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Modification of Floor Hydraulic Crane Modification of Floor Hydraulic Crane

Preprint · September 2019

DOI: 10.13140/RG.2.2.35533.38880

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 Nigerian Journal of Engineering Science Research (NIJESR).
1(1): 88-98
Copyright@ Department of Mechanical Engineering, Gen. Abdusalami
Abubakar College of Engineering, Igbinedion University, Okada, Edo
State, Nigeria.
ISSN: 2636-7114
Journal Homepage: http://nijesr.iuokada.edu.ng

Modification of Floor Hydraulic Crane

1*Olorunleke, A., 2Ukwuaba, S.I., 3Akpan, S.E.
1Department of Mechanical Engineering, Igbinedion University, Okada, Nigeria
(aregbeolorunkele@gmail.com)
2Department of Mechanical Engineering, Petroleum Training Institute, Effurun, Nigeria

(ukwuaba_si@pti.edu.ng)
3Department of Mechanical Engineering, Igbinedion University, Okada, Nigeria

(samiakpan@yahoo.com)
*Corresponding author: Olorunleke, A., aregbeolorunkele@gmail.com (+2347032293352)

Manuscript History
Received: 08-27-2018
Revised: 12-18-2018
Accepted: 12-22-2018
Published: 12-30-2018
Abstract: In this research work, the modification of floor hydraulic crane was carried out.
The modified floor hydraulic crane has the following parts; base plate/truck/pallet, battery
seat, boom and lifting switches, vertical column, horizontal arm, secondary horizontal arm,
power screw, roller, hook, nuts and bolts, and DC motors. The selections of materials for the
various components were based on the strength, machinability, toughness, ductility, and
hardness. It was designed for load of 50 to 100 kg capacities and the development of suitable
system configuration having moveable wheel attached base, hydraulic link, basic vertical
column, and connections. The assembled machine was tested to evaluate function and
reliability of the machine. The test was carried out with various loads ranging from 50 - 100
kg and the results obtained show that as the load increased, the effort required for actuating
of the lift cylinder increased. Besides, the performance of the modified floor hydraulic crane
was satisfactory and can be used in the laboratory and industry.

Keywords: Modified, Crane, Construction, Bending moment, Load, DC motor

Nomenclature
A Cross Section area of vertical column
F Shear force
L Length of each sheet
M Bending moment
W Weight
n1 Factor of safety
σ Stress

INTRODUCTION

In material handling, the cranes play a vital role in modern manufacturing industries. A crane is a type
of machine generally equipped with a hoist, wire, ropes or chains and sheaves that can be used both to
lift and lower materials and to move them horizontally. It is mainly used for lifting heavy loads and
transporting them to other places. It uses one or more simple machines to create mechanical advantage
and thus move loads beyond the normal human physical lifting capability (Mulugeta and Tesfahun,
2017). The hydraulic floor crane provides an efficient low cost alternative to other material handling
equipment. Loads on the hydraulic crane are manoeuvrable and loading, unloading and shifting of
heavy loads are made easy. The development of engineering over the years has been the study of
findings ever more efficient and convenient means of pushing and pulling, rotating, thrusting and
controlling load, ranging from a few kilograms to thousands of tones. Cranes are widely used to achieve
this. In hydraulic crane, the force generation, transmission and amplification are achieved using fluid
Modification of Floor Hydraulic Crane
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Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
_____________________________________________________________________________
under pressure. The liquid system exhibits the characteristics of a solid and provides a very positive and
rigid medium of power transmission and amplification. In a simple amplification, a smaller position
transfers fluid under high pressure to a cylinder having a larger position area, thus amplifying the force.
There is easy transmissibility of large amount of energy with practically unlimited force amplification as
reported by Micheal and Akonyi (2014).

Nigeria’s aspiration to be among the world’s first twenty industrialized nation by the year 2020 may not
be met unless adequate and indigenous workshop equipment are deployed to supplement imported
ones in all its maintenance and production shops (Abdulfatai et al., 2014). A total of 5,011,290 vehicles
were registered between 2013-2015 (Vino, 2012, Abiodun, 2016) Available data from the National Bureau
of Statistics shows that about 88,886 vehicles were imported into the country between March 2017 and
September 2017 and a total of 150000 used vehicle are imported yearly (Kunle, 2017). Repair and
maintenance of these vehicles are regular and must take place for their continued operation. This
informs the reason for the ever increasing number of such automobile repair shops in the country. Most
shops however are grossly ill-equipped for proper handling and job execution in the shops (Okoli, 2015).
Sound professional best practice aimed at workshops injury and accident prevention and reduction
ensures the utilisation of appropriate tools for any job. Motor vehicle repair and maintenance often
require the lifting of the entire vehicle or sub-assembly part of it or the lifting up and down of its heavy
components. Also, in other industries and welding shops, there are items and repairs which need the
employment of shop cranes. The lack of shop crane utilization in our industries and automobile repair
shops not only leads to injury and accident but also to poor repair and maintenance occurrence. The few
crane and lift facilities currently employed in Nigeria production and maintenance shops are all
imported at exorbitant costs. There is the need for the development of home initiated and home built
shop cranes that are affordable with simplified technology which, could be proliferated to SMEs in order
to ensure adequate usage of proper lifting tool in those sector. This research work intends to address this
issue from the angle of evolving the built of an affordable floor crane using mostly available materials.

Although, there are existing research work on horizontal floor crane but this present work is based on
the modification of the research work of Ozaime (2017) that designed and constructed a hydraulic floor
crane in the department of Mechanical Engineering, Igbinedion University Okada. The Machine was
manually operated; the load lifting mechanism is by jacking up just as we do jack up a car, the boom can
only be adjusted manually. These increases the drudgery involved in the use of this machine and hence
there is a need for its modification. The modification to this model shall be accomplished by powering
the effort- side of the machine to remove all manual operations. To achieve this, a DC motor shall be
employed because of its versatility in terms of speed control and reversibility. Fig. 1 shows the research
work of Ozaime.

Fig. 1 Ozaime Designed

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Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
_____________________________________________________________________________

MATERIALS AND METHODS

MATERIAL SELECTION
The basic considerations done in selecting materials for the floor hydraulic crane components were as
follow; Strength, Machinability, Toughness, Ductility, Hardness etc., for each components of the crane.

A. Material for Vertical Column

The vertical column was subjected to a compressive stress, and the material for the column was a cast
Iron. Cast Iron has low cost, good casting, and high compressive stress. It is primarily made of carbon
and iron with Carbon content of 1.7% to 4.5%.

B. Material for the Boom and Base Plate

Since the load applied on the various components of the floor hydraulic crane was high, the material used
to make these components were strong and hard, thus the best material suited was Carbon content up to
1.5% that possess high strength and hardness.

C. Material for the Crane Hook

The crane hook was subjected to both tensile and compressive stress, and Wrought Iron was selected.
Wrought Iron is malleable, tough and ductile material. It has Carbon content of 0.02%, 0.12% of Silicon,
0.018% of Phosphorus, 0.07% of Slag, and the remaining is Iron.

D. Material for Bolt

The material for the bolt was subjected to tensile and shearing stress and mild steel best fit the criteria to
resist these stresses, thus, it was selected as a material for bolt.

E. Material for the Pins

The pins were subjected to tensile and shearing, and materials that can withstand such stresses were
selected. Mild Steel that was ductile and possesses good tensile strength was selected.
Table 1 shows the summary of material selected for the modified horizontal crane.

Table 1 Summary of Materials Selected

S/N Component Material Justification
1. Base Mild Steel Rigidity, Availability, Cost and Machinability
2. Vertical Column Mild Steel Availability, Machinability and Cost
3. Boom (outer and inner) Mild Steel Rigidity, Availability, Cost and Machinability
4. Load Locking Facility High Carbon Steel High Strength
5. Hook High Carbon Steel High Strength, Shear Resistance

MANUFACTURING PROCESS
The modified floor hydraulic crane has the following parts; base plate/truck/pallet, battery seat, boom
and lifting switches, vertical column, horizontal arm, secondary horizontal arm, power screw, roller,
hook, nuts and bolts, DC motors. The base plates were made of caste iron metal rod. The rods were cut
according to the dimensions and they were welded using metal arc welding. The DC motor was selected
to reduce speed and increase the thrust for load lifting. Also, the DC motor controls the boom mechanism
and the lifting arm and vertical column were fitted on the base with bolt and nut. The fixed horizontal
arm was welded and the secondary horizontal arm was fixed with hook. The power screw was selected
according to the power required and weight capacity.

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Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
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MACHINING PROCESS

A. Surface Finishing
Surface finishing is done mainly by abrasive sand paper, in order to remove the dust particles and the
rusting which gets formed because of the exposure to the moisture. Using a sand paper shiny surface is
obtained and the other operations become much easier and convenient, marking can be done easily for
cutting, welding and drilling operations.

B. Metal Cutting
Metal cutting was basically done to get the right dimensions and size as per the required design, using
machines that have single point cutting tool and multi-point cutting tool. Initially the dimensions are
marked and then the metal cutting operation was done.

C. Metal Welding
Arc welding is one of several fusion processes for joining metals. By applying intense heat, metal at the
joint between two parts is melted and caused to intermix-directly, or more commonly, with an
intermediate molten filler metal. Upon cooling and solidification, a metallurgical bond is created. Since
the joining is an intermixture of metals, the final weld element potentially has the same strength
properties as the metal of the parts. This is in sharp contrast to non-fusion processes of joining (i.e.
soldering, brazing etc.) in which the mechanical and physical properties of the base materials cannot be
duplicated at the joint.

D. Grinding
Grinding is done on the edges for getting the smooth finish; the grinding machine removes the material
from the metal surface in the form of sparks.

DESIGN CONSIDERATIONS
There are three major factors considered;
i. It will be able to perform the function for which it is designed.
ii. It must be statically and dynamically stable
iii. It must be durable
iv. It must achieve its design life (i.e. minimum of 10 years)

DESIGN SPECIFICATION
i. The lower reach was 0.225 m from the floor and this was to enables it carry object from the
floor at the lowest point from the ground.
ii. The highest reach of the crane was 1 m from the floor and this was to ensure stability even
when it extends to its maximum length.
iii. The auto-lifting of the arm and this was to improve easy manoeuvrability.
iv. The capacity was in the range of 50 to100kg
v. The crane was built with four rollers at the base and this was to enable easy movement from
one point to another.

DETAILED DESIGN

A. Boom Equations
The sectional view of the boom is shown in Fig. 2.

Ax= FLCosƟ (1)

But,
σ = ⁄ (Rajput, 2000) (2)

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Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
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The boom is designed with four (4) similar rectangular sheet of 4mm thickness
Therefore,
L= ⁄ (3)

Fig.2 Sectional View of Boom

B. Bending Moment and Shear Force on the Boom

The free body diagram of the boom is shown in Fig. 3.

Fig.3 Free Body Diagram of Boom

Taking moment about point A
+∑MA = 0
Therefore,

(4)

C. Reaction at point A
∑

(5)
Shear Force at Point A
∑

(6)

D. Shear Force at Point B

(7)
Bending Moment at point B
+∑
( )
(8)
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Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
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E. Bending Moment at C
∑

(9)

F. Stress Concentration at the Notches

The side view of the groove is shown in Fig. 4.

Fig.4 Side view of the groove

( ) ⁄ (Khurmi and Gupta, 2009) (10)

G. Determination of the Reactions at the Wheels and Factor of Safety

Reaction forces RA, and RB acting on the wheels are determined by applying conditions of equilibrium,
∑ at B
∑ , to the free body diagram and
Push force equal zero and with a counter W C to prevent tipping.
(Rajput, 2010)
(11)
(12)

The forces and weights distribution on the crane is shown in Fig. 5.

Fig. 5 Forces and Weights Distribution on the Crane

⁄
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Modification of Floor Hydraulic Crane.

Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
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For a mild steel of 4mm thickness

From measurement and Testing,

⁄
Therefore substituting all the numerical values into Equations (11) and (12),
( ⁄ ⁄ ) ( ⁄ ) ⁄

Converting in Newton’s to kilogram,

The factor of safety is applied to tipping load.

Considering the condition ∑ at point A with a push force of 350 N acting at a point 0.2 m i.e. 200
mm from the base,
[ ] ( )
( )
(13)

( ) ( )

H. Design for Vertical Column

Fig. 6 shows the diagram of Vertical Column and dimensions.

Fig. 6 Diagram of Vertical Column and dimensions

But ⁄ ⁄
Using eqn. 3.2,

Cross Section area of vertical column = ,

Since the vertical column is designed with four similar rectangular sheets of 4 mm thickness.

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1(1): 88-98
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I. Design for the Boom

Fig. 7 shows the diagram of inner boom with dimension and Fig. 8 shows the diagram of outer boom
with dimension.

Fig. 7 Diagram of Inner Boom with Dimension

Fig.8 Diagram of Outer Boom with Dimension

The boom is designed with four similar rectangular sheet of 4 mm thickness

J. Stress Concentration at the Notches

Fig.9 shows the base plate and dimension.

Also using Equation (2)

Using Equation (9)

⁄

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Olorunleke et al. (2018). Modification of Floor Hydraulic Crane. Nigeria Journal of Engineering Science Research.
1(1): 88-98
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( )

Fig.8 Base plate and dimension

PART ASSEMBLY
The assembly of the various parts and structure of the project was done using nuts and bolts, welded
fixtures, fasteners, etc. The assembly of various parts of the machine follows the order stated below;
fixing of the metal roller to the ends of the base with the aid of bolts and nut. The mast was welded to the
base with aid of the arc welding machine. Pivoting of the boom to the mast with the aid of bolts and nuts
so as to allow movement of the boom produces the skeletal view of the machine. The lift cylinder
incorporated with bolts and fasteners along with load locking device. The lever handle is fixed to the rear
side of the mast making the machine ready for use. Fig.9 shows the assembled modified hydraulic floor
crane with list of component parts.

Fig.9 Assembled Modified Hydraulic Floor Crane with list of Component Parts.

RESULTS AND DISCUSSION

The assembled machine was tested to evaluate function and reliability of the machine. The test was
carried with various loads ranging from 50-100 kg and the test showed that as the load increased, the
effort required for actuating of the lift cylinder increased (i.e. increase in load is directly proportional to
effort required).
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The load locking device worked perfectly, locking the load at various heights. It was observed that the
speed of the lifting arm and booming was low and at some heights the movement of boom was paused.
The following lift heights were measured;
The minimum lift when the boom is out = 0.225 m
The minimum lift when the boom is in = 0.37 m
The maximum lift when the boom is out = 1 m
The maximum lift when the boom is in = 0.825 m

The portable crane which is designed and developed prototype is electric motors driven and moveable by
wheels in the flours of the machine shop used for lifting and jacking. It can also be used for transporting
objects from place to place in a shop replacing overhead crane. Also in transportation and haulage firms it
is used for lifting loads into the conveying vehicles, it can also serve as a jack. The operation is simple,
press to make the motor ON, use the lifting and booming switches very simple and suitable for the
purpose. Disadvantage of the portable crane may be its using of battery power that runs down over time
due to usage, impossible in the area where there is no electricity to recharge. Fig.10 shows the constructed
modified floor hydraulic crane.

Fig.10 Constructed Modified Floor Hydraulic Crane.

CONCLUSION
The design and fabrication of a modified mobile floor crane equipped with automated booming and
lifting mechanism and a load locking device was carried out successfully meeting the required design
standards. The issue of safety, manoeuvrability and ease to do work which is the drive for this
modification, was taken care of by equipping the device with a load locking device, control switch for
lifting and booming. The modified mobile floor crane was designed for load between 50 – 100 kg carrying
capacity using a suitable high capacity power screw and strong carbon steel. The mobile floor crane is
simple in use and does not require routine maintenance. It can also lift heavier loads.

RECOMMENDATION
After the production and fabrication of the floor crane, the following were recommended;
i. Persons interested to modify the current design of the portable crane for the production
workshop can make this work base study or can use as reference.
ii. Also, interested person can modify the current design for easier manoeuvre by considering
the rotation of the vertical column.
iii. The speed of the lifting arm and boom mechanism can be improved by changing the various
control motors.

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CONFLICT OF INTEREST
There is no conflict of interest associated with this research work.

REFERENCES
Abiodun, B. (2016 ). Nigeria registered 5 million vehicles in 3 years- NBS.The Vangaurd. Retrieved from
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Khurmi, R., and Gupta, J. (2009). Theory of machines, simple mechanisms. (14th Revised edition). S.Chand and
Company Limited.

Kunle, A. (2017). “Nigeria’s Vehicle Population Data reveals towering opportunities. Retrieved from
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_in_nigeria

Michael, A. and Akonyi, S. (2014). Design and Manufacture of a Hyraulic Workshop Crane. International Journal of
Engineering Research and Technology: 222-235.

Mulugeta, T. and Tesfahun, M. (2017). Design and Development of Portable Crane in Production Workshop: Case
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Okolie, P. C. (2015). Steel Work Design and Analysis of Floor Crane. British Journal of Applied Science and Technology.
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Rajput, R.K. (2010). Strength of Materials (mechanics of solids); S. Chand and Company Limited.

Vino J.A., (2012). Design and Fabrication of a Hydraulic Floor Crane. International Journal of Biotech Trends and
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Ozaime, G. (2017). Fabrication of a Hydraulic floor crane, an unpublished undergraduate thesis. Department of
Mechanical Engineering, Igbinedion University, Okada.

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