vertical column.
3. Assembly horizontal arm.
4. Assembly of hydraulic jack.
5. Connection of hoses with the hydraulic jack.
6. Installing pulleys in horizontal and vertical arm.
7. Installing high steel cable on the pulleys.
8. Attaching a hook on the high steel cable.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 17

 Design &fabrication of hydraulic floor crane
2021

CHAPTER 7

Design and calculation

SERIAL SYMBOL DESCRIPTION

NO.
1 ID Inner diameter

2 Pn Power in kw

N Motor speed in revolution per min

Q Discharge in l/min

f Frequency in Hz

In Current in ampere

I Length of truck

b Breadth of truck

H Height of truck

W Total weight

F Fibres stress in bending

D Depth of joist

L Length of joist

P Density of fluid at room temp.

A Cross section area of the hose

V Velocity of the fluid

Table 7.1 list of symbols

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 18

 Design &fabrication of hydraulic floor crane
2021

Table 7.2 specification of the project

SERIAL NAME MATERIAL DIMENSIONES

NO.

1.
Pulley Fibres Outer Dia – 3.81cm

Inner Dia -8 cm

Length -5 cm

2
Horizontal Arm Mild steel Length – 55.88 cm

Width – 5.08 cm

Thickness -2 cm

3
Vertical Arm Mild steel Length – 100cm

Diameter – 15.24 cm

4
Ball bearing Stainless steel 6400

5
Wheels High steel 7 cm

6
Handle Mild steel Length -38.1 cm

7
Base Mild steel Width - 60.98 cm

Length – 91.44cm

Thickness – 5.08 cm

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 19

 Design &fabrication of hydraulic floor crane
2021

3 tone
8. Hydraulic jack

High steel 200 cm

9. Wire

Mild steel Length -12.7 cm

10. Jack Holder Width – 12.7 cm

Fig 7.1 Dimensions

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 20

 Design &fabrication of hydraulic floor crane
2021

Fig 7.2 Dimensions

7.1 calculation of floor load

Floor load is a measure of pressure on the floor of trucks. It is necessary to avoid the
catastrophic failure.

Total weight =50 kg

 Length = 100cm=1m
 Breath 56 cm=0,56m
 Floor load =total weight /total floor area

=w/(l*b)

= 50/(1*0.56)

= 89.287 kg/m2 or 89.2870N

7.2 FORCES ON CYLINDER

1. At middle position

 Mo=5000*560 –Ra*77=0
 RA= 36363.63 N
 Reaction in the cylinder will be given by
 R cylinder =RA
 R cylinder = 36363.63
 R cylinder = 36363.63 N

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 21

 Design &fabrication of hydraulic floor crane
2021

 Ro = 41363.63 N

Fig 7.3 reaction on horizontal arm

2.At upper position

 Mo=0
 Mo= 5000*(560cos45)+RA*(77cos45)
 RA=-36363.63 N
 Reaction on the direction of cylinder will be given by
 R cylinder =RA (cos15)
 R cylinder = -35124.56 N
 Ro=-40124.56 N

7.3 Calculation of crane stability

Force on part one (load at the hook)

 Load applied to the arm at the hook is 50 kg i.e.=50*9.81

= 490.5N

 Volume of overhanging arm =L*B*H

=283.2*20*51.50
=291696 cu mm
= 0.000291696 cu m
 Density of material used is 7850 kg/cu m
 Mass of overhanging arm =volume*density
=0.000291696*7850
=2.2898kg
 Weight of overhanging arm = 2.2898*9.81

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 22

 Design &fabrication of hydraulic floor crane
2021

=22.4630N

FORCE ON PART TWO(Force at arm)

 Volume of remaining arm = L*B*H

=258*20*51.50

=265740 cu mm

=0. 000265740 cu m

 Density of material used = 7850kg/cu m

 Mass of remaining arm =volume*density

=0. 000265740*7850

=2.08605kg

 Weight of remaining arm =0. 000265740*9.81

=20.462N

FORCE ON PART THREE ( Force on vertical )

 Volume of column =L*B*H

=1000*18820.527

=18820527.60 cu mm

= 0.0018820527 cu m

 Density of material used = 7850 kg/cu m

 Mass of column= volume *density

= 0.018820527*7850

= 147.77 kg

 Weight of the column = 147.77*9.81

= 1449.3406740 N

FORCE ON PART FOUR (Force on Base)

 Volume of base =L*B*H

=620*20*51.50

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 23

 Design &fabrication of hydraulic floor crane
2021

=638600 cu mm

=0.000638600 cu m

 Density of material used = 7850kg/cu m

 Mass of the base = volume * density

=0.0315*7850

=5.0130 kg

 Weight of the base = 5.0130*9,81

=50 N

FORCE ON PART FIVE (force on base arm)

 Volume of base arm =L*B*H

=1000*20*51.50

=1030000.00 cu mm

=0.001030000 cu m

 Density of material used = 7850 kg/ cu m

 Mass of the base arm = volume * density

=0.001030000*7850

=8.085500 kg

 Weight of the base arm =8.085500*9.81

= 79.3187 N

DESGN OF CYLINDER

Let take or choose the 3 tone hydraulic jack.

 Assuming the internal pressure,

Pi= 110 N/mm2

 Material used for cylinder is mild steel = 226

 Yield strength of mild steel = 250 N/mm2

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 24

 Design &fabrication of hydraulic floor crane
2021

 Ultimate tensile strength of mild steel =410 N/mm2

 Factor of safety = 1.5 (assumed)

Pi=F/A

A=F/Pi

= 35124/110

A=319.30mm2

But, A =(pi/4)*d2

=319.30

D=20.16 mm

 Using of cylinder standard diameter,

 Bore diameter =20 mm
 Now available tensile stress =Syt/FOS s

= 250/1.5

=166.66N /mm2

 Allowable shear stress Tall = Ssy/FOS

 Ssy =yield strength in shear of the cylinder material, N/mm2

Tall =0.5 Ssy/ FOS

=0.5*250/1.5

=83.33 N/mm2

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 25

 Design &fabrication of hydraulic floor crane
2021

Material Name AISI 1018 STEEL (MS)

Material Model Type Linear Elastic Isotropic
Default Failure Creation Max von Mises stress

PROPERTY NAME VALUE UNITS

2.05 e+011 N/m2

Elastic modulus

0.29 NA
Poisson’s ratio

8e+010 N/m2
Shear modulus

7850 Kg/m3
Mass density

5.85e+008 N/m2
Tensile strength

2.8269e+008 N/m2
Yield strength

1.1e-005 /kelvin
Thermal
expansion
coefficient

52 W/(m.K)
Thermal conductivity

486 J/(kg.K)
Specific heat

0.85 NA
Hardening factor
(0.0-1.0 ;
0.0= isometric
1.0= kinematics

Table 7.3 material properties

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 26

 Design &fabrication of hydraulic floor crane
2021

FIG 7.4 views

FIG 7.5 Views

FIG 7.6 VIEW

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 27

 Design &fabrication of hydraulic floor crane
2021

FIG 7.7 Views

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 28

 Design &fabrication of hydraulic floor crane
2021

WORK PLAN

I Task Name Start Finish Duration Year 2021

D Month
March April May
1 2 3 4 1 2 3 4 1 2 3 4
w w w w ww w w www w
1 Literature 24/03/2021 4/04/2021 1 weeks
review and 4days

4/03/2021 11/04/2021 1 weeks

Problem
Analysis
Formation

2 Methodology 11/03/2021 18/04/2021 1 weeks

3 Design and 18/04/2021 5/05/2021 2 week

implementatio and 3 days
n
4 Verification 5/05/2021 9/05/2021 4 days
and Validation
5 Result 9/05/2021 14/05/2021 5 days
evaluation
6 Report writing 14/05/2021 23/05/2021 1 week
and 2 days
7 Thesis 24/05/2021
submission

Table 7.4 working plan

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 29

 Design &fabrication of hydraulic floor crane
2021

COST ANALYSIS

SERIAL NAME QUANTITY RATE TOTAL

NO. AMOUNT

1 Hydraulic jack 1 1000

1800
2 Base frame 1 600
(MS) 2400

3 Vertical arm 1 500

(MS) 1600

4 Horizontal arm 1 500

(MS) 1200

5 Cable (HS) 2 meter 200

300

6 Pulley 3 300
200

7 Wheel 4 400
200

8 Collector cable 1 200

(MS) 600

9 Bearing 1 200
600
10 Hook 1 200
300

11 1 100
handle 350

12 Nut and Bolt 1 100

100

13 Welding charge - 500

3000

14 Lathe charges - 200

3000

15 Paint - 300
300

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 30

 Design &fabrication of hydraulic floor crane
2021

16 Miscellaneous - 4000 200

Total amount 5500
Table 7.5 cost analysis

CHAPTER 8

Instruction for use

Features

 Overload safety
 Lifting/lowering speed control
 Position holding by check valve
 Hydro mechanical jack
 Hose burst safety interlocks
 Simple to use and maintain
 Compact structure

8.1 moving the load

1. Lift the load slowly and smoothly. Make sure the load is balanced and securely attached
before lifting.

2. Operate the hydraulic jack to raise or lower the load.

3. Raise the load by smoothly pumping the hydraulic jack with the handle. With new
equipment, a whining noise may occur when pumping.

4. Lower the load by slowly turning the release valve counter clockwise.

5. Too many full turns will unscrew the valve and release oil.

6. Choose the valve by the tightening it clockwise.

7. Pull the crane back ward to move the load, close to the floor and tied to the mast and legs
to prevent swinging.

8. Move the load slowly and smoothly, especially when making turns.

9. Move the cranes by hand only do not use powered device to push or pull the crane.

8.2 Cleaning the Crane

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 31
 Design &fabrication of hydraulic floor crane
2021

 Clean the crane to remove dirty and help prevent corrosion.

 Clean the crane every six months or whenever it dirty .
 Wipe all equipment to remove dirty and grease.
 Leave a lift film of oil on all surfaces to protect against rust and corrosion.
 Wipe off excessive amounts of oil to avoid the accumulation of dirty.
 Remove unnecessary objects from the area surrounding the crane.

8.3 Lubricating the crane

1. Lubricate the crane properly to help protect it from wear and rust .read the following
instructions carefully.

2. Partial disassembly may be required to lubricate the crane properly to help protect
instruction carefully.

3. Lubricate the wheels at least every 6 months. Use grease brush to apply a light film of
NLGI grease to the roller bearing on the rear caster wheels. Apply 2 to 3 drops of 150 grade
gear oil to the shaft on the front wheels, rotate the wheels to allow oil to penetrate.

4. Lubricate all pins at least every six months. Use grease brush to apply a light film of NLGI
grease to all pins.

5. Lubricate the swivel hook at least every 6 months. Apply 2 to 3 drops of 150 grade gear
oil.

6. Lubricate the jack pivot pins and other moving parts after 10 cycles.

7. Lubricate Equipment by following the m nuf cturer’s recommend tions.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 32

 Design &fabrication of hydraulic floor crane
2021

CHAPTER

CONCULUSION
The aim of our projects was to build a fully functional HYDRAULIC FLOOR CRANE
mechanism which is capable of lifting load up to 50 kg with the load and pulley system and
105 + kg from the hook attached to the horizontal arm. We accurately achieved our first goal
of lifting the loads from both the hooks and 360 degree rotary motion of the vertical column
as well as up and down movement of the horizontal arm.

We feel that our design and fabrication was a great success both in terms of strength and
stiffness. Our project weight 60 kg which is capable of lifting load up to 150 kg using
hydraulic power.

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 33

 Design &fabrication of hydraulic floor crane
2021

REFERENCES
1.DR. .J.PRABHU(2 1 )” ext book of design of Transmission Element.

2.DESIGN DATA BOOK-MAHADEVAN.

3. www.e4training.com

4. www.freepatentsonline.com

5. www.howstuffworks.com

6.Machine design by Khurmi Gupta

7.Strength of material, Se Mech

8. Production Technology rk jain

9.RK Rajpoot-Machine Component &design

10. http://www.clcall.co.uk/cl/Assets/Productd/MaterialHandling Floorcrane Heavy Duty

.jpg.

11. http://www.hydraulicjackkind.com/

12. http://www.thomasnet.com/articles/machinery-tools-supplies/bearing-types

13. http://www.engineeringtoolbox.com/metal-alloys-densities-d50htlmn

14. http://www.bizearch.com/images/product/01/53/15364.jpg

15. http://www.pappumarine.com/images/hydraulic-bottlejack.jpg

16.International Journal of Engineering and Advanced Technology (UEAT)

ISSN :2249-8958. Volume-3, isuue-2, December 2013

HARAMAYA INSTITUTE OF TECHNOLOGY: MECHANICAL ENGINEERING Page 34