Final Internship Project

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Final Internship Project
Strength and Deformation of materials (Mekelle University)
Studocu is not sponsored or endorsed by any college or university

Downloaded by MD AMAN ULLAH (ullahmdaman208@gmail.com)
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INTERNSHIP REPORT and PROJECT 2011
SCHOOL OF MECHANICAL ENGINEERING
DURATION OF PROJECT: 4-MONTHS.
PROJECT TITLE: DESIGN OF HYDRAULIC MINI CRANE
By: Brhanu H/slassie

Id No: Eit/Ue008/06
Advisor: Ins. Mewael G/hiwot (M.sc)

Supervisor: Mr. Araya Girmay
February 25/02/2019
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Declaration
This is to certify that the project work entitled “Design of Hydraulic portable crane” in MAA
Garment & Textile Factory is prepared by Brhanu H/slassie, ID.NO. Eit/ue008/06, the guidance
of In. Mewael partial fulfillment of the requirement for the award of the Bachelor Degree in
Mechanical Engineering submitted to Ethiopian Institute of technology Mekelle Department of
Mechanical Engineering.
Submitted by: BRHANU H/SLASSIE
Signature: ---------------------------------------------------
Date of submission:
Approved by:
Academic Advisor: Ins. Mewael
Signature: ------------------------------------------------------
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Acknowledgment
First I would like to thank my advisor, instructor MEWAEL, for his guidance and advice while
doing this project .I also extend my sincere gratitude and thanks to my supervisor Mr. ARAYA
GIRMAY as well as the MAA Garment industry workers for their much contribution in gathering
data and for their collaborations in whatever I wanted during the four month internship period in
the company.
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Abstracts
This document consists of the internship report that I have done in the internship program at
KEBIRE ENTERPRISE P.L.C including the brief history, back ground of the company and over
all organization of my internship hosting company, over all internship experience, production
process of the company, challenge that I have faced in the internship time and measures I have
taken to solve them. This means, how and when the factory is established and with what types of
materials were began its work and how the raw materials which are brings either from aboard or
domestic raw materials are being changed in to product and what type of steps are used to
produce these products., I explain how I improve my practical skills, upgrade my theoretical
knowledge, improving communication skills and the knowledge that I gained in terms of
entrepreneur ship skills. This report contains a project work titled design of hydraulic crane
which uses unloading of the material from the truck in spinning section that hart the workers
when they holds.
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Contents
Declaration..................................................................................................................................................ii
Acknowledgment.......................................................................................................................................iii
Abstracts.....................................................................................................................................................iv
1. INTRODUCTION...................................................................................................................................1
1. 1. Brief history of the company:..........................................................................................................1
1.2. Objectives of the company...............................................................................................................2
1.3. Mission of the company....................................................................................................................2
1.4. Vision of company............................................................................................................................3
1.5. Main raw materials and products of the company.............................................................................3
1.6. Main customers or end users of the company...................................................................................4
1.6.1. Local customers:........................................................................................................................4
1.6.2. Global customers:......................................................................................................................4
1.7. Over all Organization and work flow of the company......................................................................5
1.7.1. Over all organization of the company:.......................................................................................5
1.7.2. Work flow of the company.........................................................................................................5
2. Internship experience..............................................................................................................................6
2.1. How do we get the company?...........................................................................................................6
2.2. Section of the company we have been working................................................................................6
2.2.1. Spinning department:.................................................................................................................6
2.2.2 Knitting machine......................................................................................................................20
2.2.3. Dyeing and finishing................................................................................................................22
2.2.4. Over all Process and machine types in garment.......................................................................24
2.3 work task I have been working........................................................................................................27
2.4 work task i have been executing in the section................................................................................27
2.5. The Procedures I have been using and engineering tool, techniques...............................................27
2.6. Major challenges faced during performing our projects..................................................................28
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3. Hydraulic portable crane........................................................................................................................30
3.1.Adbantages ofhydraulic crane..........................................................................................................30
3.2. Problem Statement..........................................................................................................................31
3.3. Objective........................................................................................................................................31
3.3.1. General objective.....................................................................................................................31
3.3.2. Specific objective.....................................................................................................................32
3.3.3. Methodology of the project .....................................................................................................32
3.3.4. significance of the project .......................................................................................................32
3.3.2. scopes of the project................................................................................................................33
3.3.2.Lmitations of the project...........................................................................................................33
3.4. Literature Review...........................................................................................................................33
3.4.1. Introduction of hydraulic crane................................................................................................33
3.4.2. Buckgraund of hydraulic crane................................................................................................34
3.4.3. types of portable crane.............................................................................................................35
3.5.Methodology....................................................................................................................................36
3.5.1. Material Selection....................................................................................................................37
3.5.2. Design Specifications..............................................................................................................38
3.6. Design Analysis..............................................................................................................................39
3.6.1.Design vertical of columun.......................................................................................................39
3.6.2. Design of Boom.......................................................................................................................41
3.6.3. Design ofcrane hook................................................................................................................43
3.6.4. Design of base plate.................................................................................................................44
3.6.5. Design of the rollers.................................................................................................................49
3.6.6. Wheel selactions .....................................................................................................................50
3.6.7. Design of pins..........................................................................................................................50
3.6.8. Design of Bolts........................................................................................................................52
3.6.9. Designand selectin of bearing..................................................................................................53
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3.6.10. Design of hydraulic cylinder..................................................................................................54
3.6.11. Design of piston.....................................................................................................................56
3.6.12. Design of rings.......................................................................................................................57
3.6.13. Design of barrel.....................................................................................................................58
3.6.14. Design of hose.......................................................................................................................59
3.6.15 .lifting system.........................................................................................................................59
3.6.16. lifting hight............................................................................................................................61
3.7 Resalt and discation.........................................................................................................................63
3.8 Cost analysis....................................................................................................................................66
4.Over all benefit the internship................................................................................................................68
4.1 Theoretical knowledge.....................................................................................................................68
4.2practical knowledge..........................................................................................................................68
4.3Improving industrial problem solving capability..............................................................................69
4.4Inter personal communication skill...................................................................................................69
4.5Team playing skill.............................................................................................................................69
4.6Leadership skill................................................................................................................................69
4.7Work ethics.......................................................................................................................................70
4.8Entrepreneurship skill.......................................................................................................................70
5. GENERAL CONCLUSION AND RECOMMENDATION...................................................................71
5.1 Conclusion.......................................................................................................................................71
5.2 Recommendation.............................................................................................................................71
6. REFERENCES......................................................................................................................................75
7. PART AND ASSEMBLEY DRAWING OF HYDRAULIC LIFTING MACHINE...........................76
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List of Figures Figure Number ………………………………….…………. Page

Fig.2.1 uniflok machine--------------------------------------------------------------------------------------8
Fig.2.2.uniclean machine-------------------------------------------------------------------------------------9
Fig.2.3.unimix machine-------------------------------------------------------------------------------------10
Fig.2.4. Carding machine-----------------------------------------------------------------------------------13
Fig.2.5. draw frame------------------------------------------------------------------------------------------14
Fig.2.6. UNILAP machine----------------------------------------------------------------------------------14
Fig.2.7. Combing machine---------------------------------------------------------------------------------16

Fig.2.8. Roving frame (Speed frame) machine----------------------------------------------------------19
Fig.2.9. Ring frame machine-------------------------------------------------------------------------------20
Fig.2.10. Winding machine---------------------------------------------------------------------------------22
Fig.2.11. single jersey circular knitting machine--------------------------------------------------------23
Fig.2.12.dyeing machine------------------------------------------------------------------------------------24
Fig.2.13. finishing machine--------------------------------------------------------------------------------26
Fig.2.14. garment process and product-------------------------------------------------------------------37
Fig.3.1. Hydraulic crane------------------------------------------------------------------------------------41
Fig.3.2. Vertical column----------------------------------------------------------------------------------43
Fig.3.3. Boom------------------------------------------------------------------------------------------------39
Fig.3.4.Hook--------------------------------------------------------------------------------------------------41
Fig.3.5.Base plate--------------------------------------------------------------------------------------------43
Fig3.6.roller------------------------------------------------------------------------------------------------------------45
Fig3.7. pins---------------------------------------------------------------------------------------------------49
Fig3.8.bolt and nut------------------------------------------------------------------------------------------51
Fig.3.9. bolt---------------------------------------------------------------------------------------------------52
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Fig.3.10. piston Cylinder-----------------------------------------------------------------------------------53
Fig.3.11. Piston and piston rod-----------------------------------------------------------------------------54
Fig3.12. lifting height hydraulic crane--------------------------------------------------------------------62
Fig3.13. Minimum lifting height hydraulic crane-------------------------------------------------------63
List of Diagram……………………………………………………..Page
Diagram 1.1.Over all organization of the company----------------------------------------------------5
Diagram 1.2 Work flow of the company-----------------------------------------------------------------5
Diagram 1.3.Spinning process-----------------------------------------------------------------------------7
Diagram2.1. Production flow of garment department------------------------------------------------24
List of Tables……………………………………………………Page
Table3.1.Wheel sellection----------------------------------------------------------------50
Table3.2. Selection of bearings----------------------------------------------------------------------------53
Table3.3. Result of each component----------------------------------------------------------------------64
Table3.4. Cost estimation-----------------------------------------------------------------------------------66
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CHAPTER ONE
1. INTRODUCTION
This internship program has a great roll in giving very interesting practical knowledge which
forces us to have enough confidence in our work. It also make as problem solvers and solution
developers. This internship also sees as what an employed engineer do in the company increasing
social network and sharing idea with those students is also its nice feature. Specially acquiring
work ethics, management system, leading projected, helping each other are a questionable uses
that we get from.
1.1. BRIEF HISTORY OF THE CAMPANY
MAA Garment Factory, which is a subsidiary of Kebire Enterprises P.L.C., is

established and registered in April 2001. Maa garment factory, established in June 2004 in
the northern part of Ethiopia-Mekelle, specifically kuiha, owned by Kebire Enterprises Plc.
2
with a total production area of nearly 15000 m . MAA Garment Factory is furnished with
new, state-of-the-art production equipment and machines acquired from the most respected
companies /factories in the worldwide garment industry.
The flexible and superior technological capacity it have, coupled with it’s highly
committee workforce, gives it leverage to achieve its objectives and success fully compete in
the global market.
The newly established project (MAA TEXTILE) which comprises Spinning, Knitting and
Dyeing & Finishing is started since 2007.The project is divided in to two phases
 Project phase I comprises of Knitting, Dyeing & Finishing
 Project phase II is spinning.
Maa garment & Textile factory, found on the outskirts of Mekelle city, is ideally situated for
national and international communication, nearby the main highway to Addis Ababa
and within a kilometer of Mekelle International Airport.
These links allow it to deliver its goods on time to local and international customers. Maa
Garments & Textiles in collaboration with many companies Implementing the Inter- national
Benchmarks and make it international competitive. This includes enhancing the productivity,
quality and export market performance through various interventions that includes design
and realizing efficient layouts, designing and implementing proper overall management and
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Planning, finding export market and working backwards all the way to be different production
chains and processes to realize the market
MAA Garments and textiles a factory is big factory which consists of all activities of making
complete clothes. In MAA garments &textiles there are about nine departments. These are:-
HRD, Finance, Marketing, Dyeing and finishing, Spinning, Knitting, Garment Electrical
&Quality.
1.2. Objectives of the company

 To produce high quality wearing apparels that can compete in the international market.
 To attract capital and technological know-how
 To generate reasonable profit
 To focus on strategies that can manifest the customer’s satisfaction.
1.3. Mission of the company

The mission statement originates from the total customer satisfaction for excellence in the textile
fields particularly in Ethiopia and in general in Africa besides in exporting and importing of these
textile products. Training and skills for the human resource development of the inhabitants so
much required. Generally, the mission of the company includes;.
 To have sustainable production capacity and contribute in the development of the national
and international countries.
 To make profit by competing in the global market.

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 To generate foreign exchange by increasing export.

 To create employment opportunity to the community.
 To achieve sustainable product capacity.
1.4. Vision of company

The vision of the company become a best reference leading for textile and garmenting industries
and creating a huge part of excellence for these textile and garment fields particularly in Ethiopia
and generally in Africa. Generally, the company vision depends on the following listed points.
 To become the most customer oriented manufacturing by creating a quality excellence in

the textile and garment fields in Africa.
 It is reference for Ethiopian textile and garment industries.

 Creating a condition that MAA-Garment can become leadership than other textile
industries.
 Good for customer satisfaction.
 Readability and commitment.
 Profitable and good quality production
 Protect the environment by modernized way out the wastage from garment
1.5. Main raw materials and products of the company

MAA-Garment textile P.L.C uses different raw materials in order to produce different fabrics.
These raw materials are supplied from different areas locally or globally, but the garment used its
own cotton and other raw material from its farm to feed its company. So that the garment
comprise of natural cotton and exclude as much harmful and toxic substance in them .this way its
main concern is laid on natural and organic methods in the growing process that is, the
commonly used raw materials are the followings.
 Cotton,
 Polyester,
 different type dyestuffs,
 LPG (Liquid Petroleum Gas),
 Furnace oils,
 Chemicals,

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 Auxiliaries and Accessories.
Main products of the company
Typically, MAA-Garment can be produced the following products as listed below;
 suits,  gowns,
 shirts,  jackets,
 trousers,  Dyed and printed fabrics,
 dresses and blouses,  Defence wear fabric, and
 polo shirts,  Finished raw fabrics.
 T-shirts
1.6. Main customers or end users of the company
Customers are the consumers of one company’s product and these also play an important role in
increasing the potential of the company’s production capacity by balancing the demand and
supply of the company. MAA-garment textiles P.L.C have different customers. These are local
and global market customers.
1.6.1. Local customers:

 MESSEBO cap, trouser, work jacket and over all of long sleeves
 TIGRAY police: trouser, shirt and long sleeves
 OROMIA police and federal police: workers uniform, trouser, shirts and trousers
 AMHARA police and military of national defiance: cap, trouser and shirt
 Federal police and Somali police: cap, trousers and shirts
 Royal foam
 Abyssinia foam
1.6.2. Global customers:

 Edwards , MOC and BONGHWA in AMERICA
 Walls/WALMART
 OBERMEYER in germen
 DVH apparels in CHAINA
1.7. Over all Organization and work flow of the company

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1.7.1. Over all organization of the company:
Diagram 1.1.Over all organization of the company:

1.2.1. Work flow of the company
Diagram 1.2 Work flow of the company

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2. Internship experience
2.1. How do we get the company?

According to the national education curriculum of Ethiopian universities, all under graduated
engineering students must have ordered one semester or four-month internship program on
industries in order to develop and achieve their practical knowledge at the required level of their
goals. Due to this reason, MU EIT-M College gives us an internship request paper. After us
searching the nearest company of us, we have already entered to MAA-Garment P.L.C. When we
arrived to MAA-Garment factory, they cooperate in good manner and immediately reported on
the management office and also give us awareness about all departments or sections, rules and
regulations of the company.
2.2. Section of the company we have been working

The company consist five departments or sections in consecutive manner. These sections are;
 Spinning
 knitting
 dyeing and finishing
 garment section
I were getting the chances to asses all sections in our given periods for each department
1.2.1. Spinning department:

Spinning is a process of converting bale (raw cotton or polyester) through a number of processes
so as to produce quality yarns that can further be used as an input to weaving and knitting
departments. In this department, the process starts from blow room section. In this section there
are four lines called A, B, C, and D lines “A" line known as ring frame line, B and C lines
together used for the open end line, and D line is for polyester of both open and ring line. Cotton
is fed to the system by either UNI FLOK machine or manually whereas polyester is fed
manually.

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Spinning process includes the following
Diagram 1.1.Spinning process
1.2.1.1. Blow room:

 Blow room is the initial stage in the spinning process; the name blow room is given
because of the ‘air flow’ and all process done on the blow room because of air flow. Blow
room consisting of different machine to carry out the objective of blow room. In blow
room the tuft size of cotton became smaller and smaller.
 It is a section where the supplied compressed bales are opened, cleaned and mixing or
blending for making uniform lap of definite length
 Blow room is the first room of the spinning process and that performs some operations or
objectives.
 Opening of the baled fibres into small tufts.

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 Cleaning of fibres by removing foreign matters.

 Mixing of different component fibres.
 Dust removal (eliminate small size micro dust particles from the fibre), and
 Recycling of the wasted fibres.
Blow room has also some machines with in their functions as below. These are;
1. UNIFLOK /Automatic bale opener (Reiter model A10): It is used to bale opening, suck the
fiber, minimizing visible foreign materials and increasing color mixing. The main advantages of
UNIFLOK machine are;
 Opening of the bale.

 Remove visible foreign materials.
 Transfer the sucked cotton to the conveyor
Fig.2.1 uniflok machine.

 MAIN PARTS OF THE UNIFLOK
 suction(impeller, casing and discharge)-it’s a turbo machine which consist the rotary part
and flow fluids and done vacuum to suck the cotton from high pressure to low one the
impeller rotate at high speed by the flowing air create high kinetic energy. the casing is
like diffuser which reduce the kinetic energy and increase the pressure because of its
shape(large area)
 Motors- it’s a machine driven by the electric current and drive the shaft mounted on the
suction parts connected by either belt or other power transmission parts, generally the
motor start the motion of everything in the section

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 Gear, belts and chain (for power transmission)-the transmit power or the used to move the
UNIFLOK sliding across the conveyor.
2. Semi-Automatic bale opener (B and C line feeder): this opener is used to open and clean
automatically after opened the bale and over all wastes of fibers, slivers etc. manually by the
operators.
3. UNICLEAN Machine (Reiter model B10)
Fig.2.2.uniclean machine
It is used to remove the heavy impurities like sand, dirt, fine, trash and dust particles. The activity
of this machine was; Adjust the angle of grids bars and the space between them using machine
setting on the display.
The responsible person must be checking the UNICLEAN machine for better qualified product
productions especially by checking naps, seed coat naps, length, dust, trash, maturity and short
fiber contents.
4. Auto Mixer (UNIMIX): it is used to mix the fiber and increase production quality. The
advantages of auto mixer are temporary storage of production and mixing.

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Fig.2.3.unimix machine
5. UNIFLEX (Reiter model B 60): it is used to remove the heavy impurities like sand, dirt, fine
trash and dust contents. It has an activity of adjusting the angle of grids bars and the space
between them using machine setting on the display.
 working operation and flow of blow room
First the raw material(cotton) is taken UNIFLOK and the UNIFLOK send to the conveyor
attached to the UNIFLOK and the conveyor attached with the room duct that the cotton moved
through it .there is a motors, fan and blower which give energy to the cotton across the duct and
then the processed cotton enter to the UNICLEAN to remove dust and impurity the after the
cleaned cotton enter to the UNIMIX machine to mix with other raw material to increase its
strength and to minimize its cost then after it enters to the UNIFLEX and finally to the condenser
then after to the second process of carding machine enter through the duct.(every machine in the
blow room have their own motor, fans and power transmission parts.
 Working flow of blow room
1.2.1.2. Carding machine

Carding is the second process in the spinning process after blow room which is used to done
changes the processed cotton in to continuous web or silver, it clean and parallelizes the fiber. It’s
the action of reducing tufts of entangled fibers into a filmy web of individual fibers by opening
the tufts. It is used to minimize naps, short fiber content and used for good formation of sliver.

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Due to the high amount of naps removal it is said that, "well carded is half spun." The main
advantages of carding machine are;
 Reducing tuft of entangled fibres.

 To produce a rove like fibre called silver which is uniform in length.
 Opening to individual fibres.
 Elimination of impurities.
 Dismantling (disentanglement) of naps.
 Elimination of short fibre content, fibre orientation and sliver formation.
The person, who controls quality on carding machine, must be check the count, naps,
seed coat naps, length, dust, trash, maturity and short fibre content of the raw
materials.
Fig.2.4. Carding machine
 Main actions of the carding machine

 Action between fee roller and taker in
 Action between taker in and cylinder
 Action between cylinder and flat
 Action between cylinder and doffer
 Main parts of carding machine and operation procedure
1. Ducting pipe 2.chute feed 3.Feed roller
4. Transport roller 5.brush roller 6.flat
7. Taker in 8.suction duct 9.main cylinder
10. Doffer 11.striping device 12.calendering roller

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Coiler 14.can
First supplying raw material by ducting pipe from blow room, chute feed evenly compress,
transport roller forwards the material to feed plate, taker in opens the material to small flocks
when the material passes to main cylinder, mote knives, grid bars and carding segments eliminate
a great part of impurities .grid equipment, suction dust to carry a way the waste. Main cylinder
and fixed carding segments designed to assist the carding operation. The main carding operation
occurs between flats and cylinder. Cleaning unit cleans striper’s fibers and naps. the doffer
combine the fiber in to a web, stripping device and doffing master draw the web from the doffer,
calendar roller calendars the cotton and move towards, at last coiler and can the fabric is
produced.
1.2.1.3. Draw frame:

It’s a process in yarn manufacturing of spinning that used to elongate the silver and strength the
silver by reducing its weight when pass through pairs of roller, this silver are drawn and
elongated to straighten and create greater uniformity. it is used to improve material (sliver)
evenness.
The main activity (working principle) of draw frame is;
 Doubling and drafting of 6 or 8 cans in one sliver cans,

 Dust removal, blending
 Fibres parallelization, and
 Drawing the final stage of quality improvement.
The quality control and the responsible person of this machine must be check the quality and
production of the machine output relatively it's in put. That is checking for;
 Evenness,
 Mass variation,
 Count and elongation.

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Fig.2.5. draw frame
 Detail of the draw frame machine (zone of do)
*Creel zone-its known us feeding zone ,6-8 feed silver passing through guide roller, guide bars
and feed to drafting zone.
*guide roller-it guides the passage of feed silver and act as a stop motion when feed silver breaks.
*auto leveler –the main task of traveler is to eliminate deviation in mass per unit length.
*drafting zone-it’s a zone for a process of decrease the weight per unit length of silver
*coiling-the rotary movement are required for cycloid coiling of silver
 Working principle of draw frame

Take the silver through all guide roller and feed to draw frame Creel the required number
of cans and draw the silver forward, operate the control switch for inching starting and
stopping the draw frame, by inching feed the material and start running, piece the silver
during the breakage.
 Waste from draw frame-filter waste, clearer waste and silver cut

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1.2.1.1. UNILAP (Lap former):

is used to proper feed of combing machine. This means, prior to combing the slivers are formed
in to lap. The main operation of UNILAP machines is, parallelization of the feed fiber depending
upon the sliver draft. And also, the quality control must be check for sliver evenness, mass
variation, count and elongation
Fig.2.6. UNILAP machine
1.2.1.1. Combing machine:

Combing is the process of removing predetermined amount of short fibers. That means, it is used
to remove short fiber contents and naps, parallelization and improving the final stage of yarn
quality. The person who controls quality can be checked for the short fiber content, evenness,
strength, amount removals of waste presented, mass variation, count variation and seed coat
naps.
Fig.2.7. Combing machine

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1.2.1.4. Roving frame:

It is an intermediate process in which fibers are converted in to low twist lea called roving, the
silver which taken from draw frame is thicker so it is not suitable for manufacturing of yarn, its
purpose is to prepare input package for next process .this package is to prepare on a small
compact package called bobbin used to prepare suitable feed materials to ring frame and some
twist insertion.
 Objective of roving
The main objective of roving frame is given below
 attenuation –drafting the draw frame silver in to the roving

 twisting-to insert the twist in to the roving
 winding-winding the twisting roving on the bobbin
 package building
Main principle of roving frame is;
 Draft the sliver by means of drafting rollers.

 Twist the sliver using flyer and winding it in the bobbin.
 Conversion of sliver to rovings.
 Winding the rove in to bobbin.
Importance part of roving machine
 Drafting device
 Flyer
 Bobbin
 Spindle
 Twisting methods
Working principle of roving frame
The silver supplied from silver can ,pass around a feed roller, and is feed to drafting device ,it
then pass through an eyelet, a hallow leg , and the pressure finger of the flyer which is mounted
atop the spindle, and then twist on the bobbin in the form of roving.

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Fig.2.8. Roving frame (Speed frame) machine
For better quality and good production of yarn, the quality control must be check for roving
bobbin evenness, mass variation, count and twist of the rove.
 factor affecting the roving
Critical factor affecting the roving is given below
 The amount of twist and compactness of the roving.

 Linear density and uniformity of the twist.
1.2.1.5. Ring frame machine:

Ring frame is start after a roving process is end and the fiber mass of the roving is reduces by a
drafting unit, and it’s the process of further drawing out roving in to the final yarn count needed.
Generally ring frame is a process we get the yarn from roving. it is used to give strength for the
yarn and easily handling, storage and transportation of the yarn. And also, it inserts the required
amount of twist and wind up the yarn on to suitable packages. The person who controls quality
must be checked for the evenness, mass variation, count and twist variation, thick and thin
places, elongation, naps, shrinkage and hairiness of the materials.
Function of ring frame
 To draft the roving for conversion of very fine strand of some fiber to form yarn
 To impart strength to the yarn by inserting the necessary amount of twist
 To collect twisted strand called yarn
Limitation of ring spinning

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 Low twisting rate

 Low production
 Small bobbin size
 Frequent doffing and limited speed of traveler.
Different portion of ring frame
 Roving bobbin balloon

 Bobbin holder ring rail
 Guide roller ring
 Cams shafts
 Traveler lappet
 Guide bobbin tube and draft arrangement
Feature of ring machine
 Generate less heat and dissipate heat quickly

 Have sufficient elasticity for easy insert
 Less friction and wear resistance
Operation involved in ring frame
 Creel  Winding
 Drafting  Building
 Twisting  Doffing
Mechanical parts and their function in the process
 Motor- it’s a machine driven by electric current and drive either pulley or fly wheel, and
the motor is give and start motion, in the ring frame the motor transmit power to pulley by
belt which mount on the motor and this pulley transmit to the shafts mounted on bearing
at the ground of the frame( 2 motors both side and 2 pulley both side with a metal belt)
 Pulley- it’s a mechanical machine parts used to transmit power by rotated on its surface
either belt, chain and other. in the ring frame the pulley located at the ground and other

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area, on both side of the ring there is 4 pulley , 4 shaft ,4 motors and one long circular
metal belt rotate on the pulley driven by the motors.
 Shafts-it’s either rectangular or round long or short machine elements that used to
transmit power to the other machine element mostly connect with gear and mounted on
bearing, but in the ring frame the shaft located in many area at ground, at the middle and
at the main task happened area which the roller and the cam rotate on the shaft ,when the
shaft gets power and rotate, the roller and the cam rotate on it because of connection and
the task is starting, the shafts gets power from the motor and belt. Generally power from
ground to the middle and finally to the top where the task is happen.
 Roller-it’s a mechanical machine parts that mostly used to reduce the thickness of
material and to draw material when the parts pass through the rotated roller. In the ring
machine the roller attached with the shaft and rotate with the shaft and done the task.
 Cam-it’s a mechanical machine parts that used to convert the rotary motion in to
reciprocating motion( up and down motion)in the ring machine the roller attached with
the shaft and rotate with the shaft and convert the thicker cotton in to the yarn.
Operation of ring frame
First there is a roving bobbin inserted on its holder on the creel, when the machine gets
power the cotton on the roving bobbin starts loosen and pass through the first roller and
gets in to the cam then after the thicker cotton changes to yarn and finally gets the second
roller and reduce its thickness finally twisted on the ring bobbin.

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Fig.2.9. Ring frame machine
1.2.1.6. Winding machine:

it in spinning process winding is the last process , and it is the transfer of spinning yarn from one
package in to a large package(cone) containing considerable long length of yarn. is used to wind
in to suitable package called cone for easily transferring to knitting departments and to increase
the strength of the yarn. The person should be control and check the quality of winding yarn by
removing faults like thick and thin places, in correct applications of lubricants (wax) in which
applied to the yarn surfaces, winding in to a suitable packages(cone).
Object of cone winding
 To improve quality of yarn
 To get suitable yarn package
 To remove dust and clean the yarn
 To reduce labor cost
 To improve the efficiency of the yarn for the next process
 Generally transfer from small package to the one desired large package of yarn
Main parts of the cone winding
 Creel-to hold the bobbin
 Yarn tension and guide-provide required tension to the yarn
 Cradle-to hold the cone for winding and it lie on upper part of machine above winding
drum
 Winding drum-it’s a metallic drum and its surface is polished, it has a groove cuts in toot
 Motors
 splicer
 Empty cone package and dead weight

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Operation principle of cone winding
First the machine gets power from motors and yarn supplies gets from a bobbin and the yarn go
to the cone by yarn stop motion guide, since the cone are on holder and contact with drum, cone
rotate due to the friction of drum and drum finally became winding on the cone, this type of
winding is controlled with yarn guide, winding is stop with stop motion mechanism when the
yarn breakage, when cone gets predetermined width discreet from drum and connect
automatically and placed the new one.
Fig.2.10. Winding machine
1.2.2. Knitting machine

Knitting machine is a machine or device used to create knitted fabrics in a semi or fully
automated, knitting process is a process after the spinning process is done and the packed cone
winding yarn is further processed and changed in to yarn fabrics, there are numerous type of
knitting machine in textile area, but the most well-known types are the circular and flat knitting
machine and in MAA-Garment textile the circular knitting machine is used to produce the yarn
fabrics. Circular knitting machine or knitting in the round is a form of knitting that creates a
seamless tube, when knitting circularly, the knitting is cast on and the circle of stitches is joined.
Generally circular knitting machine is mostly used in textile industry, and works by rotating and
connection b/n the needle and sinker, but there are numerous type of circular knitting machine
but the MAA-Garment taken and worked by single jersey circular knitting machine type which
done the task by connection between the needle and sinker, but the other mostly they have not a
sinker only have double needle arranged vertically and horizontally (interlock circular knitting
machine).

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Single jersey circular knitting machine- it’s a circular knitting machine which has normally
rotating (clockwise) cylinder, at one set of needle bed. It used sinker. Single jersey circular
knitting machine comprise of many parts
 Parts of single jersey knitting machine
Different knitting machine parts and their function are given below
 Creel-is the holder of the packed cone yarn, cone is placed in a creel for feeding the yarn
to the feeder.
 Feeder- the yarn is feed through the feeder
 Sensor-is an automatic controlling system, when the yarn pass through these sensor then
if any yarn break and any problem occur then it automatically stop by this sensing system.
 Cylinder-it’s the main part of the machine and carries needle, sinker and cams
 Spreader-is used to spread the knitted fabrics before take up roller
 Latch needle-this type of needle has a special sliding latch with other common features,
this part is used to form loops
 Cam- it’s a machine element changes rotary motion in to reciprocating motion, but in
knitting the cam used to help the needle to form knit loops, tuck loop and miss loops
 Sinker- used to sink or kink the newly laid yarn, to hold down the old loop and support
the old loop as the new loop is drawn through it
 Vent-cleaner-to clean and remove dust
 Power transmission parts(motors, gears, pulley, belts, shaft and bearing)
 Coin-balancing the yarn with respect to the roller, and sensing
 Take up roller- used to take up the fabric from cylinder
 Cloth roller-the final product, cloth wound on this roller
 Yarn fabrics

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Working process of single jersey circular knitting machine
First the motor gets energy and transmit to pulley by belt and to pulley by second belt and there
is a shaft mounted on pulley and the shaft mounted on bearing on the other portion, this shaft
transmit power to a large gear that connected to pulley by shaft and this pulley transmit power to
coin by belt then the yarn is driven and pass through the coin and taken by the needle, the needle
then down and lock with the sinker then we get the product of yarn fabrics and the product drawn
to down by roller and wound on cloth roller.
Fig.2.11. single jersey circular knitting machine
1.2.3. Dyeing and finishing

Dyeing is the process of adding color to textile products like fibers, yarns or fabric, by using
natural and synthetic dyes for giving attractive look. Dyes have an efficiency of bonding to the
materials molecules such like by hydrogen bonding, Vander Waals or ionic forces and in certain
cases chemically bounded by covalent bonds. Dyeing machine is a machine that used to dyeing
or coloring of material like, yarn, fabrics in garments. Textile dyes include acid dye for dyeing
wool.
This plant comprises the latest laboratory, HPHT dyeing machine and color kitchen. The
HPHT machinery can dye knitted, woven made of 100% cotton and blends. The
laboratory comprises SPECTROPHOTOMETER, AUTOMATIC DISPENSER, SAMPL
DYEING MACHINE, LIGHT FASTNESS TESTER, CROCK METER, PER
PYROMETER, SHIRNKAGE TESTER, WASHING FASTENES MACHINE, and

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DRYER AND LIGHT CABINET EQUIPEMENT. Dyeing section has a capacity up to

8.1 ton per day
Fig.2.12.dyeing machine
Finishing
This process and machine used to improve quality of the fabrics such as smoothness,
illustriousness, softness and shine.
This plant comprises the following machine
 Tension less dryer and STENTER (MONFORTES from germen)
 Super slitting machine (CORINO) from Italy
 STENTER frame: A machine that dries fabric to a specified width under tension. The
machine consist essentially a pair of endless chains on horizontal tracks. The fabric is
held firmly at the edges by pins or clips on the two chains that diverge as they advance
through the heated chambers and adjusting the fabric to the desired width.
 SANFORISING process: In this process, the fabric and backing blanket (rubber or wool)
is fed between a feed roller and a curved braking shoe, with the blanket being under some
tension. The tension on the blanket is released after passing the fabric and blanket
between the roller and braking shoe. The net result is compaction.
 Calendaring: this is a process where a fabric compressed by passing between two or

more rollers under controlled conditions of time and temperature.

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Fig.2.13. finishing machine
1.2.4. Over all Process and machine types in garment

The factory can produce both woven and knitted garments. Its designed to produce men shirts,
women blouses, trousers for men from light, medium, and heavy weight and other product. There
is different section in this department such as
 Cutting section
 Embroidery section
 Sewing section
 Finishing
Garment production flow
Production flow of garment department
Diagram2.1. Production flow of garment department

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Cutting machine: Separation of parts as they are in the pattern drawn on marker plans.
Cutting requires:
 Precision of cut.
 Clean edges, and
 Unfused edges.
Machines in this cutting section are;
1. Spreading machine: spreads bundle of rolled fabrics.
2. Band knife: used to cut the bundled form of the table spreader fabrics.
3. Esteemed man: used to cut according to the precise and self-esteemed manner.
 Embroider machine: It is a simple technique that involves very basic things like needles,
threads, and stitches in which convene are laid on the fabric according to the design
patterns. Various types of stitches used during embroidering are:
 Cross-stitch
 Chain stitch
 Button stitch etc.
 Fusing machine: a process in which interlining is bonded to the outer fabric by means of
athermoplastic resin. The fusible interlining consists of a base cloth, which carries on its
surface a thermoplastic adhesive resin usually in the form of small dots, which will melt
when heated to a specific temperature.
 Pressing machine: Pressing or finishing of a garment refers to the section where the
ready sewn, trimmed and quality checked garment from the sewing lines are going to iron
pressed, tagged, folded and then packed in the carton. After this, processes the garments
are ready to ship or dispatching. Pressing makes a large contribution to the finished
appearance of garments and this gives attractiveness at the point of sales.
 Spreading machine: The objective of spreading is to place the number of plies of fabric
that the production planning process has dictated to the length of the marker plan in the
colours required correctly aligned as to length, width, and without tension.
 Seam machine: seaming is the application of series of stitches or stitch types to one or
several thicknesses of materials.

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 Sewing machine: is the dominant process in garment assemblies. Satisfactory garment

assembly and performance depend on correct choices of stitches, seams, threads, needle,
sewing machine and fabrics to be sewn.
 Stitching machine: Is defined as “one unit of conformation resulting from one or more
strands or loops of thread intra-looping, inter-looping or interlacing by passing into or
through materials.
Press and finishing section
Finishing
This section of the garment factory is equipped with washing plant, steam production facilities,
auto press machine and auto packing devices.
Fig.2.14. garment process and product
1.3. Work task I have been working
In each of departments, I have been worked and see the machine and its part with its working
operation one by one, but at the spinning and knitting section I see machine and their behaviors
deeply because there is many mechanical machine parts that related to our educational program.
1.4. Work task i have been executing in the section

I have been executing in all departments, but mainly have been executed in spinning and knitting
department especially in spinning section. That is, I executing my work tasks starting from
spinning section which give the desired colored to the fabric and corino machine which squeeze

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and cut the dyeing fabric then to the Mon forts machine which squeeze and give the desired
length and width to the fabric then after finally transfer to the garment section. And finally I
select problem in this section and I design hydraulic portable crane machine which unloaded the
packed materials from the truck to the ground.
1.5. The Procedures I have been using and engineering tool, techniques
While I work in MAA-Garment P.L.C I have been using the following procedures or steps.
Step1. Discussion on our tasks: first, understanding deeply about the theoretical parts of our tasks
and discuss with colleagues then realize the science besides that tasks.
Step 2.Realizing and identifying problems in which faced us in each department:
Generally, while performing my tasks there were existences of challenges. So, to overcome this
problem or challenges we answered them by relating with practical knowledge.
Step 3.Summarizing and recommendation:
Finally, I would like to understand the facts and gave recommendation for future improvements.
How good we have been in performing our work tasks
During performing period of our work tasks, we really gained practical knowledge rather than
other important activities. That is, we gained like;
 Engineering problems and their solutions (problem solving methods).

 How to prepare work disciplines.
 How to set the machine settings, changing spacers, and top roller smoothness using
Varner calibres.
 How to test the count of sliver and roving using wrap blocks.
 We practice our theoretical design in to real design by identifying problem such as design
of hydraulic portable crane machine and we have been tried to take our best things, to
make good communications management leaders, engineers, workers (operator), quality
head, spinning head, operational manager of the company, and the employers. Due to this
smooth communication, we improve our work tasks in which we have been faced by
different problems by gaining best knowledge.

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1.6. Major challenges faced during performing our projects

During performing my task in the company, i see good and bad things. Due to this reason, there
were some challenges faced during our internship programs. These include;
1. Those who tests the sliver and roving count quality control operators they do not work
correctly and they have carelessness.
2. The workers who test the coefficient variation co% and unevenness u% of rove in the
physical laboratory were not responsible to test the rove above five bobbins.
3. The air condition of the physical laboratory is not work properly.
4. The AFIS tester is out of work. So, it is difficult to test like staple length of the fibre.
5. The roving machines are worked continuously per shift and the maintenance program in
machines is only one machine per week. So, to set the machine parameters in general it is
difficult to achieve at the required goal.
Measuring taken to overcome these challenges
Even though the machine is manufactured and produce in a broad country such as Germany and
our country worker have a little knowledge about the garment machine, it needs knowledge,
machine ethics and way of increase productivity. When the machine injured the company needs a
better maintenance worker who have a good knowledge about each machine to back its
productivity and to increase profit by increase the machine productivity, but this is not happen, in
addition there were some persons that were not responsible to solve this problem. But, we tried to
communicate to the quality head and the operational manager of the company to advise us to
solve these problems by communicating with those is not responsible persons. Then we
approached smoothly to the other volunteer workers to search the required information’s by:
1. Explaining internship programs.

2. Observing in detail the machine spare parts.
3. Working with and getting ideas from technicians and machine operators. Generally, by
collecting soft copies, referring machine manuals from excellent quality head department,
engineers, and office persons to refer the required things for doing our tasks.

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CHPTER-THREE
3. HYDRAULIC CRANE
3.1. INTRODUCTION
The Hydraulic Portable crane is a product selected into the application of design axiom for this
project. Hydraulic Portable crane is a small crane that can be broken down into several parts for
ease of transportation. It must be assembled and bolted into a place where to be used effectively.
Hydraulic crane designed for a whole range of floor lifting job. They are transportable and
require no external power. They can be used where no overhead lift is available and relatively

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short lift required. It also increase efficiency and productivity while decreasing operator bending
and risk of back injury. The portable crane is widely used in mechanical engineering filed for
assist any heavy duty job. There are various types portable crane that are available in the market
with a various function and features.
3.2. Advantages of hydraulic crane

 Most powerful means of lifting objects
It is one of the most powerful means of lifting objects is with the strength of a
hydraulic crane. By harnessing the strength that liquid under pressure gives, and the
ease with which it can be used, it is possible to transfer a relatively small amount of
effort from one place to another, and hydraulic cranes are amongst the most efficient
lifting systems available in the modern workplace.
 Extremely stable in use
Because the hydraulic cranes use a fixed system of pipes, constant pressure can be
maintained once a part of the system has been moved into place, and this makes
them extremely stable in use, and able to support relatively large weights.
 Very easy to maintain

Hydraulic cranes are amongst the simplest systems that you can use within any
industrial process, and are very easy to maintain. Provided that all the pumps and
pistons are regularly checked for any leaks, and potential stress points
3.3. PROBLEM STATEMENT
In the MAA garment factory observe a problem of unloading of the cotton bale from the truck
which is measured up to 4.5 meters height. This uses a lot of peoples to unload the material up
to 8-10 peoples usually the cotton bale is over lapped to each other the labor workers use a stick
to drop this packed material to ground. Until now in this factory they use a back ward and
traditional method of unloading. The safety of both the material and the labors becomes in the
danger and to complete the task it needs 1-2 days per single trailer. This consumes more time.
since the weight of the single cotton is about 200kg it becomes difficult to carry by human
binges Therefore it is difficult to unload such load using human binges .Due to large number of

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defect rates, which results in unloading of the material from the truck the production lines in
the MAA garment usually did not meet their target or planned production. And also since they
are using very backward method and time consuming to unload the material the score of
production retards back. Therefore I am interesting to design a mini crane to simplify the task
and to solve their problem.
3.1. Objectives of this project

The objective of this project is categorized in to general and specific objectives.
3.1.1. General objectives
The general objective of the project is to design and produce portable and moveable lifting
crane to unload packed cotton materials that is beyond the capacity of human being applying
only small force in the production machine shop.
3.3.1. Specific objectives
The details of the objectives of the project are listed as follows;
 To design portable hydraulic crane.

 Cost analysis
 Prepare part and 3D model of each part.

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3.3.2. Methodology of the Project
The methodology incorporated in design and development of portable crane in the

production shop of maa garment Industry is indicated as follows;
• Data source identification, collection and analyze;
 Data Collection
The data collection process was conducted in the two perspectives of data types, which include:
 Primary Data
 Oral interview with selected persons
 Company observation
 Secondary Data
 reading books
 visiting web sites
3.3.3. Significance of the project

This project has great significance for the company and for the customers of maa garment P.L.C.
It helps to increase its production and profitability of the company by having proper hydraulic
crane to unload the packed cotton. And the task will be performed on time
Designing of hydraulic crane has the following significance
 To minimize cost expenditure for labors that is made for operating the work.
 Specifically in maa garment factory to minimize wastage of time for waiting to unload
the material.
 To minimize risk of life and property
 To produce the working prototype of portable, moveable crane for the production.
 To determine the overall cost of the crane production
 To ensure safety
 To make easy working operation

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 Finally, to documentation of the project
3.3.4. Scope of the Project
Generally the scope of this project is staring from short definition of the title project till to the
reference.
Specifically still chapter three it includes introduces about the background, statement of problem,
objective, and methodology of the project. Literature review is coming next in the forth chapter.
The main design of the project is done in chapter five. In this chapter part design, material
selection and part drawing are included. The last chapter is about conclusion, recommendations
and references of the project.
3.3.5. Limitation of the study
The investigator has faced some problem from this problem there was unwillingness of some
responses, the supervisor of the company are busy and peoples coming from the foreign country
was not understand the important of internship to the company and also to the interns.
3.4. LITERATU RE REVIEW
3.4.1. Introduction
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 things and transporting them to other places. It uses one or more simple machine
to create advantage and thus move loads beyond the normal capability of a man. Cranes are
commonly employed in the industry the loading and unloading of loads, in the construction
industry for the movement of materials and in the manufacturing industry for the assembling of
heavy equipment. In material handling, the cranes play a vital role in modern manufacturing
industries. Hydraulic mini cranes are heavy equipment used primarily for lifting. These hydraulic
mini floor Cranes, provide an efficient low cost alternative to other material handling equipment.
Strong, robust, study and built to very standard. Laden, these cranes are maneuverable and
loading, unloading and shifting of heavy load. Hydraulic Crane structure consists of vertical
column, inner boom and outer boom, and the hydraulic system with electrical box assembly.
3.4.2. BACKGROUND OF THE HYDRAULIC CRANES.

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The development of lift machine or crane has reached through different time starting the first
crane for lifting heavy load was invented by ancient Greeks in the late 6th century BC. The
heydays of crane in ancient times come during Roman Empire when construction activity
soared and buildings reached enormous dimensions. The Romans adapted the Greeks cranes and
developed it further. The simplest Romans crane is the trespasses, which consists of a single
beam jib, a winch, a rope, and a block containing three pulleys. Having this mechanical
advantage of 3:1, it has been calculated that a single man working the winch could raise 150kg
[3pulles*50kg=150kg], assuming that 50kg represent the maximum effort of a man can exert.
Over a long time period heavier crane type featured five pulleys (pentaspastos) or in case of the
largest one a set of three by five pulleys (polyspestos) and came with two, three, or four masts
depending on the maximum loads. The polyspestos when operated by four men at both side of
the winch could readily lifts 3000kg[3 ropes*5 pulleys*4 men*50kg=3000kg] If the winch was
replaced by a trade wheel, the maximum load could be doubled to 6000kgs, because the trade
wheel have much bigger mechanical advantages due to its higher diameters. This means
comparing with the construction of Egyptian pyramid where in 50 men are needed to move 2.5
tons of stone up the ramp (50kg per persons). The lifting capability of the Roman polyspastos is
proved to be 60 times higher than the Egyptian system of lifting stones. During the high middle
age the trade wheel was introduced on large scale after the technology had fallen in the Western
Europe with dismiss of Western Roman Empire. The earliest reference to the trade wheel
reappears in the archival literature in France about 1225. Generally vertical transport could be
done more safely and inexpensively by crane than customary method. Typical areas of
application were harbors, mines, and in particular building sites where the trade wheel crane
played a pivoted role in the construction of lofty Gothic cathedrals. In contrast to the modern
cranes, middle age cranes and hoists –much like to their counter parts in Greece and Rome were
primarily capable of a vertical lift, not used to move loads for considerable distance horizontally
as well. It is not worthy that middle age cranes rarely featured ratchets or brakes to forestall the
loads from running backwards. This curious absence is explained by a high friction force
exercised by middle age trade wheels, which normally prevented the wheel from accelerating
beyond control.
With the onset of the industrial revolution, the first modern cranes were installed at harbors for
loading cargo. In 1838, the industrialist and business man sir William Armstrong designed a

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hydraulic water powered crane .His design used a ram in a closed cylinder that was forced down
by a pressurized fluid entering the cylinder. Thus the valve on the cylinder regulates the amount
of fluid intake relative to the load on the crane. The mini crane was invented in Newcastle by
William Armstrong in about (1845) to help load coal in to barges at the Quayside.
3.4.3. Types of portable crane
Thus cranes are broadly categorized into three
1) Overhead crane
2) Fixed cranes and
3) Mobile crane
 Overhead crane
It is being used in a typical industrial shop. The hoist is being operated via a wired push button
station to move system and load along any direction .un overhead mechanism crane is also
known as abridge crane where in the hook and by line mechanisms runs along two widely
separated rails. Overhead crane is typically consists of lifter single beam or double beam
construction. It can be built by using typical steel beam or more complex box grinder type.
Double Grinder Bridge is more typical when there is a need for heavy capacity system of 10tons
and above. The basic components of overhead cranes are the hoist to lift the item, the bridge, a
trolley to move along the bridge. Most of the time over head cranes are applicable in steel
manufacturing industry and vehicle/truck production industry
 Fixed cranes
Fixed cranes are preferable in order to insure the ability to carry heavy reaches greater heights
due to increased stability. These types of cranes are characterized by the fact that their main
structures does not move during the period of use. However many can still be assembled and
disassembled. The structure basically is fixed in one place. There are many different types of
fixed cranes such as Tower cranes, self-erecting, telescoping, Hammerhead, Gantry cranes, Deck
cranes, jib cranes, and bulk handling cranes. However most of them are used under construction
sites. Only few of them like jib cranes Gantry and deck cranes are used in mechanical
engineering operations.
 Mobile cranes
For effective and versatile operation cranes can also made to be mobile. Mobile cranes are
designed in different manner in order to be used on the road, rail, water and air. There are many

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different kinds of mobile cranes. That are truck mounted, side lifter, rough terrain, all terrain
cranes, pick, and carry cranes, telescopic handler crane crawl crane, pail road cranes, floating
Aerial crane and also portable crane.
Working principle of mini crane
3.5. Methodology
During designing of our project we take different methodology. First we collect data for analysis
from different resource to select our material that is suitable for a design and we access analytical
formulas from books. Then design analysis using different formulas and their result and
conclusion. Finally the part drawing using AutoCAD with final assembly of a machine has been
discussed. Generally methodology of our design:-
 Collection of data
 Design analysis
 Result and conclusion
 Conclusion and recommendation
 AutoCAD assembly dra
 Part and descriptions of portable hydraulic crane

1. vertical column
2. Boom
3. base plate
4. Hook
5. Nuts and Bolts
6. Pins

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Fig.3.1. Hydraulic crane
3.5.1. Material Selection

Material selection is a means of selecting material that best suited for the member of machine
to be designed. As a designer material selection should be done carefully in order to design
each components, that will serve till the end of service life. The basic considerations done in
selecting
Materials are; Strength, Mach inability, Toughness, Ductility, Hardness…etc. for each
components of the crane.
 Material for vertical column
Load that the vertical column subjected to is compressive, and material for the column is
selected to be cast iron, because it 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%
 Material for the boom and base plate

Since the load applied on these components is high the material used to make these components
should be strong and hard, thus the best material suited for is steel which has carbon content of
up to 1.5% which results in an increased strength and hardness.
 Material for the crane hook

Thus the crane hook is subjected to both tensile and compressive stress, and wrought iron is
selected for it, because it is malleable tough and ductile material. It has carbon content
of0.02%, 0.12% silicon, 0.018% of phosphorus, 0.07%of slag, and the remaining is iron.
 Material for Bolt
The material for the bolt is subjected to tensile and shearing stress and mild steel best fit the
criteria to resist these stresses and is selected as a material for bolt.
 Material for the Pins
In my project pins are subjected to tensile and shearing. The material selected for the pin
should be ductile and we have selected mild steel.
 Design, fabrication and testing of hydraulic crane

lOMoARcPSD|20091439
In this paper, design, fabrication and testing of hydraulic crane is intended to replace the
local or traditional method of lifting heavy load with hand with emphasis being laid on
performance, safety and reliability. Also, hydraulic crane is capable of carrying load up to
800kg at a time was developed using locally available materials. The design of the
hydraulic crane involved analysis of forces acting in various member of the crane
structure, analysis of the links mechanism, determination of pressure developed in the
actuator at maximum load, material selection and cost evaluation. Its fabrication details
involved some workshop operations such as marking out, cutting, machining, welding and
surface treatment which was accomplished using locally available materials.
3.5.2. Design specification
In my design
 The total (maximum) load to be carried is 400kg

 The pressure of the working line is 3500 pa (cylinder pressure for lifting the load)
 The maximum lift height is 5m from ground(from geometric analysis)
 the length of boom is 3m
 The safety factor is 4(safe for these lifting machines)
 The maximum load to be holed weight is 3.924KN
3.6. Design analysis
3.6.1. Design of vertical column

Vertical column is modeled as a strut or short compression member thus it is exposed to a
compressive stress and this stress is the sum of simple stress component and flexural (bending)
components.
σc = P / A + MC) / I
= P / A + (PecA) / IA
σc= p[1+ec/k2]/A
Where: k = radius of gyration √I/A

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C = distance b/n axis of column

e = eccentricity
Therefore: c=0.15m/2, e=1.6m
Fig.3.2. Vertical column
The column cross section subjected to compression stress is
NOTE: Buckling always occurs about the axis having minimum radius of gyration or least
moment of inertia, therefore in our case buckling occur along horizontal direction (I xx).The area
of column cross section is
A=
=/4
A=0.025m2
K=
= 0.08321
=
= 7.4886MPa

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Checking in buckling of the column

Calculating the critical load that can cause buckling:-
Pcr=where I=moment of inertia
E=young’s modules
Le=length effective=2L (one side open)
k = constant=2
Momentinertia (I)
I=
=
=75.319*106mm4
The young’s module for the material is 200GPa
pcr=
pcr =4646.056KN is the maximum critical load that can cause buckling.
in order to safe my design ppc……
3.92SO my design is safe in beckling
Referring to text book of machine design by KHURMI and GUPTA, The maximum value of
crushing stress (σc) that will develop in cast iron is given to be 400MPa to 1000Mpa. Since the
induced compressive stress due to the applied load is not greater than the maximum crushing
stress developed in the cast iron. Therefore the vertical column is designed safe.
3.6.2. Design of Boom
The boom is modeled as simply supported beam, and it is subjected to a bending stress due to
bending moment developed at the fixed end where it is pinned with the vertical column.

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Fig.3.3. Boom
σb = M / Z
Where:
Z = section modulus
M = Bending Moment at point A
σb = Bending stress
Since the boom is hollow rectangular cross section, the area of boom to which the effect of load P
induces the stress is:
A= 3.0 (0.12 − 0.108)
A = 0.036m2
• Moment of Inertia
Ixx = 3.0 (0.12 −0.108)3 / 12 m4

Ixx = 1.17072*10-4 m4
• Distance from neutral axis extreme fiber (c) is;

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C = (0.12) / 2m=0.06m
• Section Module (z)
Z= I/c= [1.17072*10-4/(0.06)]m4
Z=1.9512*10-3m3
• Bending Moment (M) is;
M =P*L, L= length of boom
M= 3.924KN *3.0m = 11.772*103 Nm

σb = M / Z
= 11.772*103 Nm / 1.9512 *10-3 m3
σb=6.0332Mpa
NOTE: The material selected for the boom is standard steel Fe E-520-Indian standard
designation, and it has a minimum yield stress of 520Mpa and the allowable bending stress is;
σb=Sy/n
n= factor of safety which is assumed to be 4
=520Mpa/4
σb =130Mpa, Allowable bending stress.
Since the allowable bending stress developed is greater than the induced bending stress due to the
load applied, then the boom is designed safe.
3.6.3. Design of crane hook
Hook is the component which is fixed with the boom and it is used for hanging the load on the
boom which moves up and down in lifting the load.

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Fig.3.4.Hook
(From Shigley’s “Mechanical Engineering design”, 8 th edition –Table 3.4)
rc= ri+h/2 and rn=h/ln(ro/ri)
Due to the applied load the hook is subjected to tensile and compression stress with moment
M=P*rc.
• Normal stress
σ = P / A + My / ( Ae ( rn − y ) ) , rn– y =r
But rc = 3cm+4cm/2 = 5cm
rn=4/ln(7/2)=4.72cm
e = rc- rn= (5 − 4.72) cm = 0.0028m
Cross sectional area at which the load act is,
A=2cm*4cm=8cm2=8*10-4m2
Moment due to the load applied, M = P * rc, => 3924N*0.05m = 196.2 Nm.
→ Substituting r from 3 to 7 I can determine the stress developed in compression and tensile
side.
For r = 3cm
σ = 3924N / 8*10-4 +196.2 Nm (0.0472 − 0.03) / (8*10-4 (0.0028) (0.03))
σ = 55.122MPa
For r = 4cm

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σ = 3924N / (8*10-4)+196.2 (0.0472 − 0.04) / (8*10-4 (0.0028) (0.04))

σ = 20.671MPa.
For = 5cm
σ = 3924 / 8*10-4+196.2 (0.0472 − 0.05) / (8*10-4 (0.0028) (0.05))
= 0 Mpa
For r = 6cm
σ = 3924/ 8*10-4+196.2 (0.0472 − 0.06) / (8*10-4 (0.0028) (0.05))

σ = −13.78071429MPa…………….compressive stress
For r = 7cm
σ = 3924/ 8*10-4+196.2 (0.0472 − 0.07) / (8*10-4 (0.0028) (0.05))

σ = −23.62408MPa………………compressive stress
NOTE, since the induced tensile and compressive Stress are less than for the crane hook, i.e.
wrought iron which have a stress of 250MPa to500MPa and 300MPa under tensile and
compressive respectively, then hook is designed safe. The ultimate tensile and compressive stress
of the material that is selected
3.6.4. Design of base plate
Base plate /Truck serve as a base for carrying all the weight of the proposed design project. In
addition it carries the load by all the components of the crane .It is composed of four bars and
each of them is modeled as a beam.
Fig.3.5.Base plate
Bar 1 and Bar 2 are side bars on which the center connecting bar is supported over. And the other
is end bar which is provided at the back end of the two side bars to give extra strength. To know

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the stress developed in these components first I should know the all loads applied and let’s first
calculate all the masses of all the other components.
Masses of vertical column:
Volume vertical column
V=A*L
A=
A=
A= 0.025m2
V= 0.025m2*2m
V=0.0132m3
Since the material for the vertical column is made from cast iron, the mass density of cast iron is
7250kg/m3.
ρ = m / V, m=ρV
= (725kg/m3)(0.0132m3)
mv = 95.7kg, mass of Vertical column
Mass of Boom:

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The volume of the boom is
V=A*L
= [(120*120) − (106*106)] (3000)

V= 0.009492m3
The boom is made of standard steel, and the mass density of steel is 7850kg/m3
ρ = m / V, m=ρV
= (7850kg/m3)(0.009492m3)
m = 74.5kg, mass of boom
Mass of vertical column support:
V = A*h
= [(60*70) − (52*62)] 1200
= (4200 − 3224)1200
V = 0.0006048m3
The material for the support is selected to be cast iron, which have mass density of 7250kg/m3.ρ
= m / V,
m = ρ* V
= 7250*0.0006048
m = 4.4kg, mass of vertical column support.
Mass of crane hook

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The cross sectional area of crane hook is assumed to be equal to thin circular plate of 6 cm inner
diameter and 14 cm outer diameter having a thickness of 2 cm.
V = A*t
= [π (do2-di2)]/4(t)
=π/4(7cm2-3cm2) (2cm)
V=62.832*10-6m3
Since the material for crane hook is wrought iron, which have mass density of 7780kg/m3
m = ρ* V
= (7780)(62.832*10-6)kg
m=0.5kg
The mass of other components like hydraulic tank with the fluid, hydraulic cylinder , pin , bolts
with nut, all in one are estimated to be 25kg.Additionally the design is proposed to lift a load of
400kg ,and the total mass applied on the base plate is,
m= (95.7+ 74.5+ 4.4+ 0.5+ 25+ 400) kg
=600.1122kg
PT=mT*g
=600.1122kg*9.81m/s2 =5.89KN
Center connecting bar :
Due to the load P the bar is subjected to equal bending moment at both end of the plate. At both
end there are two reaction forces to encounter the bending of beam due to the load applied. And
these are equals to half the load applied.

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R= 2.945kN
A= (200*80) − (193* 73) mm2
A = 1900mm2 = 0.0019m2
Section Modules
Z = (200 *80)3–(186 * 66)3/12

=5.69*10-5 m2
• Moment at the two end of bar
MA,B=(PT*L)/4
= (5.89KN*0.0516)/4
M= 0.075981KNm
σb = M/Z
=75.981Nm/5.96*10-5m3
= 12.7485*105N/m2
= 1.2748MPa, Induced stress.
The material selected for the center bar of the base plate is standard steel of Indian standard
designation FeE520, having yield strength of 520N/mm2. Taking the factor of safety equals 4.
σ =Sy/ n =520/4 =130 N/mm2
Since the induced stress is less than the ultimate bending stress, then the bar is designed
safely.
3.6.5. Design of the rollers

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Fig3.6.roller
On this mechanism I have used 4 rollers. They are designed for

bearing.
Taking the material of the roller to be the same as that of the base, a
high strength low alloy steel with, σ t= 485 Mpa, σy = 345 Mpa and
factor of safety =4
, F = 3920N, t = thickness, d = dpin = 10mm (internal diameter)

and taking
=87Mpa then
t = = =4.5mm
For better stability let’s take t = 6mm and to avoid wear of the leg the
outside diameter should be greater than 1.5dpin + rpin= 15 + 5mm, do =
20mm, then let’s take do=30mm
3.6.6. WHEEL SELECTION
The types of wheels I have used are swivel H-series medium duty castors (from
wheels and castor catalogues). The wheels are swivel and can be fixed to one
directional movement.

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Table3.1.Wheel sellection
The wheel diameter I have selected is 100mm with ball journal. The load capacity
is 750kg which is greater than the mass of the yarn including the table (700kg).
3.6.7. Design of pins
Due to the load applied at the end of the boom and the load by the boom itself, the pin that
connect the vertical column and the boom is subjected to shearing stress. The shearing force
applied on the pin that connects the vertical column with the boom can be obtained using the
principle that summation of moment on the pin that connects the actuator and boom is zero.
ΣMB =0
= 1 (Rc) = 0.1(W) + 2 (P)
W = (74.5Kg) (9.81m/s2)
W =730.85N
P =3.924KN

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Rc= (73.085+ 7848) /1
= 7921.08N
Rc= 7.921KN,Shear force on pin .
Fig3.7. pins
d=
=14.02mm…….
Say d = 20mm, Diameter of pin at lower extreme.
The length of pin is slightly made to exceed the width of vertical column, that is
L= (200 + 15) mm
L = 215mm
3.6.8. Design of the bolt

About is a form of threaded fastener with an external male thread. Bolts are closely related to
screws. In order to rotate the simple crane we need the average humane force of 200Napling on
the lever which is 30cm from the axis of the column.
T=F*r
=200N*0.3m

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=60Nm
Fig3.8.bolt and nut
Here the bolt is placed 25cm from the axis of the column.
P shear=T/Rpn…….where n is number of bolts say 4
=60Nm/0.25*4
=60N
τ = P/A, where a=area of shear
= 4*60N/πd2…….take dcore of the bolt to be 25mm
=240N/π*0.252
= 0.1223Mpa=122.23kpa
The material selected for the bolt is standard steel Fe E-520-Indian standard designation, and it
has a minimum yield shear stress of 520Mpa and the allowable bending stress is;
b =y / n, n factor of safety which is assumed to be 4. 520Mpa / 4=130Mpa, Allowable bending
stress. Since the allowable bending stress developed is greater than the induced bending stress
due to the load applied, then the boom bolt is designed safe.
Fig.3.9. bolt

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3.6.9. Selection of bearings
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. Because the balls are rolling they have a much lower coefficient of
friction than if two flat surfaces were sliding against each other.
Table3.2. Selection of bearings
Due to the Excellency of the above tapered roller type and double-row, deep-groove ball bearing
types are selected from the rest one. But due to the expensiveness (cost) of tapered bearing, the
double-row deep groove ball bearing is appropriate.
From the standards the outer diameter is equal to the internal diameter of the lower column. And
the internal diameter should be equal to the outer diameter of the higher column.
Do=16cm=160mm
Bore diameter=90mm
Width=30mm
Fillet radius=2mm ball bearing is selected.
 Design of Hydraulic system
A hydraulic system consists of a pump, a tank, filters, and individual types of valves, hydraulic
Cylinders and hoses between the different units.

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Generally a forwarder has separate systems, one for transmission and one for the working
Hydraulics. The load-sensing hydraulic system is based on the physical principle that fluids are
entirely incompressible. The pump delivers an oil flow at high pressure. By controlling the
valves, the fluid is delivered to both chambers in the hydraulic cylinder depending on the
direction of movement that is desired as oil is dropped simultaneously from the other cylinder
chamber. The tank works as storage for oil but it is also important to eliminate the air bubbles
that are generated by the pump. There are extra fine filters installed in all hydraulic
Hydraulic cylinder or also known as linear hydraulic motor is a mechanical actuator that is used
to give a unidirectional force through a unidirectional stroke. Hydraulic cylinders get their power
from pressurized hydraulic fluid, which is typically hydraulic oil. Design of hydraulic cylinder
consists of design of cylinder, design of piston rod, hinged pin, design of flat end cover design of
piston,
3.6.10. Design of Cylinder
The main function of cylinder is to retain the working fluid and to guide the piston. Hydraulic
cylinder usually made of cast steel or cast iron, But for our design purpose we select cast steel
because of high heat resistance, easily machine able and low cost.
Fig.3.10. piston Cylinder
The values taken for our design are;
σt = permissible t’ensile stress

= 80N / mm2
p = maximum pressure inside the Cylinder
= 3.5N / mm2
F = load that is applied on the actuator

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= 212,615.4189N.
Then, inner diameter of the cylinder is (di):-
F = p *di2 / 4* p
di = =
=280mm,say,
• Thickness of the cylinder;
Let, t= thickness of the cylinder
t = ri − 1}
Where, ri = di/2= 280mm/2=140mm
t= {140mm - 1}
t = 9.22mm.
• Outer diameter of the cylinder
Let, do = Outer diameter of the cylinder
do =di + 2t = 280mm + 2 ( 9.22mm )

= 298.44mm
The cylinder head may be taken as flat circular plate whose thickness may be determined from
the following relation.
Let, th = is the thickness of the head
σc= allowable circumferential stress in N/mm2
=30 to 50Mpa.
Take, σc = 40Mpa (for our design purpose)
th = di (/ σc)
Where, C = constant = 0.1
th = 280mm / 40N/mm2} = 26.2mm.

• And the length of cylinder is:-
L = 2*do

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= 2* 298.44mm = 596.88mm
3.6.11. Design of Piston:
Piston is moved by a fluid, or it moves the fluid which enters the cylinder. The most commonly
material used for piston is cast iron, cast aluminum, forged aluminum, cast steel, and forged steel.
But the material we selected for our design purpose is cast iron. Piston is consists of the
following parts, Head or crown, Piston ring, Skirt, Piston pin, Piston head:- The thickness of
piston head (tH), according to Grashoff’s formula is given by:-
Fig.3.11. Piston and piston rod
tH =16σt
p = Maximum pressure
Do= Outer diameter of the piston,
σt = tensile stress, =38MPa.
Note: The outer diameter of the piston is assumed to be equal to the inner diameter of the
cylinder. Therefore the outer diameter of the piston is 280mm.
tH = (16 *38 )
= 4.8mm, say, tH= 5mm
3.6.12. Piston rings:
The piston rings are used to impart the necessary radial pressure to maintain the seal between
the piston and cylinder bore. The radial thickness (t r) of the ring may be obtained by considering
the radial pressure between the cylinder wall and the ring.
tr= Do

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Where
Do = Outer diameter of piston
σt = Allowable tensile stress in Mpa, it may be taken 85MPa to 110MPa fore cast iron rings.
tr =280mm
tr = 9.56mm.
And also the axial thickness of the piston ring (ta) is:-
ta = 0.7tr to tr
= 7mm to 9.56mm, adopting
ta =8.5mm.
We also know that the minimum axial thickness of the piston ring is:
ta = Do / 10nr,
Where nr= No of rings =4
t= 280mm/10 (4) = 7mm.
Thus the axial thickness of the piston ring as calculated (i.e. ta = 7mm) is satisfactory. The
distance from the top of the piston to the first ring groove, i.e. the width of the top hand:-
b1 = tH to 1.2 tH
= 5mm to6mm,taking,b1=5.5mm
And the width of the other hand of the ring
b2 = 0.75ta to ta
= 6.63mm to 8.5mm, taking, b2 =7.5mm
We know the gap between the free ends of the rings:
G1 = 3.5tr to 4tr
= 33.46mm to 38.24mm
And the gap when the ring is in the cylinder,
G2 = 0.002Do to 0.004Do

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= 0.56mm to 1.12mm, let's adopt
G1 = 36mm, and G2 =1mm
3.6.13. Piston Barrel:
It is a cylindrical portion of the piston. The maximum thickness (t3) of the piston barrel may be
obtained from empirical relation:
t3 = 0.03Do +b + 4.5,
Where
b = radial depth of piston, and it is taken to be 0.4mm greater than the radial thickness of piston
ring
I.e. b = tr + 0.4mm
Therefore, t3 = 0.03Do + tr +4.9
t3= 0.03 (280) + 9.56 + 4.9 = 22.86mm,
Say, t3= 23mm.
And the piston wall thickness (t4) towards the open end is decreased and should be taken as:-
t4 = 0.25t3 to 0.35t3
= 0.25 (23) to 0.35 (23) mm
= 5.75 to 8.05mm, Adopting
t4 = 8mm.
3.6.14. Design of Hose
Hose used to transport working fluid under pressure from the pump to the cylinder or from
cylinder to reservoir. Here I used flexible material for the pipe which is rubber.
Material selection; Rubber (grade AMG)
ϬUT=200MPa, ϬUC=240MPa, τ UT=350MPa
Assumptions; internal diameter of the pipe
d=15mm, L=3000mm and
Factor of safety FS=1.5 (since it doesn’t affected by high load)

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Let us assume thin cylinder; this applied when

 The stress across the pipe section is uniform
 The internal diameter of the pipe is more than 20 times its wall thickness d/t > 20.
ϬT= (PD/2t), pressure is the same in the closed direction so p= 3.5N/mm2
ϬALL=ϬUT/FS=200/1.5=133.33N/mm2
t=PD/2Ϭall= (3.5 N/mm2)/2 * 133.33N/mm2
=0.01313mm
Cheek for thin;
d/t> 20
15/0.001313mm >20,So this is correct.
Thickness of the pipe is t=0.001313mm
3.6.15. Lifting system
 Electrical motor control design
How to control the movement up and down of the load
I am using the logo software to control the up and down motion of the crane. In this design only a
control circuit is simulated for the motor to control its actuation system (rotation of the shaft,
ON/OFF power of the motor).
This simulation is using logo software to control the direction of rotation of the motor.
When switch one is ON and switches number two is OFF the shaft motor rotates clockwise
direction. When switch number two is ON consequently the shaft motor continuously rotates
clockwise direction. so that the load is lifted up ward.

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When switch number two is ON and switch number one is OFF the shaft motor rotates
anticlockwise direction. If we turn on both the switches the switch which is turned ON first will
start its operation.
Here the system is used to lift the load up and down as required. Thus the system works by
allowing a certain amount of fluid to pass through the hose. The system is made of three basic
components.
1. Electrical system box
2. Solenoid coils
3. Electric motor
 Electrical system box:
This system box include power indicator, switch indicators, raising indicator, switch, and push
buttons for raising the piston rod up and down. When the push buttons are pressed, electrical
energy will turn the solenoid and the respective valves will be opened forcing the pressurized oil
to pass through the hose.
 Solenoid coils:
It is used to close and open the rising and lowering valve, when we press up and down push
button. There are different types of solenoid; of these I used electrically actuating double acting
coil.

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 Electric motor:
The motor is used to compress and pump the oil from the oil tank to the actuator through the
hose.
Motor specification:
Power = 3000W
Speed = 340rpm
3.6.16. Lifting height
• The maximum height that the hydraulic crane can lift is obtained as follow
Fig3.12. lifting height hydraulic crane
From cosine low:

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1372 = 1722 + 1002 -2(172) (100) cos(α) θ = 1800 –(22.76 +16.39)0
α = cos-1[0.6051] θ = 140.850
α = 22.760 M = 300 sin (50.850) = 232 cm
From sin low: N = 137 cos120 = 134 cm
Sin22.760/137 = sin β/100 K = 63 cos120 =62.32 cm
β = sin-1[0.2823] H = M+ N+ K = 498 cm
β = 16.390 H = 4.98 m
• Minimum height that the hydraulic crane can pick up objects from is obtained as:
Fig3.13. Minimum lifting height hydraulic crane
From Cosine law:
θ = cos-1[(137)2+ (100)2 – (137)2]/2(137)(137)
θ = 74.570

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M = 300* cos(86.57)0 = 59.2
h =300cos120 – M
h = 234.2 cm
3.7. Result and Discussion

In order to analyze the machine easily the design result is presented into a table below.
Table3.3. Result of each component
No Components Material Input Manually Calculated

Selection Data Result
1 Vertical column Cast iron do= 0.2m
di =0.09m
A=0.025m2
I=75.319*106mm
2 Boom Standard steel Fe E- σb = 130 Mpa do= 0.12m
520 Indian standard di = 0.108m
A =0.36mm2
Ixx = 1.17072*10-4m4
Z = 1.9512*10-3m3
M = 11.772*103Nm
σc= 6.0332Mpa
3 Hook Wrought iron rc = 0.05m

rn = 0.0472m
e = 0.0028m
A= 8*10-4m2
M = 196.2Nm
4 Base plate Cast iron mT = 600.1122kg
pT = 5.89 KN
5 Pins Mild steel from Rc = 7.921 KN

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Indian Max =25.625MPa

standardization d =20 mm
L= 215mm
6 Bolt Standard steel Fe E- σb = 130 Mpa Dcore = 25 cm
520 Indian standard
7 Bearing do = 160mm
dbore = 90mm
b = 30mm
rfilet= 2mm
8 Hydraulic cylinder cast iron Pressure p= di = 280mm
3.5N/mm2 t = 9.22mm
do = 298.44mm
th = 26.2mm
L = 596.88mm
9 Piston cast iron do = 280mm
tH = 5mm
10 Ring tr = 9.56mm
ta = 8.5mm
b = 5.5mm
b2 = 7.5mm
11 Piston barrel t3 = 23mm
t3 = 8mm
12 Hose Rubber d = 15mm
L = 3000mm
t = 0.001313mm
13 Power and speed P = 3KW
N = 340rpm
14 Lifting height Hmax = 4.98m~ 5m
Hmin = 2.34m~2m
 Discussion

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Generally, the overall geometry of this hydraulic lifting machine enables the operator to transport
it even between two machines because of its slim dimensions. The simplicity of the components
and good lubrication makes it long lasting and easy to maintain.
The engineers and the MAA-Garment textile factory officials strongly believe that this machine
greatly helps in saving labor health and time. With a small energy input it can lift significant
amount of load. It has a load rotating capacity of 400Kg.
3.8. Cost analysis
As we have mention in the above the machine can be constructed and it is under economical
hydraulic lifting cranes. The total cost of the material mansion below
The manufacturing cost is lower than the market product. It reduces 8500 birr.
Table3.4. Cost estimation
S.N MATERIAL COST IN
O BIRR
1 Mild steel angle rod 300
2 Circular rods (15mm dia) 3200
3 Wheel 600
4 Electrical board 8000
5 Welding cost 2000
6 Bearing 260
7 square plates 2100
8 Hose 1000
9 Oil tank 700

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10 BOLT 630
11 Motor 30000
Total cost 48,790birr
 Reduced costs value

Once the existing product has been assessed, to find design or component alternatives that serve
to reduce costs without risking value or increase value without adding cost. The most ideal
situation is to find alternatives that reduce costs while adding value.
 Cost Reducing Ideas
Reduction
• Reduce the number of components • Reduce specifications (e.g., material
• Combine components strength requirements)
• Reduce or change packaging
Elimination
• Eliminate redundant or unnecessary • Simpler shapes
components • Simpler assembly process or sequence
Simplification • Relaxed tolerances or dimensions
• Simpler design
Modification
• Less expensive materials • Less expensive finishes
• More efficient manufacturing • Use alternative transportation methods

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CHAPTE -FOUR
4. Over all benefit the internship

During the internship duration I have got many knowledge and good understanding related to;
4.1. Theoretical knowledge
In terms of theoretical knowledge the internship is help me to relate the educational knowledge
with real world. Other advantages are it is helping me to know the work ethics of the industries,
the information flow (communication) system In this department by simple observation and
observing past data I try to know the work flow of the department as well as any kind of
problem .Generally I gained the following experiences from the MAA garment company:-
 How to communicate with persons and formality of company.
 Experience of leadership and work ethics issues
 Knowledge &good understandings of theoretical knowledge related to Practical skill.
 Interims of practical skill, operating of different machines. In Management &Textile

Company there are more than 58 kinds of machines. So more or less I familiarize with
those machines related to the I rename, application, and maintainability and operation
system.
 I improve how to cooperate with other person. That means how to do with team.
 Identifying of different problems, such as

 high west of cotton

lOMoARcPSD|20091439
 Un scheduled working of the machine
 Loss a lot of human force

4.2. Practical skill:
In terms of practical skill I improved my knowledge in operating some machines like
spreading machine, sewing machines, and hand cutter
Machine, fusion machine and the pattern making machines like Gerber (computerized)
CAD/CAM system patternmaking and how to maintain different type of machines.
More or less I am familiarizing with these machines relative to their name, application, code,
and maintainability and operation system. E.g. Spreading machine: this machine is used for
spread in for layering the fabric clothes and after layering the fabric it needs to cut as the
customer needs by using pattern and cut properly.
4.3. Improving Industrial Problem Solving Capability
I have learnt how to found problem areas, how to get problems, how to select specific problems
& how to solve each problem in every systematic way.
4.4. Inter Personal Communication Skill
As we know, to have such place the behavior of good interpersonal communication has great
value because one person may judge you from your speaking whether you are talented or not. So
the four months we past in maa garment factory were good enough for improving our
interpersonal communication skill with different workers of the company because nothing is to
be hide there. Since most things are done openly. This phenomenon makes us to communicate
freely with the workers.
4.5. Team Playing Skill

This internship has a core point during the team work by sharing different ideas theoretically and
skills practically with different student that have different performance that join to the company
from different university. I gate a good knowledge how to specify and solve a specific problem
by discussing in team.

lOMoARcPSD|20091439
4.6. Leadership Skill
Throughout this internship I have gained a lot of leader ship skills, some of them are
mentioned below
 How to establish direction as leader of a team
 How to Align people
 How to Motivate and inspire people
 How to Focus on team and overall goals
 How to Communicate with each people
 How to be Honest on your action
4.7. Work Ethics
 To be on time at work and leave work by right time

 To be responsible in analyzing, interpreting and gathering data
 To be truthful in professional report that is submitted to the research
 To be respective to each other Punctuality
4.8. Entrepreneur ship Skill
An entrepreneur ship is the process of creating something new with value by devoting the
necessary time and effort, assuming the necessary risks and expecting rewards for under taking,
from my internship program I gained different ideas to:
 Make myself free from the limit of standardized pay for standardized work.
 Avoid things that limit me to do some new innovations.
 Be Free from routine, boring and unchallenged jobs and it makes me interested in:
 High need for achievement of my own goal
 Willingness and ready to take moderate risk

lOMoARcPSD|20091439
CHPTER – FIVE
5.1. CONCLUSION AND RECOMMENDATIONS

5.1.1. Conclusion
For many years cranes have been designed for lifting heavy objects with different capacity in
different work sites. Portable cranes are of one type of cranes designed for lifting objects which
are beyond the capacity of human being. As MAA GARMENT INDUSTRY is one of the
companies where in many different lifting operations is practicable. This lifting operation by
using portable and moveable hydraulic crane which is not being use before, I have identified
that there is the need for using hydraulic portable crane to lift up and dawn objects these are
beyond the capacity and difficult of human power. Thus this paper provides the design of each
part of portable crane. And the design analysis for each part is checked that it is safe
accordingly the size of each parts of the crane.
The maximum carrying capacity 400kg and maximum lifting height is estimated as greater than
5m from the ground run by using 3KW electric motor rotating 340rpm.
5.1.2. Recommendation
From this design it is recommended that for everyone who concerns this problem the design
contains an electrical switch to control the motion which needs to high handling safety so the
company must have to give high concern for the installation and operation of the switch. And
during installation of the portable hydraulic crane the company must have to give attention to the
mounting of electrical motors. Generally it is recommended that MAA garment & textile plc

lOMoARcPSD|20091439
should have to actively work closely with universities and other higher educational centers in
order to solve problems associated with manufacturing process by having technological
knowledge transfer between them. Also the university should have to be responsible in providing
potential support for student by strengthening university-industry linkages. Finally I recommend
that anybody who interested to modify the current design of the portable crane for the production
workshop of our design can make this work base study or can use as reference.
Symbols and Descriptions

A…………………………………….Cross sectional area
W…………………………………...Width / depth
C…………………………………….Distance b/n axis and end fiber
I……………………………………...moment inertia
Z…………………………………….section module
E……………………………………modulus of elasticity
………………..………………….mean diameter
………………………………….shear maximum
……………….…………………....bearing pressure
-………………..………………...crushing load
-……………………………………bending
-…………………………………...cross sectional area
………………………………….y.ield strength
………………………………....ultimate strength
………………………………….mass
…………………………………..gravity
F…………………………………...force

lOMoARcPSD|20091439
G…………………………………..modulus of rigidity
T-………………………………….torque
P-…………………………………….power
………………………………….ns-factor of safety stress
…………………………………..shear stress
D ………………………………….nominal diameter
Dh………………………………….Diameter of hinged pin of piston
Di……………………………………Inner diameter
Do……………………………………Outer diameter
T…………………………………….torque
I……………………………………moment of inertia
………………………………….thickness
D…………………………………....mean coil diameter
………………………………….core diameter
M……………………………….......moment

lOMoARcPSD|20091439
References
[1] New world encyclopedia “Crane (machine)” found

www.newworldencyclopedia/entery/crane (machine).
[2] R.S. Khurmi and J.K. Gupta.“ Text book of Machine design” 8th edition, EUROASIA
PUBLISHING HOUSE (PVT.)LTD .2005.
[3] Budynas-Nesbett. “Shirley’s Mechanical Engineering Design”, 8th edition, McGraw Hill
companies, 2008.
[4] Merriam, “Engineering Mechanics and Statics”, 5th edition, JOHN WILEY & SONS, INC
2000.
[5] “Strength of Material”, 2nd, edition, D. VAN NOSTRAND COMPANY, INC, 1940
[6] Joseph E. Shirley and Charles R. Mischief. “Standard hand book of machine design” 2nd
edition, 1996.
[7] David H. Musket. “Machines and mechanisms; applied kimamatics” university of Dayton,
1999.
[8] John Wiley & Sons. “Strength Of Material And Structure”, 4th edition, ARNOLD co-
publisher in North, central, and south America, New York, Toronto.
[9] Ferdinand P. Beer, et al. “Mechanics of materials “Texas Tech University, 2006.
[10] Victor Dias da Silva. “Mechanics and strength of materials” university of Coimbra, 2006.

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 Assemble drawing and part AutoCAD drawing

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Final Internship Project

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Final Internship Project

Strength and Deformation of materials (Mekelle University)

Studocu is not sponsored or endorsed by any college or university

INTERNSHIP REPORT and PROJECT 2011

SCHOOL OF MECHANICAL ENGINEERING

DURATION OF PROJECT: 4-MONTHS.

PROJECT TITLE: DESIGN OF HYDRAULIC MINI CRANE

By: Brhanu H/slassie

Advisor: Ins. Mewael G/hiwot (M.sc)

PREPAR BY BRHANU DDEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING Page i

Downloaded by MD AMAN ULLAH (ullahmdaman208@gmail.com)

INTERNSHIP REPORT and PROJECT 2011

Academic Advisor: Ins. Mewael

PREPAR BY BRHANU DDEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING Page ii

Downloaded by MD AMAN ULLAH (ullahmdaman208@gmail.com)

INTERNSHIP REPORT and PROJECT 2011

PREPAR BY BRHANU DDEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING Page iii

Downloaded by MD AMAN ULLAH (ullahmdaman208@gmail.com)

INTERNSHIP REPORT and PROJECT 2011

PREPAR BY BRHANU DDEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING Page iv

Downloaded by MD AMAN ULLAH (ullahmdaman208@gmail.com)

INTERNSHIP REPORT and PROJECT 2011

1. 1. Brief history of the company:..........................................................................................................1

1.2. Objectives of the company...............................................................................................................2

1.3. Mission of the company....................................................................................................................2

1.4. Vision of company............................................................................................................................3

1.5. Main raw materials and products of the company.............................................................................3

1.6. Main customers or end users of the company...................................................................................4

1.6.1. Local customers:........................................................................................................................4

1.6.2. Global customers:......................................................................................................................4

1.7. Over all Organization and work flow of the company......................................................................5

1.7.1. Over all organization of the company:.......................................................................................5

1.7.2. Work flow of the company.........................................................................................................5

2.1. How do we get the company?...........................................................................................................6

2.2. Section of the company we have been working................................................................................6

2.2.1. Spinning department:.................................................................................................................6

2.2.2 Knitting machine......................................................................................................................20

2.2.3. Dyeing and finishing................................................................................................................22

2.2.4. Over all Process and machine types in garment.......................................................................24

2.3 work task I have been working........................................................................................................27

2.4 work task i have been executing in the section................................................................................27

2.6. Major challenges faced during performing our projects..................................................................28

PREPAR BY BRHANU DDEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING Page v

Downloaded by MD AMAN ULLAH (ullahmdaman208@gmail.com)

INTERNSHIP REPORT and PROJECT 2011

3. Hydraulic portable crane........................................................................................................................30

3.1.Adbantages ofhydraulic crane..........................................................................................................30

3.2. Problem Statement..........................................................................................................................31

3.3.1. General objective.....................................................................................................................31

3.3.2. Specific objective.....................................................................................................................32

3.3.3. Methodology of the project .....................................................................................................32

3.3.4. significance of the project .......................................................................................................32

3.3.2. scopes of the project................................................................................................................33

3.3.2.Lmitations of the project...........................................................................................................33

3.4. Literature Review...........................................................................................................................33

3.4.1. Introduction of hydraulic crane................................................................................................33

3.4.2. Buckgraund of hydraulic crane................................................................................................34

3.4.3. types of portable crane.............................................................................................................35

3.5.1. Material Selection....................................................................................................................37

3.5.2. Design Specifications..............................................................................................................38

3.6. Design Analysis..............................................................................................................................39

3.6.1.Design vertical of columun.......................................................................................................39