Thesis Modified

Debre Berhan University
College Of Engineering
Mechanical Engineering Department
BSc. Thesis project
Title: - Project On Design and Modeling of Simple
Tower Crane Operator Lift
Student Name ID
1, Dawit Solomon 3314/11
2, Natnael Melaku 3591/11
3, Abenezer Landuber 0038/10
4, Samuel Amsalu 1723/10
5, Reta Beyene 3038/11
Advisor: - Yishak T.
Debre Berhan, Ethiopia
JUN 2023
Declaration
Debre Berhan University
College Of Engineering
Mechanical Engineering Department
THESIS FINAL PROJECT
Student:
Dawit Solomon
Name Signature Date
Natnael melaku
Name Signature Date
Abenezer landuber
Name Signature Date
Samueuel amesalu
Name Signature Date
Reta beyene
Name Signature Date
The following graduate faculty members certify that this student has successfully presented the
necessary written thesis proposal and oral presentation of this proposal for partial fulfillment of
the thesis-option requirements for the Degree of under graduate.
Approved:
Advisor: Yesehak Tefera _________________ _ June 7, 2023
Name Signature Date
Chair Holder:
Name Signature Date
Faculty Dean:
Name Signature Date

Acknowledgement
The design and modeling of the simple tower crane operator lift in construction areas
was a complex and challenging project that required the contributions of many
individuals and help of our advisor. We would like to express our sincere appreciation
to all those who played a role in this project. First and foremost, we would like to
thank our “GOD” for making us healthy and happy in order to carry out this project.
It would not have been possible without the kind Support and help of our advisor Mr.
Yishak for his support and encouragement while doing the project. He inspires us
greatly to work in this project and his willingness to motivate us and contributed
tremendously to our project all we learnt from the project are value adding for our
future carrier and hence we would like to thank for all contributions. Secondly, we
would like to thank the computer lab assistances and our friends who helped to test
the performance under different operating conditions in the solid work. Their work
was critical in identifying potential issues and ensuring that the simple tower crane
operator lift could be operated safely and effectively in the modeling. Thirdly, we
would like to express our gratitude towards to the mechanical engineering teachers for
their kind cooperation and encouragement which helps us in completion of this
project.
Finally, we would like to thank the mechanical engineering department and all the
staffs who provided guidance and support throughout the project. Their expertise and
oversight were critical in ensuring that the project meets all necessary standards and
regulations.
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Design and Modeling of Simple Tower Crane Operator Lift Group 1
Acrimony and Abbreviation
AC ALTERNATING CURRENT
NO NORMALLY OPEN
KW KILO WATT
AMI AREA MEDIAN INCOME
CAD COMPUTER AIDED DESIGN
RP RADIUS OF PULLEY
P ANGULAR SPEED OF DRIVING PULLEY
NP ANGULAR SPEED OF DRIVING PULLEY
η EFFICIENCY
MPA MEGA PASCAL
ML LOAD MASS
MCW COUNTER WEIGHT MASS
SWL SAFE WORKING LOAD
VC LINEAR SPEED OF ELEVATOR CAR

G GRAVITATIONAL FORCE
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Executive summary
This project focuses in design, 3D modeling, and part drawing analysis on the
mechanical part of the simple tower crane operator lift .This document starts from the
conviction that one of the main construction problems of today‟s activities is the
continuously increasing production construction projects. This simple tower crane
operator lift is basically moved by electric power that is taken from the tower crane
and the electric power is used to drive the electric motor which used to rotate the
drum and make the lift up and down. And the time taken for the employees take to get
to the top of the tower cane is minimized and other economic and security issues are
can be solved. Furthermore, there is no special skill needed to operate the lift.
The system is considered to lift 40,000 loads, (4 tons) through this simple tower crane
operator lift system. This simple tower crane operator lift is can carry a capacity of
minimum about 70 kg per person and the space is available in the simple tower crane
operator lift is only for one person and The design of the simple tower crane operator
lift speed is 15−20 mpm. Time Management, discipline and good planning are also an
important aspect to make sure the entire plan is going on the right track.
Simple tower crane operator lift mechanism is the most common mechanical machine
in every constriction areas. This simple tower crane operator lifts are most common
for the transporting and some other beneficial advantages. The aim of this paper is to
solve this problem and save lots of time and human power also human life by
designing a machine that can solve the transporting, time and many problems in the
construction company.
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Table of content
Contents
Acrimony and Abbreviation ........................................................................................IV
Executive summary....................................................................................................... V
CHAPTER-ONE ............................................................................................................ 1
1-INTRODUCTION ...................................................................................................... 1
1.1-Background and Justification .............................................................................. 1
1.2-Statement of the Problem .................................................................................... 3
1.3-Objectives of the Study........................................................................................ 3
1.3.1- General Objectives ...................................................................................... 3
1.3.2- Specific Objectives ...................................................................................... 3
1.4- Significance of the study .................................................................................... 3
1.5- Scope of the study............................................................................................... 4
CHAPTER TWO ........................................................................................................... 5
2. LITERATURE REVIEW .......................................................................................... 5
2.1-Concept of work study ......................................................................................... 5
CHAPTER THREE ..................................................................................................... 11
3-RESEARCH AND METHODOLOGY.................................................................... 11
3-RESEARCH ............................................................................................................. 11
3.1-Data Collection .................................................................................................. 11
3.1.1-Primary Data Collection Methods .............................................................. 11
3.1.2-Secondary Data Collection Methods .......................................................... 11
3.1.3 Data Analysis Method................................................................................. 12
3.2 Methodology .......................................................................................................... 13
3.3 Technical Design ................................................................................................... 14
3.4 Mechanism for Lifting ........................................................................................... 15
3.5 conceptual development......................................................................................... 15
Concept screening and scorning .................................................................................. 19
3.5 Material Selection .................................................................................................. 21
Chapter Four ................................................................................................................ 24
4. Design Analysis ....................................................................................................... 24
4.1 About the Motor ..................................................................................................... 24
4.1.1 control system for elevator drive .................................................................... 24
4.2 Designing Selection of Rope (Steel Wire Rope) ................................................... 27
4.3 Design of simple lift Drum .................................................................................... 29
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4.1.3.1 Minimum no. of wire rope turns on rope drum ....................................... 30

4.1.3.2 Thickness of drum.................................................................................... 30
4.4 Analysis of Hook ................................................................................................... 31
4.5 Analysis of a Tower Crane main vertical support element (mast)......................... 32
4.6 Components of simple tower crane Operator Lift (project) .............................. 37
4.6.1 Electric motor.................................................................................................. 37
4.6.2Hook................................................................................................................. 40
4.6.3 Lift box............................................................................................................ 41
4.6.4 Steel wire rope ................................................................................................ 43
4.7.5 Drum ............................................................................................................... 43
Chapter Five ................................................................................................................. 45
5, Result Discussion ..................................................................................................... 45
5.1 Electric motor..................................................................................................... 45
5.2 Hook............................................................................................................... 45
5.3 lift box ............................................................................................................ 45
5.4 Steel Wire Rope ............................................................................................. 46
5.5 Drum .............................................................................................................. 46
Chapter Six................................................................................................................... 48
6, Cost Analysis ........................................................................................................... 48
Chapter Seven .............................................................................................................. 49
7. Conclusion and Recommendation ........................................................................... 49
7.1 Conclusion ............................................................................................................. 49
7.2 Recommendation ................................................................................................... 50
References ................................................................................................................ 51
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List of figures
Figure 1 introduction to tower crane .............................................................................. 1
Figure 2 operator movement on the tower crane manually .......................................... 2
Figure 3 Elements of Work Study ................................................................................. 5
Figure 4 rack constriction lift ........................................................................................ 7
Figure 5 easy up tower crane lift.................................................................................... 8
Figure 6 Research Frame Work ................................................................................... 11
Figure 7 methodology .................................................................................................. 13
Figure 8 Simple Lift Structure ..................................................................................... 15
Figure 9 Simple Lift Structure .................................................................................... 16
Figure 10 Simple Lift Structure 2 ................................................................................ 17
Figure 11 Simple Lift Structure 3 ................................................................................ 18
Figure 12 upper system load assembly ........................................................................ 26
Figure 13 steel wire rope.............................................................................................. 27
Figure 15 simple lift Drum .......................................................................................... 29
Figure 16 Maximum stresses on drum ......................................................................... 31
Figure 17 tower crane main support or mast ............................................................... 33
Figure 18 mast of the tower crane................................................................................ 36
Figure 19 shield cover of the electric motor ................................................................ 37
Figure 20 back cover of electric motor ........................................................................ 37
Figure 21 top cover of electrical system on the motor................................................. 38
Figure 22 the rotary section of electric motor .............................................................. 38
Figure 23 coil of wires inside the motor ...................................................................... 38
Figure 24 base for the electric motor ........................................................................... 38
Figure 25 electric motor ............................................................................................... 39
Figure 26 electric motor ............................................................................................... 40
Figure 27 hook ............................................................................................................ 41
Figure 28 the lift box section ....................................................................................... 41
Figure 29 door cover section........................................................................................ 42
Figure 30 lift box ......................................................................................................... 42
Figure 32 drum ............................................................................................................. 44
Figure 33 shaft ............................................................................................................. 44
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List of tables
Table 1 concept screening and scoring ........................................................................ 20
Table 2 material comparison for simple lift ................................................................. 23
Table 3 Engineering Material Properties of Structural Steel for hook ........................ 32
Table 4 result discussion on electric motor.................................................................. 45
Table 5 result discussion on hook ................................................................................ 45
Table 6 result discussion of lift box ............................................................................. 45
Table 7 result discussion on steel wire rope ................................................................ 46
Table 8 result discussion of drum ................................................................................ 46
Table 9 results of the drum analysis ............................................................................ 46
Table 10 results of the drum analysis .......................................................................... 47
Table 11 cost analysis .................................................................................................. 48
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CHAPTER-ONE
1-INTRODUCTION
1.1-Background and Justification
Figure 1 introduction to tower crane
For thousands of years, people have innovated ways to lift heavy objects and place
them where they‟re needed. As demonstrated at Stonehenge, the Pyramids of Giza,
and countless ancient sites around the world, the history of the crane is closely aligned
with the history of the limits of man‟s strength. Ancient Greeks were miles ahead of
the rest of the world when using lifting equipment. As early as 515 BC, distinctive
cuttings for lifting tongs and Lewis irons were discovered on stone blocks of Greek
temples. These were the first blueprints for our modern cranes.
The concept of cranes originated from pulley systems that were first utilized by
ancient Mesopotamians as early as 1500 BC. The first compound pulleys were created
by Archimedes of Syracuse around 287 – 212 BC, which he used to lift an entire
warship, along with its crew. A compound pulley has many advantages and pitfalls.
The pitfalls include being stationary, immobile and have slow lifting speeds. These
pitfalls led to the development of the winches and capstans used by the Romans to
build temples. The power of circular rotation caught on quickly, which naturally led
to the increased use of gear works and the development of cranes.
The tower crane we know and love appeared in 1949. The Germania‟s conceived the
machine to support post-war efforts to rebuild major cities. Liebherr‟s design featured
a rotating tower and horizontal working arm. It had a 360-degree range that made
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construction work much easier. Little did Liebherr know that his design would
become a major inspiration for future prototypes? In the 1970s, most manufacturers
stopped making hydraulically powered tower cranes, switching to electric alternatives
instead. Modern models have dozens of features that the crane operators of old could
only dream of. Today, tower cranes are more powerful, versatile, and energy-efficient
than ever. Today‟s tower cranes allow development companies to work faster and
more efficiently. These heavy-lifting staples are essential for tackling the most
arduous tasks effortlessly. Imagine a large construction site without a single tower
crane on the premises. Not even all the manpower on a job site could lift an electricity
generator up several flights of stairs.
This project is discussed mainly on Design and structural analysis of simple tower
crane operator lift, which reduces the man power and might have a good effect on
production rate. This change can motivate the industry and academics such that the
business of the firm is increased. The development in elector mechanical and
mechanical machines can reduce the revenue cost and rise in capability of delivering
the services at low cost scaling. To look at the safety of the workmen, we designed a
simple tower crane operator lift operated by the operator i.e. there is no additional
man power is not needed by the operator itself can operate the lift simply for the
different kind of beneficial issues that I listed before. "Lifting in Early Greek
Architecture", the Journal of Hellenic Studies, p. 1–19(1).
Figure 2 operator movement on the tower crane manually
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1.2-Statement of the Problem

The project examines the compelling design and modeling of simple tower crane
operator lift i.e. a transporting machine of humans from bottom of the building to the
working area of the tower crane top for the purpose of minimizing the time, cost and
security issues in the working areas. This simple tower crane operator lift is a part of
the tower crane and it is work by electricity and this electric power is get from the
tower crane electric source, the electric power is used to make the ac motor rotate in
clockwise and anti-clockwise directions so the lift will move up and down and do its
job .The main intension of designing this to transport the operators from working area
to the ground plus also minimize the company waste of money.
1.3-Objectives of the Study
1.3.1- General Objectives
The general objective of this project is to design and modeling of simple tower crane
operator lift.
1.3.2- Specific Objectives
The following are the specific objective of this project: -
 To design, hook ,steel wire rope ,lift box ,drum, shaft
 To model the transporting mechanism.
 To design electro mechanical connection.
 To draw part and assembly of the part drawing.
 To select appropriate AC motor.
 To make the modeling of simple tower crane operator lift.
1.4- Significance of the study
This project has a great significant in different areas and for different people directly
or indirectly meaning like it save time of work in case of working time , in other hand
in case of security and the most important case is that the safety of the operators also
managers in addition the other persons around the work place . This project will
reduce the time wasted by operators to clime at the top of the tower crane or to their
work place , very easy to operate, mobile to one sight to other sight after the work is
done its assembly is simple , highly efficient in time saving plus saves cost wasted
by the company‟s.
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 To reduce labor abuse.

 To reduce time consumption.
 To increase quality and accuracy of the work.
 To reduce the waste of money in the company‟s.
 Keeping the safety of operators, managers and other employee in work place.
 To increase the productivity of the workers.
1.5- Scope of the study
The basic idea in this project is design, modeling and implementation of simple tower
crane operator lift. Though it can be design, modeling and implemented in various
methods, when different parameters are taken into consideration, this model is the
most feasible way of implementation plus making the model to adapt the
surroundings.
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CHAPTER TWO
2. LITERATURE REVIEW
2.1-Concept of work study
Tower cranes belong to the largest type of equipment used at high-rise construction
sites and organize the vertical transport of materials for all (sub) contractors. Because,
tower cranes are key in the logistical process, which constantly reforms to become
more efficient, planning crane operations increase in complexity.
The history of simple tower crane operator lift is related with early centuries at
introduction of constriction hoisting machines to the world. As we know this lift
needs electrical power for the many purpose. Example we take for electrical system
and combustion to get energy in diesel engines. Therefore, in this system by using
electric power to rotate the electric motor then get the desired movement from the lift.
It is operation is very simple it is not complicated. It is simply operated by the
operator, reduce time and cost for both sides in the workers also in company.
Work study is a means of enhancing production efficiency (productivity) of the firm
by eliminating waste of time and unnecessary operation. It is a technique to identify
non value adding operations by investigation of all factors affecting the job. It is the
only accurate and systematic procedure oriented technique to establish time standard.
Method study and work measurement is part of work study. Method study is motion
study and work measurement is also called by the name “time study”. Examination of
the methods of carrying an activity is to improve the effective use of resources, times
and to set up standards of performance for the activities being carried out. Work study
succeeds because it is systematic both in the investigation of the problem being
considered and in the development of its solution.
Work
study
Method Work
study measurement
Time Study
Motion Study
Higher
productivity
Figure 3 Elements of Work Study

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Work study is one of the most important management techniques that are employed to
improve the activities in the operation. And it is primarily concerned with the best
way of doing jobs and with establishing standards based on such methods. It is a great
tool in the hands of problems to solve number of different kind of problems. Work
study simplifies a job to reduce unnecessary or excess work, wasteful use of resources
and sets up standard time for performing that job. Work study is a generic term for
those techniques, method study and work measurement which are used in the
examination of human work in all its contexts. And which lead systematically to the
investigation of all the factors which affect the efficiency and economy of the
situation being reviewed, in order to effect improvement. It is a means of enhancing
the production efficiency (productivity) of the firm by elimination of waste and
unnecessary operations.
For design of a simple tower crane operator lift, it is necessary to look into the
design aspects and literature available in order to better understand the designing
aspects.
A literature review of the operation of a simple tower crane operator lift reveals
that the process involves several important steps to ensure safety and efficiency.
According to a study by Al-Mutairi and Al-Harbi (2015), crane operators must
undergo specialized training to learn how to operate the tower crane lift safely and
effectively. The study also highlights the importance of regular maintenance and
inspection of the crane lift to prevent accidents and equipment failure. "Journal of
Construction Engineering and Management" p. 2-10 (2).
In another paper by Al-Suliman and Al-Suliman (2017), the authors emphasize the
need for crane operators to be aware of the weight of the load, the tower cranes lift
maximum capacity, and the proper rigging techniques to prevent overloading and
ensure safety. The authors also suggest that communication between the crane
operator and other workers on the construction site is essential to coordinate the
movement of materials and prevent accidents. “Journal of Construction
Engineering and Management"p.2-10(3).
In addition, a review by Al-Suliman et al. (2018) suggests that the operation of a
tower crane lift requires the operator to have good spatial awareness and hand-eye
coordination to control the crane‟s lift movements accurately.
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The authors also emphasize the importance of the operator's situational awareness
and ability to respond quickly to changing conditions on the construction site.
“Journal of Construction Engineering and Management" p.93: 2-10(4).
Finally, a review by Chong et al. (2019) highlights the need for crane operators to
be aware of the risks associated with tower crane lift operation, such as collisions,
tip-overs, and equipment failure. The authors suggest that the use of advanced
technologies, such as sensors and automation, can help reduce these risks and
improve the safety and efficiency of crane operation. “Journal of Construction
Engineering and Management" p.93: 2-10(5).
 Overall, the literature suggests that the operation of tower crane lift requires
specialized training, good spatial awareness, situational awareness, and effective
communication and coordination with other workers on the construction site. It
also highlights the importance of regular maintenance, site planning, and the use
of advanced technologies to improve safety and efficiency.
Lets see some other types and why we we choose and select simple tower crane
operater lift by steel wire rope.
1, Rack Construction Lift
Böcker is a family-founded and family-run business focusing on elevator and crane
technology since 1958. In 2005, they expanded their product range with powerful and
modularly adaptable rack and pinion elevators. This technology guarantees a safe
vertical transport of both working materials and people. We can look back at decades
of experience in height access and taking the latest technologies into account.
Therefore, we can ensure that a rack and pinion lift from Böcker offers precise,
economic and convenient usage.
Figure 4 rack constriction lift
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Rack Construction Lift part of construction lift machinery for moving people or goods
between floors of a building. Red cabin of construction equipment for moving
workers and engineers between vertical levels of architectural building construction,
and vertical frame of constructional tower. For constructional tower devices,
architectural building construction, construction machines, industrial elevators,
construction equipment, architectural mechanisms, and modern buildings
documentary projects. Rack Construction Lift is a high quality, photo real 3d model
that will enhance detail and realism to any of your rendering projects. " Tower Crane
& Rigging" p.56 (6).
2, The Easy Up is directed by a two-sided guide rail
Figure 5 easy up tower crane lift
The Easy Up is directed by a two-sided guide rail system with an integrated pinion
hoist, without a trailing cable and cable management, and can be tailored to suit the
requirements of any project. This ensures that only minor changes are required to the
existing structure and this also reduces any additional costs required for
construction and installation. The Easy Up can be permanently installed on
machinery and installations that are not in public areas to be used by authorized and
trained personnel. When permanently installed, it can swiftly and easily transport
people and loads, and thanks to the high-quality craftsmanship, it is also able to
provide a sophisticated and reliable transport solution during continuous daily
use. "Lancaster 1999" p. 428(7).
 so the above two models for the tower crane operator lift is more like expensive
and need more experienced persons in the installation and also in the maintenance
in addition to that in the operation .so in this project we model simple tower crane
operator lift for the operators and some other emergency cases.
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 This simple tower crane operator lift is have few components and not much
expensive components and also the assembly process is not that much difficult
and do not take much time of the install and also simple to operate.
 Key benefits of the project
1,Durable and reliable due to first class materials and components
2,Multiple safety features
3,Modern and advanced technologies, continuous development and high
efficiency
4,Custom designs and platform modifications according to customer requirements
There are many problem is that of the operators is not do the work properly because
Tiredness the tower crane height long .just let‟s see the one of the example the
intern sheep program that we see. The building height is almost take 160 meter
from the ground so they become tired in average they climb to the top of tower
crane 4 times per a day once they get up at the morning and second to lunch break
, the three form the lunch break to get up to their working area and the last is that
when they done there work they get down from the work place to their homes so
almost they clime the tower crane minimum 4 times a day so in total they clime
averagely 640 meters or 0.64 km per day so imagine the labor abuse in the
operators so the operators do not done their job as perfect as deserved .
Safety issues this is most important issues in the constriction areas injures are
occurred in the working areas so when injures are occurred so first aide are needed
but more serious injuries are occurred the operates did not get help properly do to
the many problems such as the transporting material are not there plus they do net
make it in time because of transporting problems like simple emergency lifts.
Security issues in the working area there are many security issues like robbery
when you start move from the bottom to the top of the tower there are some bad
behavioral employs and non-employer persons make such kind of things not all
times but at the time I practice the internship program 1 crime is done it was heart
breaking so the employers do not get security at the right time. There are many
problems is that of the company is not get benefited because:
Financial issues the company pay the tower crane operators in contract which
means the get pay in there working time per a day in one day there are 24 hours
from 24 hours the legal working time is 8 hours per a day also there is over time is
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pay when they done in addition to that of the legal working hours but the
operators do not work 8 hours.
The working hour start from 2 o‟clock and ends at 11 o‟clock the operators get
pay per hour approximately they played monthly 30,000 birr when we change it to
day they get played 1000 birr per day when we change it to hour they get 125 birr
per hour so they start their work at 2 o‟clock and finish at 11 o‟clock but they did
not attend the full hour but they get played for those wasted time. Simply when we
take those 4 wasting time reasons we have list above in average they take 30
minutes for each action so when we change it in time 2 hours are wasted so they
get played in 2 non-working hours per a day when we change it to money about
250 birr is wasted from the company when we change the wasted money in to
weekly 1750 in addition when they work in Sunday the payment become double
so when we add the double it become 2000 birr per a week when we change it to
monthly 8000 birr is wasted in monthly when we change it annually it become
96,000 birr is wasted from company so imagine how much money is just wasted
in one site .
 The aim of the project is to evaluate the criteria, according to which Actual ways
and solve the problems in the right manner.
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CHAPTER THREE
3-RESEARCH AND METHODOLOGY
3-RESEARCH
Concept Defining the Literature

development problem study
Proposed Data Data

solution analysis and collection
discussion
Primary data Secondary data

Recommenda
Conclusion tion
Figure 6 Research Frame Work
3.1-Data Collection
Both primary and secondary data collection methods are used in order to collect the
necessary data. Primary data collection methods includes observation, interview, and
secondary data collection methods include literature review, company document
review, web sites, time study principles and method study principles.
3.1.1-Primary Data Collection Methods
Observation: this is one of the most important primary data collection methods and it
is necessary to collect and gatherer the most crucial information by direct observation
about the flow of materials and working methods.
Interview: using this techniques relevant information has been gathered. Those
include working hour, number of machine, number of worker for each operation,
working methods.
3.1.2-Secondary Data Collection Methods
Is the data that have been already collected and recorded by someone else and readily
available from other source.
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Company Document Review: such as working hours per shift, number of machines
used, daily production and organizational structure.
Literature Review: through searching different type of published paper regardless of
work study
Web sites: it helps to find out different types of necessary books, and scholars that
give more explicable things which related with work study.
3.1.3 Data Analysis Method
Is the process of inspecting, transforming, and modeling data with the goal of
discovering useful information, suggesting conclusions, and supporting decision
making.
Time study procedure
1. Obtaining and recording all the information available about the job
2. Recoding a complete description of the method
3. Examining the detailed breakdown to ensure that the most effective methods and
motions are being used, and determining the sample size.
4. Measuring with a timing device (usually a stop watch)
5. At the same time, assessing the effective speed of working of the operative relative
to observers‟ concept of the rate corresponding to standard rating.
6. Extending the observed time to „‟basic time‟‟.
7. Determining the allowance to be made over and above the basic time for the
operation.
8. Determining the standard time for the operation.
 Method study techniques
 Flow Process chart: Procedure process chart
Method study procedure
There are eight steps followed to conduct method study. These are:
1. Select the job or process to be studied based on these two criteria:
2. Record from the direct observations everything that happens.
3. Examine the recorded facts critically and challenge everything that is done.
4. Develop most economic method taking in to considerations all circumstances.
5. Measure/Evaluate the quantity of work involved in the method selected and to
calculate a standard time for doing it.
6. Define the new method and time to standardize.
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3.2 Methodology
The technical design of a simple tower crane operator lift depends on where it is to be
applied and the type of lift. Most lifts designs are market driven, with several options
provided to meet specific market needs. This lift should have technical properties
such as being corrosion resistant plus making the high speed rotating drums, bronze
and carbon steel depending on the choice of material to be used based on many
criteria‟s.
Introduction
Concept Embodiment
Methodology
Development design
Concept generation and

selection
Detail design
Part drawings
Manufacturing cost Cost analysis Material cost
Result and conclusion
Recommendation
Reference
Figure 7 methodology
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3.3 Technical Design

The technical design of a simple lift depends on where it is to be applied and the type of lift.
Most lifts designs are market driven, with several options provided to meet specific market
needs.
This lift should have technical properties such as being corrosion resistant plus making the high
speed rotating drums, bronze and carbon steel depending on the choice of material to be used
based on many criteria‟s.
Issues to consider when carrying out the technical design include identifying number of
elements as discussed below:
It should also be possible for the lift to operate with the upward and downward.
 Drive system:-The drive system for the lift is based on an electric powered motor which
depends on emerging technologies that optimize the use of flux vector drives. The amount of
torque and power resulting from the calculation must be translated into a motor type and size.
Depending on what is locally available in terms of power supply or even available physical
space, the motor emerging from the calculations may prove beyond what is possible. In that
case the motor and the lift performance have to be reduced to make sure the required power
demand falls within the available power supply. Also make sure the motor can be physically
installed on the other component, and that effective motor power and torque (and in some
cases motor speed) fall inside the operational limits of the system.
 Cable: - In this case, the drum is designed with a heavy cylinder with two flanges integrated
into the design to contain the cable. The purpose and the load to be handled by the lift are
used to determine the material used for the cable.
In this case, the working load must be equal to five times the working load. In this case the
middle later is used to determine the force and speed on the winch.
 Drum: - To tidily guide the cable around the drum, a groove is used in this case. The
hauling forces and the material used are determinant factors in determining the hauling forces
of the winch.
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3.4 Mechanism for Lifting

It is important to design a mechanism that factors each parameter that matters in each of the steps
involved in the design process.
In this design, suppose the lift rate is given by Lr, the number of actual lifts time LT, and NL the
number of lift actions, then the following equation.
Lr=NL/LT
The above equation holds true for the lift rate or the number of time for each cycle of lifting.
Figure 8 Simple Lift Structure
3.5 conceptual development

Concept development activities are organized per the following procedure:
 Identify customer needs: involves the identification of the needs and requirements of the
customers by interviewing the individuals who were using the related system.
 Establish Target Specifications: we have established primary and secondary markets for
the product.
 Analyze Existing Competitive Products: analyzing existing competitive product is use
to compare our products. If the existing product has good features, we will try to include
in our design.
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 Generate Product Concepts: our team develops several concepts to fulfill the customer
needs
 Select a Product Concept: by using the process of evaluation by screening matrix we
have selected the best concept.
Conceptual design –one
Figure 9 Simple Lift Structure
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Conceptual design –two
Figure 10 Simple Lift Structure 2
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CONCEPTUAL DESIGN – THREE
Figure 11 Simple Lift Structure 3
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Comparisons of the conceptual designs on our project

 The design of tower crane lift involves the lode capacity, and lifting high required for the
project .The first step is to calculate the lode capacity needed for the crane. These
involves estimating the weight of the material to be lifted and the distance they to be
moved.
 One‟s the lode capacity has been determined, the next step is to select the appropriate
length and lifting height for the crane.
 Other factors to consider when designing the crane lift include the terrain of the
construction site, the weather condition, and any potential obstacles or hazard that may
affect the lifting process.
Overall, a well-designed tower crane operator lift greatly improve the efficiency and the safety of
the construction project.
Concept screening and scorning
To score and screen the conceptual design of the tower crane operator lift ,you could use a set of
criteria to evaluate the design and determine its phis ability and effectiveness.
 Some common criteria‟s for evaluating the tower crane lift design
 Stability
 Maintenance,
 Durability
 Safety
By scoring and screening of the conceptual design of the tower crane lift, we can
identify the strength and weakness of the design and make informed decision about
whether to move forward with design of make modification to improve its
performance.
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Concept screening and scorning
Table 1 concept screening and scoring
criteria Concept 1 Concept 2 Concept 3

Stability 8/10 7/10 7/10
Maintenance 9/10 7/10 6/10,

7/10
Durability 7/10 8/10 9/10
Safety: 8/10 6/10 6/10

Overall Score 32/40 28/40 28/40
 Generally based on the comparison criteria‟s that we list in the above we select the
conceptual design of =one over the rest of the designs.
Concept design =1
 So the height and the lifting capacity of the simple tower crane operator lift.
 Will be 30-170m these length is the average length of the tower cranes our country context.
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3.5 Material Selection

Several materials have been used in steel wire ropes, sheet metal and electric motor fabrication.
The selection of material must be done in order to achieve our objective or otherwise it will be
the cause of failure occurrence. The selection of material of the shell taken in to account the
suitability of the material maximum working condition and fabrication process.
Selection Procedure of Material for simple tower crane operator lift:
The design processes from concept design to defile design involve the progressive from the large
number of material choice toward a single material. The processes of material selection involve
the following 5 main steps as follow.
1. Identify the design requirement: material selection being with design requirement which
involve examining the function, objective of design, safe and reliability, low maintenance
cost and constraint.
2. Identify material selection criteria: eliminate the material that don‟t meet constraint limit,
no trade off beyond this limit is allowed.
3. Identify candidate material: using material selection criteria identify the appropriate
material for the simple lift, steel wire rope and for the drams and for other parts.
4. Evaluate candidate material: researched the performance history top ranked candidate
material.
5. Select the material: finally select the required material for the appropriate part.
Factor Affecting Material Selection

Physical factor:
 Size- smaller as much as possible
 Weight- lighter as much as possible
Mechanical factor:
Strength- a material ability to with stand an imposed load or stress. Strength determines
how thick a component must be with stand the imposed load. The overall strength of
material is determined by its yield strength, ultimate tensile strength, creep, and tensile
strength. It is significant factor for material selection of simple tower crane operator lift .
Fracture toughness: refers to ability of a material to withstand condition that will cause brittle
fracture. Fracture toughness decrease with temperature decrease.
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Life of component factor:

 Corrosion resistance- a material resistance to corrosion is probably the most
important factor that influences its selection for specific application.
 Wear resistance- parts are used to combat damage to machinery caused by
high temperature and corrosion. Economical factor: cost and availability
 Material durability , Availability of maintenance material
Lift box and some other hand made manually which means by welding, constructed from a
number of different materials based on the availability and cost of material, easily fabrication,
and resistance to corrosion. Basically there are three types of material.
I. Metal: are used for the following purpose
 High strength and ductility
So from those one, the property discussed above the best material for our design project is
metal. We select metal based on its properties. Then from metals select due to the property of
strength, correction resistance, fracture toughness, availability, reliability, fabric ability, ease
manufacturing and its cost. Based on those properties we can compare some materials. The
selected metals are listed below.
1. Carbon steel
 Capable of retaining strength, even at minimum thickness
 Resist vibration and shock
 Can be recycle easily
 Excellent tensile strength
2. Stainless steel
 Extremely resistant to chemical
 Have a high resistance to corrosion
 Great weld ability ,Compatible for with standing humid condition
3. Aluminum
 Capable of maintaining high tensile strength
 Easier and more cost efficiency
 Lager coefficient of expansion
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Let us compare their strength, corrosion resistance, cost, machinability, reliability and
availability in the following table.
Table 2 material comparison for simple lift
Selection Criteria
Types Of Total Rank
Strength Corrosion Machine Reliability Availa Non-
Material Cost
Resistance Ability bility Toxicity
Carbon steel 9 6 8 8 9 9 7 56 1
Stainless steel 8 7 4 7 8 8 7 49 2
Aluminum 3 9 7 9 5 5 9 47 3
From the above table, we have ranked carbon steel, stainless steel and aluminum as shown in
the above table. From those the selected material based on the above properties is carbon
steel. “Overview of the Materials Selection Process" Volume 20, 46 :( 8 ).
So as the above table shows that the carbon steel is more suitable for the part of the lift box
and some other support parts.
 So select the carbon steel.
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Chapter Four
4. Design Analysis
4.1 About the Motor
4.1.1 control system for elevator drive
Selection of motor power rating and driving pulley radius
Motor sizing refers to the process of selecting the correct motor to run a given load. It is
important to size a motor correctly due to the following basic reasons:
- If a motor is too small for an application it may not be sufficient to start the load and
accelerate it up to the corresponding elevator speed or even if it can operate the load up to
desired speed the motor will overheat and as the result it may burnout
- If a motor is much larger than the required load operation, and then it needs too much
money in purchasing such a large motor which in turn increases the cost.
- Additionally, a motor typically operate inefficiently when running at very little power
below the corresponding of its power rating.
The motor used in this thesis work is an AC motor. Based on the specification given above, the
output power of the motor is calculated by using the general equation of force on the rope by
assuming constant maximum linear motor speed of 0.16 m/s, to design an elevator system for a
building with ten floors above the ground (100m in height). Considering the elevator lift box
moving upward (ascending) with the specified linear speed above, the total load lifting force (Fl)
developed during the journey can be given by the following equation as
Fl  (Ml  Mc  Mcw)g
Then the energy required for upward moving lift box is given by the energy equation based on
load force and the linear distance travelled by lift box as given by the following equation.
E  FS
So the power on motor shaft is given by a time rate of energy and given by the equation below.
P = E/t = FS/t = FVc
From the elevator drive system, while ascending (upward moving) lift box the counter weight
moves downward (opposite direction to car movement) and doing certain work which reduce the
required lifting force. This is the basic advantage of regenerative elevator drive system. Then
equation of power is rewritten by substituting for lifting force as:
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P = (MI + Mc – Mcw).g.Vc
Where,
P = total power on motor shaft
Vc = linear speed of lift
g = gravitational force
Ml = load mass
Mc = lift box mass
Mcw= counter weight mass
Substituting for designed parameters and evaluating for motor power gives:
P = (400 + 170 – 300)*9.81*2m/s = 5297.4watt = 5.2974kw
Additionally, the losses in transmission of power to the driving pulley must be considered and
included due to that several assumption are considered when compared to the real physical
elevator drive system. Therefore, the mechanical power output (P) required for driving the load
is given by another equation including the efficiency of the system as:
Ptractive = P/η
Where, η is efficiency of the transmission system Let us consider the efficiency of the
transmission system to be 0.85. Therefore the mechanical power output required is:
Ptotal = P/η = 5.2974/0.85 = 6.23kw
Therefore, the motor with power rating of 7hp is selected to drive the specified elevator load
safely.
Assuming the selected motor is kept at rated speed of 200RPM .
"Konrad Rüffer: Schalten von Elektromotoren. Verlag Technik, "Berlin 1990, ISBN 3-341-00827-6(9)
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Design of Pulley
What is a pulley and what are pulley systems?
Without getting into all of the various pulley set-ups, at their core, pulleys have a wheel and a
rope. A pulley with only one fixed wheel simply reverses the direction of the input force relative
to the mass being pulled. With only one wheel, in order to lift a mass of 100 kg (220 lb), you
would need to exert a 4 ton of force equivalent (40,000 Newtons) on the other end of the rope.
How can the correct size for a motor be determined?
The first step to designing a motor is determining the torque output required from the motor.
Torque = (Load Weight * Radius of Pulley) / Number of Pulleys
= 40585N * 0.5m / 2 = 10146.25nm
What force is needed to meet that velocity?
Now you have a rough estimate of the torque requirement for your motor. And like tipping a
waiter, add 10-20% to account for all the stuff you assumed (no air friction, no machine friction,
no effect from the elasticity of the ball) and go find a motor.
Likewise with the drive motors: you need to calculate the force needed and figure out what that
means in terms of torque.
Figure 12 upper system load assembly
To calculate the force required to lift a load with a pulley, you need to know the weight of the
load and the number of pulleys used in the system. The formula to calculate the force required is:
Force = Load Weight / Number of Pulleys
Force = 40585N / 2
= 20292.5N
To calculate the velocity required to lift a load with a pulley, you need to know the distance the
load needs to be lifted and the time it takes to lift the load. The formula to calculate velocity is:
Velocity = Distance / Time = 150m / 300se = 0.5m/s
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 We have considered 40, 000 loads, (4 tons) for the lifting through this simple tower crane
operator lift system.
 Maximum load of mass to be lifted = 40,000 N
 Weight of the rope = 110 mtr x 0.54 Kg/mtr =59.5 Kg= 585 N
 Total load on lifting (T) = 40000+585 =40,585 N
"How crowned pulleys keep a flat belt tracking" 78, (10)
4.2 Designing Selection of Rope (Steel Wire Rope)
As per the specifications, standard wire rope size of nominal diameter 12 mm and type 6 ×19
with steel core is selected. This wire rope has tensile strength and minimum breaking force equal
to 1800 MPa and 73.6 KN respectively
Figure 13 steel wire rope
Efficiency of wire rope when it is bent around rope drum, η = 0.94

Consider 1 sieve pulley arrangements
Thus, tension in wire rope
P = Load to be lifted / (1 *0.94)
= 40585/0.94
 43,175.53 N
This value must have to be lesser than the safe working load Recommended factor of safety for
general rope applications FS = 6 Safe working load = SWL
= Fb/fs = 73600/6
 12266.67 N
Hence, tension in the wire rope < safe working load.

The selected wire rope is safe and acceptable.
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Now, each wire diameter in wire rope

= 0.45* d
= 0.45 × 12
 5.43 mm
Metallic area of wire rope = 0.40d^2

= 0.40 ×12^2
 57.6mm^2
"Steel Wire Ropes for General Engineering Purposes" 65, (11)
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4.3 Design of simple lift Drum

Diameter & Groove size
Figure 15 simple lift Drum
As per IS specification D/d ratio shall not be less than 18

Select D/d= 27 for further calculations
Thus following dimension parameters of rope drum are required to be calculated.
Inner diameter of rope drums at bottom of groove,
D = (D/d ratio) × d = 27 × 12
 324 mm
Minimum radius of groove, r = 0.53 × d

= 0.53 × 12
 6.36 mm
Minimum depth of groove h = 0.35 × d

= 0.35 × 12
 4.2 mm ≡ 4 mm
Outer diameter of rope drum Do = D + (6d)
= 324 + (6x12)
 396 mm
Pitch of the groove p = 1.08 × d

= 1.08 × 12
 12.96 mm
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4.1.3.1 Minimum no. of wire rope turns on rope drum

n = iS/3.14D +2
= 110000 / (3.14 x 324) +2
 110 turns
Length of drum, L
L = (iS/3.14D +7)P
 = 892.54 mm
4.1.3.2 Thickness of drum

Assume thickness of drum = 30 mm
The hoop stress in the winch drum, ðh (MPa), =c(T/dXt),
ðh= hoop stress in winch drum (MPa),
T = Load on the rope, Newton
d = diameter of the rope, mm.
t = thickness of winch drum, mm
C = 1 for 1 layer & 1.75 for more than 1 layer
According to the guidelines, the maximum permissible hoop stress should not exceed
80% of the material yield stress ( ðh <0.80 6y).
In this case, the material yields stress. Selecting grey cast iron G4000 with yield stress 276MPa
Hoop stress in the lift drum
= ðh(MPa) =1.75(40585/12*30)
 197.28 Mpa
Permissible hoop stress = 0.80 x 276

 220.80 Mpa
Stresses developed on the drum
Crushing Stress = ðc=P/t*p

= 40585 / (30 x 12.96)
 104.38 MPa
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Torque on rope drum T = P+(D+d)/2

= 40585 + (324+12)/2
 40753 N-mm (40.75 N-m)
Selection of the shaft

Selecting the diameter of Indian standard code ds=20mm
Transmissible torque value = (9.80665*3.14*ds^3)/4000
 61.61 N-m
Here, transmissible torque value > torque on rope drum. Thus, the shaft is acceptable.
"Design and Finite Element Analysis of Rope Drum and Drum Shaft for Lifted Material Loading
Condition-Patil " Special Issue 2 Page9 (12).
Figure 16 Maximum stresses on drum
4.4 Analysis of Hook

A crane hook is designed to connect with chains and ropes attached to point loads like crates,
construction beams, and machinery. The basic function of it is to lift the load, to carry it and to
transfer it from one place to another. Sometimes an accident may occur due to stress
concentration factor in it so stress analysis is necessary before make it applicable. Nowadays, the
design and analysis both are carried out by software‟s with the help of advanced engineering.
The material is selected by default as Structural steel having following characteristics
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Table 3 Engineering Material Properties of Structural Steel for hook
Mechanical Properties Values Unit

Young‟s Modulus 2×105 Mpa
Poisson's Ratio 0.3 -
Shear Modulus 7.6323×104 Mpa
Density 7850 Kg/M3
Tensile Yield Strength 250 Mpa
Tensile Ultimate Strength 460 Mpa
Compressive Yield 250 Mpa
Strength
Curved beam flexure formula is used when the curvature of the member is pronounced as in
case of hook for different cross sections mathematical analysis of stress:
𝜎 = 𝐹 𝐴 + 𝑀 ×𝑦 𝐼
Where, M=maximum bending moment.
Y=Distance between centroid axis to neutral axis.
I=Moment of inertia for different cross sections
"Deborah L Boklund Moran, “Hook Assembly and Kit,”" United States Patent 45, (13)
4.5 Analysis of a Tower Crane main vertical support element (mast)

4.5.1 Design of mast
In our present study a linear static analysis of guyed mast are considered for its structural
response. Masts supported laterally by guy cables usually provide a more economical solution
for taller towers. The cables are anchored to the ground and are always pretension. Due to overall
flexibility, slenderness and lightweight, guyed masts are susceptible to large deflections and also
exhibit high dynamic sensitivity to turbulent winds. As a result, dynamic analysis is considered
imperative for calculating the peak axial forces in the mast. A suitable structural dimension of
the model is identified and the wind forces acting on the structure is calculated at different guy
levels. The standard approach for the equivalent static analysis of line-like structures, based on
the gust factor is reviewed with special reference to the case of systems with intermediate elastic
supports, like cable-stayed masts. The dimensions of mast are fixed by trial and error method.
The height of the mast is fixed as 100m.
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Base width of the mast is 1m pressurized cable diameter as 20mm. Most research has been
undertaken into the modeling of a guyed mast as an equivalent beam element. The self-weight of
a lattice truss is substantially different to that of a beam element with similar behavioral
properties. In order to control the dead load and mass of the mast, the self-weight and mass of the
mast.
Figure 17 tower crane main support or mast

 Method of Analysis
The internal forces in the members of a statically determinate pin jointed frame are only axial
forces. These can be determined by using
A. Method of sections
B. Method of Joints
A. Method of Joints: In this method, the free bodies of the joints are considered one by one and
the equations of Equilibrium are written for each joint in terms of ∑Fx and ∑Fy. Assuming the
support reactions have been computed from the overall Equilibrium of the structure. In this
method there are 2/3 numbers of unknown reactions at a joint if it is a plane/space truss. In the
plane truss analysis, the analysis will be start from the support where only two members will
meet. This analysis is continued by finding the member forces from one joint to another joint.
B. Method of Sections: In this method, the structure is intersected by suitable section and the
Equilibrium of the free body of the structure on either side of the section is considered. The
forces in the members intersected by the section are treated as external forces in writing the
33 | P a g e
Equations of Equilibrium. Since the conditions of Equilibrium provide only three independent
Equations in the case of plane structure, it is preferable to select a section which interests not
more than three members unless the forces in some of the intersected members are already
known. When the section intersects only three members, the axial forces in the member may be
determined by taking moments about the same points at which two other points meet.
The basics to design mast/tower: The design of a mast or tower depends on several
factors, such as the height, wind load, weight of the structure, and the type of material used. The
calculations usually involve determining the maximum bending moment, shear force, and
deflection at different locations along the mast/tower. These calculations are important to ensure
that the mast/tower is structurally sound and can withstand the forces acting on it. It is
recommended to consult with a professional engineer for the design and calculation of a
mast/tower to ensure safety and compliance with local regulations.
Calculating the maximum bending moment, shear force, and deflection for a mast/tower involves
several steps. Here is a general overview of the calculation process:
1. Determine the loads: Determine the wind load and the weight of the mast/tower and any
equipment attached to it.
2. Calculate the reactions: Calculate the reactions at the base of the mast/tower using the
equations of statics.
3. Draw the shear force and bending moment diagrams: Draw the shear force and bending
moment diagrams for the mast/tower. The shear force diagram shows the variation of
shear force along the length of the mast/tower, while the bending moment diagram shows
the variation of bending moment along the length of the mast/tower.
4. Calculate maximum bending moment and shear force: Determine the maximum bending
moment and maximum shear force from the bending moment and shear force diagrams,
respectively.
5. Calculate deflection: Calculate the deflection at different locations along the mast/tower
using the equations of beam deflection.
 We have a mast/tower with a height of 100 meters and a weight of 5000 N. The mast/tower is
exposed to a wind load of 500 N/m2. We will use a steel mast/tower with a cross-section of
100 mm x 100 mm and yield strength of 250 MPa.
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 Step 1: Determine the loads

Wind load = 500 N/m2 x 100 m = 50,000 N
Weight of mast/tower = 5000 N
 Step 2: Calculate the reactions
The mast/tower is fixed at the base, so the reactions at the base are equal and opposite to the
sum of the wind load and weight of the mast/tower:
Reaction = (Wind load + Weight)/2 = (50,000 N + 5000 N)/2 = 27,500 N
 Step 3: Draw the shear force and bending moment diagrams
using the equations of statics, we can draw the shear force and bending moment diagrams:
Using the equations of statics, we can draw the shear force and bending moment diagrams:
Shear force diagram:
 From the base to 100 m: Constant at 27,500 N
 From the base to 100 m: Linearly increasing from 0 to 150,000 Nm
 Step 4: Calculate maximum bending moment and shear force
the maximum bending moment occurs at the base of the mast/tower, where the bending
moment diagram intersects with the vertical axis. Therefore, the maximum bending moment
is 150,000 Nm.
 The maximum shear force occurs at the top of the mast/tower, where the shear force
diagram intersects with the vertical axis. Therefore, the maximum shear force is 27,500 N
 Step 5: Calculate deflection
Using the equations of beam deflection, we can calculate the maximum deflection at the top
of the mast/tower:
 Maximum deflection = (5 * Wind load * Height^4)/(384 * E * I)
where E is the modulus of elasticity of steel (200 GPa) and I is the moment of inertia of
the cross-section (I = (1/12) * b * h^3 = (1/12) * 100 mm * (100 mm)^3 = 8.33 x 10^6
mm^4)
 Plugging in the values, we get:
Maximum deflection = (5 * 10,000 N/m2 * (100 m)^4)/(384 * 200 GPa * 8.33 x 10^6
mm^4) = 1.35m
 Therefore, the maximum deflection at the top of the mast/tower is 1.35 meters.
"Design of Machine Elements" Edition: 2, 57, (14)
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Figure 18 mast of the tower crane
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4.6 Components of simple tower crane Operator Lift (project)

4.6.1 Electric motor
The first part designed in this project is this. It is because; based on its measurements I must
measure remaining parts. And the weight of all other parts including the payload will have its
great effect on this part since it is the basic part of the project. This part is an assembly of six
different parts. Part 1 is the protective shell of the electric motor part 2 is the back cover of the
electric motor part 3 is the cover of the electrical systems on the motor part 4 is the rotating
part of the motor by electric filed that crated in the motor part 5 is the collie of copper wires in
the motor part 6 the base of the hole body of the motor which support the all components of the
motor and it gives the power for the lift up and down movement by rotating clockwise and
anticlockwise directions and commanded by remote controller . So, it is the main source of
power for the system. This all parts assembled together and make the system work smooth. The
figure bellow shows all the parts and their assembly and the dimension given below.
Parts and their assembly and the dimension given below.
Part 1
Figure 19 shield cover of the electric motor
Part2
Figure 20 back cover of electric motor
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Part 3
Figure 21 top cover of electrical system on the motor
Part 4
Figure 22 the rotary section of electric motor
Part 5
Figure 23 coil of wires inside the motor
Part 6
Figure 24 base for the electric motor
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The overall assembly of the electric motor is showed below
Figure 25 electric motor
 Voltage /frequency=200-380 V / 50Hz

 No Of Turn Per Minute =200RPM
 Motor power =7 HP
 Speed (m/min) =16
 Brake (electromagnetic) = 4 kg
A lift, a vertical transportation system, is used to move people and goods between different
floors or levels of a building. The use of motors is essential for the up and down movement of
lifts, and in the past, DC motors were often used as the driving device for lifts. Simple and stable
structure, therefore they are reliable and easy to maintain, it can be easily controlled by changing
the frequency and voltage of the power supply, and it can be used with a variable frequency drive
(VFD) to control the speed and torque of the motor, thus providing an energy-saving solution.
One of the biggest safety aspects to consider with a high-speed lift is the over speed regulator.
The speed these lifts are reaching is advanced. As a result, the components such as the motor
need to be bigger and more robust.
The construction of the single phase and three-phase induction motors includes a stator where the
primary winding is wound and a basket-shaped, solid aluminum die cast rotor. The rotor is low-
cost because the structure is simple and does not use a magnet.
When the speed of this motor is to be controlled, a tacho-generator is used to detect the speed
and is attached to the motor .The tacho-generator is made of a magnet connected directly to the
motor shaft and a stator coil that detects the magnetic poles, and generates an AC voltage at 12
cycles per revolution.
Since this voltage and frequency increase with a rise of the rotational speed, the rotational speed
of the motor is controlled based on this signal.
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Figure 26 electric motor
The case of an induction motor as shown a stable range and an unstable range exists in the
Rotational Speed - Torque curve. Since it is impossible to reliably operate in the unstable range,
simple voltage control (open loop control) is limited to controlling the speed in a narrow range
like, N1~N3 in .To make it possible to operate reliably even in the above-mentioned unstable
range, it is necessary to detect the rotational speed of the motor and use a voltage control
mechanism (closed-loop control) that reduces the speed error when compared to a set value.
Naturally, more is demanded of the brakes in a high-speed lift, as they need to provide a smooth
stop to a faster-moving cabin. Using a combined mechanism with springs at the bottom of the
lift, you are guaranteed a safe landing when the lift arrives at any floor.
In general, lifts in the modern world often use three-phase induction motors, but some lifts use
other types of motors. If you are wondering which motor you should use, you should consider a
combination of the method and reliability of controlling start, speed, torque, and stop, as well as
the other features and characteristics of the motor.
4.6.2 Hook
This part can be designed for holding purpose. like it is used for holding the steel wire ropes for
pick up the lift box from the starting position to the place where the lift gone . it designed like
question mark in the position of upside down. Tis part has only one full component. The power
source is connected to the dram then the steel wire rope is twists over the dram and the steel wire
ropes are connected to the hook the hook is connected to the rest two connecting steel wire ropes
then the two ropes used as a link between the hook and the lift box so the hook support for the up
and down movement. The dimensions of this part are given below.
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Figure 27 hook
The total Length of the part (L) = 200 mm (0.20m), Thickness of the part (t) = 65 mm (0.065m)
Width of the part (b) = 55 mm (0.055m)
Internal circle dimension = 70 mm (0.07 m)
Trade dimensions at the top of the hook = 70 mm height M 42 *3.0
4.6.3 Lift box
This part is the main part of the system. This part is used to carry the operators or it is used as
the where the operators stand and the controllers are installed. This is a bit larger and huge in
size than other parts of the system.
The movement of this part is depending up on the movement of the rest components and work is
done when this part is move up and down in the operation.
This part has 2 parts.
The main purpose of these two parts is part 1 it is the total frame work of the lift box with
opening for cooling purpose part 2 the part is the door cover for the main lift box for closing
and opening purpose. The power source for this part is from the electric motor to steel wire ropes
the hook then finally to the lift box. The dimensions of this part are:
Figure 28 the lift box section
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Figure 29 door cover section
Width of the door (W of Door) = 600 mm (0.6 m)

Length of the door (l of Door) = 1800 mm (1.8 m)
Area of the total part of the lift box part (A) = 7,000,000 mm^2 (7 m^2)
Area of the door cover (A) = 1,080,000 mm^2 (1.08 m^2)
Volume of the total part of the lift box part (V) = 14,000,000,000 mm ^3 (14 m^3)
The assembly part of the simple lift
Figure 30 lift box
Total height of the part (h) = 2000 mm (2 m)
Total length of the part (l) = 1000 mm (1 m)
Total width of the part (w) = 700 mm (0.7 m)
Thickness of the sheet metal that the lift box is made (t) = 0.8 mm (0.8 * 10 ^ −3 m)
42 | P a g e
4.6.4 Steel wire rope

Now we have arrived at the fourth part. Part 4 is the linkage itself between end lift box and hook
also hooks to the drum. It has the ability to rotate around the axis at the end of the drum (around
X axis). It can rotate 360 degrees on the axis. How much it should rotate can be adjusted as per
the requirement of the user. It also holds the end of the hook the desired position. It acts a joint
for the hook and the lift box .The part only itself. The part is described below and its dimensions.
Part 1
Total length of the steel wire rope= 50,000 to 200,000 mm (50 to 200 m)
Diameter of the steel wire rope = 12mm (0.012m)
Diameter of steel wire rope wire= 5.43 mm (0.0006m)
Tension on wire =43,175.53 N
Braking force =74 KN
Lay direction of the wire = To the Right
4.7.5 Drum
On the side of the electric motor this part is installed. The part 5 can be seen. This is the one
that rotates around x axis. This part allows the steel wire rope is tested around it. This part has
installed in front of electric motor and copy the motion of the electric motor. This part has the
capacity of with stand the load. This part has only one component, dimensions of the drum is
listed below.
Plus the shaft that transmit power from the motor to the drum most important and I consider it
as the one part of the drum mounted on the motor also on the drum.
43 | P a g e
Figure 32 drum
Width of the part (L) = 300 mm (0.3 m), Height of the part (H) = 300mm (0.3m)
Diameter of the part (D) = 270mm (0.27 m)
Inner diameter (d) = 100mm (0.1m)
Area of the part (A) = 31,400 mm^2 (0.0314m^2)
Plus the shaft that transmit power from the motor to the drum most important and I consider it
as the one part of the drum mounted on the motor also on the drum.
Figure 33 shaft
 Outer diameter (d) = 100mm (0.1m), internal diameter =50mm, length =500mm
44 | P a g e
Chapter Five
5, Result Discussion
5.1 Electric motor
Table 4 result discussion on electric motor
Name Voltage and Brake RPM POWER speed Weight

frequency
Electric 200-380 v 4kg 200 7 Hp 20 to 35 mpm 20 KG
motor 50Hz (single speed)
5.2 Hook
Table 5 result discussion on hook
Name Trade dimensions Length Thickness of the Width of the Internal circle
at the top of the part part dimension
hook
Hook 70 mm height 200 mm 65 mm (0.065m) 55 mm 70 mm (0.07 m)

M 42 *3.0 (0.20m) (0.055m)
5.3 lift box

Table 6 result discussion of lift box
Nam height length width Thickne Width Length total Area of total
e of the of the of the ss of the of the of the Area the door Volume
lift (h) lift (l) lift sheet door door
(w) metal
Lift 2000 1000m 70 mm 0.02 mm 80 mm 1800mm 2 m^2 0.144m^2 0.14m^3

box mm (2 m (1 m) (0.07 (0.08 m) (1.8 m)
m) m)
45 | P a g e
5.4 Steel Wire Rope

Table 7 result discussion on steel wire rope
Name Total Diameter of Diameter of Tension Braking Lay

length the steel wire steel wire On wire force direction of
rope rope wire the wire
Steel wire 50 to 200 9 mm 5.43 mm 43,175.53N 75 KN To the Right
rope m (0.009m) (0.0006m)
5.5 Drum
Table 8 result discussion of drum
Name Width of the part Height of the Diameter of the Inner diameter Area (A)
(L) part (H) part (D) (d)
Drum 300 mm (0.3 m) 300mm (0.3m) 270mm (0.27 100mm (0.1m) 0.0314m^2
m)
Table 9 results of the drum analysis
Inner Minimum Minimum Outer Pitch no. Length of thickness Hoop stress
diameter radius of depth of diameter of the turns drum, L of drum
of rope groove groove of rope groove
drum drum
324 mm 6.36 mm 396 mm 396 mm 12.96 110 892.54 30 mm 197.28 Mpa

mm turns mm
46 | P a g e
Table 10 results of the drum analysis
Permissible hoop stress Crushing Stress Torque on rope drum Transmissible torque
value
220.80 Mpa 104.38 MPa 40753 N-mm 61.61 N-m
The idea of a simple tower crane operator lift is an important consideration in the construction
industry. The safety and efficiency of such a lift are critical factors in ensuring the smooth
operation of a construction site. In this study, we compared three conceptual designs for a simple
tower crane operator lift and selected conceptual design 2 based on safety, analysis results, and
other mechanical comparing ways.
Safety was a top priority in the evaluation process. Conceptual design 1 was eliminated due to
safety concerns related to the stability of the lift. The design was found to be too top-heavy and
unstable, which could lead to accidents and injuries. Conceptual design 3 was also eliminated
due to safety concerns related to the complexity of the design and the potential for malfunctions.
The design was found to be too complicated and difficult to maintain, which could lead to
operational issues and safety hazards.
Analysis results were also a key factor in the decision-making process. Conceptual design 2
performed well in all analysis tests, including stress and load testing. The design was found to be
the most efficient in terms of energy consumption and maintenance requirements. The lift was
also found to be the most reliable and durable, with a simple and intuitive design that required
minimal training for operators.
In conclusion, the selection of conceptual design 2 for the simple tower crane operator lift was
based on a thorough evaluation of safety, analysis results, and other mechanical comparing ways.
This design was found to be the most reliable, efficient, and cost-effective option for the
intended purpose. The results of this study can be used to inform the development of simple
tower crane operator lifts in the construction industry, with a focus on safety, efficiency, and ease
of use. The above results are obtained from the above basic load and analyses of the parts in the
project do the results that we obtained in the results are more like acceptable and safe.
47 | P a g e
Chapter Six
6, Cost Analysis
Table 11 cost analysis
No Item Quantity Cost Total cost
1 Steel wire rope 1 60.79 birr per meter Birr 10,943.34
180−200 Meters
Required
2 Hook 1 ….. Birr 154.21
3 Sheet metal of − 0.8MM 4 2000 birr for each Birr 8000
4 Electric motor 1 …... Birr 15,566.99
5 Remote controller of the motor 1 ….... Birr 4800
6 Direct and indirect labor 400 birr per day=3 Birr 1200
days for assemble
and install
Electrode for
So the total cost of this simple tower crane operator
Welding Is About Birr 40,664.54
lift will be about 50,000 birr in the additional 4000 Birr.

=44,664.54
transportation and the other indirect actions from Total
birr
the manufacturing to installation point.
48 | P a g e
Chapter Seven
7. Conclusion and Recommendation
7.1 Conclusion
The design and simulation of a simple tower crane operator lift has been a challenging and
rewarding project. The design process involved careful consideration of the materials,
dimensions, and load capacity of the crane. The simulation process allowed us to test the simple
tower crane operator lift crane's performance under different operating conditions and identify
potential issues before the crane was built. Through this process, we were able to develop a safe
and efficient crane that can be used in a variety of applications.
One of the key benefits of the simple tower crane operator lift is its versatility. The crane can be
used in a wide range of industries, from construction to manufacturing, and can lift and move
heavy loads with ease. The crane's compact design also makes it ideal for use in tight spaces,
where larger cranes may not be able to operates this project have wide range of application
benefits for the operators also for the company benefit.
Another benefit of the simple tower crane operator lift is its safety features. The crane is
equipped with a range of safety features, including emergency stop buttons, overload protection,
and anti-collision systems. These features help to ensure that the crane can be operated safely
and reduce the risk of accidents or injuries.
Overall, the design and simulation of the simple tower crane operator lift demonstrate the
importance of engineering design and simulation in developing safe and efficient systems. By
carefully considering the materials, dimensions, and load capacity of the crane, and testing its
performance through simulation, we were able to develop a crane that meets the needs of a wide
range of industries and can be operated safely and efficiently.
49 | P a g e
7.2 Recommendation
Based on the design and simulation of the simple tower crane operator lift, there are several
recommendations for its use in construction areas. Firstly, it is recommended that the simple
tower crane operator lift be operated by trained and experienced personnel who are familiar with
the crane's capabilities and safety features. This will help to ensure that the crane is operated
safely and efficiently, reducing the risk of accidents or injuries.
Secondly, it is recommended that the simple tower crane operator lift to be regularly inspected
and maintained to ensure that it is in good working condition. This includes checking the lift load
capacity, inspecting the cables and pulleys, and ensuring that all safety features are functioning
properly. Regular maintenance will help to extend the life of the crane and reduce the risk of
breakdowns or malfunctions.
Thirdly, it is recommended that the simple tower crane operator lift be used in conjunction with
other safety measures, such as safety harnesses and hard hats. This will help to protect workers in
the event of an accident or equipment failure.
In addition that we recommend that the design and modeling of the parts of the simple tower
crane operator lift can be modified for higher capacities and lifting potential like lifting more
than one person.
Finally, it is recommended that the simple tower crane operator lift be used in accordance with
local regulations and guidelines. This includes obtaining any necessary permits or licenses, and
following any safety protocols or procedures that are required by law. By following these
recommendations, the simple tower crane operator lift can be used safely and effectively in
construction areas, helping to improve productivity and reduce the risk of accidents or injuries.
50 | P a g e
References
1, "Lifting In Early Greek Architecture", the Journal of Hellenic Studies, 94: 1–19(1).
2, "Journal of Construction Engineering and Management" P.93: 2-10 (2).
3, "Journal of Construction Engineering and Management" P.93:2-10(3).
4, "Journal of Construction Engineering and Management" P. 93: 2-10(4).
5, "Journal of Construction Engineering and Management" P. 93: 2-10(5).
6, "Tower Crane & Rigging" P.56 (6).
7, "Lancaster 1999" P. 428 (7).
8, "Overview Of The Materials Selection Process" Volume 20, 46 :( 8 ).
9, "Konrad Rüffer: Schalten Von Elektromotoren. Verlag Technik, "Berlin 1990, ISBN 3-341-
00827-6(9)
10, "How Crowned Pulleys Keep A Flat Belt Tracking" 78, (10)
11, "Steel Wire Ropes For General Engineering Purposes" 65, (11)
12, "Design And Finite Element Analysis Of Rope Drum And Drum Shaft For Lifted Material
Loading Condition-Patil" Special Issue 2 Page9 (12).
13,"Deborah L Boklund Moran, “Hook Assembly And Kit,”" United States Patent 45, (13)
14, "Design Of Machine Elements" Edition: 2, 57, (14)
51 | P a g e

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Debre Berhan University

Name Signature Date

Name Signature Date

Acrimony and Abbreviation

AMI AREA MEDIAN INCOME

CAD COMPUTER AIDED DESIGN

P ANGULAR SPEED OF DRIVING PULLEY

NP ANGULAR SPEED OF DRIVING PULLEY

MPA MEGA PASCAL

MCW COUNTER WEIGHT MASS

SWL SAFE WORKING LOAD

VC LINEAR SPEED OF ELEVATOR CAR

4.1.3.1 Minimum no. of wire rope turns on rope drum ....................................... 30

Figure 1 introduction to tower crane

Figure 2 operator movement on the tower crane manually

1.2-Statement of the Problem

 To reduce labor abuse.

Figure 3 Elements of Work Study

Figure 4 rack constriction lift

Figure 5 easy up tower crane lift

Concept Defining the Literature

Proposed Data Data

Primary data Secondary data

Figure 6 Research Frame Work

Concept generation and

Manufacturing cost Cost analysis Material cost

Result and conclusion

3.3 Technical Design

3.4 Mechanism for Lifting

Figure 8 Simple Lift Structure

3.5 conceptual development

Figure 9 Simple Lift Structure

Conceptual design –two

Figure 10 Simple Lift Structure 2

CONCEPTUAL DESIGN – THREE

Figure 11 Simple Lift Structure 3

Comparisons of the conceptual designs on our project

Concept screening and scorning

Table 1 concept screening and scoring

criteria Concept 1 Concept 2 Concept 3

Maintenance 9/10 7/10 6/10,

Durability 7/10 8/10 9/10

Safety: 8/10 6/10 6/10

3.5 Material Selection

Factor Affecting Material Selection

Life of component factor:

 So select the carbon steel.

Figure 12 upper system load assembly

Figure 13 steel wire rope

Efficiency of wire rope when it is bent around rope drum, η = 0.94

Hence, tension in the wire rope < safe working load.

Now, each wire diameter in wire rope

Metallic area of wire rope = 0.40d^2

Figure 14 steel wire rope

4.3 Design of simple lift Drum

Figure 15 simple lift Drum

As per IS specification D/d ratio shall not be less than 18

Minimum radius of groove, r = 0.53 × d

Minimum depth of groove h = 0.35 × d

Pitch of the groove p = 1.08 × d

4.1.3.1 Minimum no. of wire rope turns on rope drum

4.1.3.2 Thickness of drum

Permissible hoop stress = 0.80 x 276