2911]12]2011

nLkIC1 WA11 UNIVLkSI1¥ DU8AI CAMÞUS

GLAkLD 1kCLLL¥ CkANL
8S9DL Ŷ DLSIGN AND MANUIAC1UkL 3


1he pro[ecL ls Lo famlllarlze wlLh Lhe CLA8Lu 18CLLL? C8AnLţ lL ls requlred Lo deslgn geared Lrolley
carne mounLed on an lŴbeam of known lengLh and load raLlng and a glven seL of speclflcaLlonsŦ 1he
deslgns are produced on SCLlu LuCL v20

2 | 9 a g e


CCN1LN1S ÞAGL


1Ŧ Introduct|on 3

2Ŧ Des|gn S

3Ŧ Ca|cu|at|ons 8

4Ŧ Mater|a| kequ|rement and Manufactur|ng Þrocess 1S

SŦ keference 13

6ŦContr|but|on 14









3 | 9 a g e


Introduct|on
1rolley crane ls a llfLlng machlneţ generally equlpped wlLh a wlnderţ wlre ropes or chalns and
sheavesţ whlch can be used boLh Lo llfL and lower maLerlals and Lo move Lhem horlzonLallyŦ lL uses
one or more slmple machlnes Lo creaLe mechanlcal advanLage and Lhus move loads beyond Lhe
normal capablllLy of a humanŦ Cranes are commonly employed ln Lhe consLrucLlon lndusLry for Lhe
movemenL of maLerlals and ln Lhe manufacLurlng lndusLry for Lhe assembllng of heavy equlpmenLţ
1he deslgn show below ln flgŦ1Ŧ1 shows an Cverhead 1rolley CraneŦ 1he purpose of such mechanlcal
equlpmenL varles accordlng Lo Lhe needs of masslve verlLy of lndusLrlesŦ 1he auLomoblle lndusLry
uses overhead cranes for handllng of raw maLerlals and heavy parLsŦ

I|g 1Ŧ1 1ro||ey crane des|gn]structure
1he llgure above shows Pand geared Lrolley whlch ls manually used by Lhe efforL of Lhe
operaLorŦ 1he operaLor's efforL ls Lransferred lnLo Lhe holsL moLlon by Lhe operaLor pulllng
Lhe hand chalnŦ 1he hand chaln Lurns a pockeLed hand chaln wheel LhaL acLuaLes Lhe Lrolley
crane mechanlsmŦ 1hls Lype of Lrolleys are used for heavler loadsţ load spoLLlng accuracyţ or
lf Lhe Lrolley ls mounLed very hlghŦ
1he manual overhead Lrolley crane uses gears and wheels for lLs mechanlcal operaLlonŦ A
gear ls a roLaLlng machlne parL havlng cuL LeeLhţ or cogsţ whlch mesh wlLh anoLher LooLhed
parL ln order Lo LransmlL LorqueŦ 1wo or more gears worklng ln Landem are called a
Lransmlsslon and can produce a mechanlcal advanLage Lhrough a gear raLlo and Lhus may be
consldered a slmple machlneŦ 1he mosL common slLuaLlon ls for a gear Lo mesh wlLh
anoLher gearŤ however a gear can also mesh a nonŴroLaLlng LooLhed parLţ called a rackţ
Lhereby produclng LranslaLlon lnsLead of roLaLlonŦ
1he dlrecLlon and Lhe speed aL whlch Lhe Lrolley moves along Lhe beam are dependenL on
Lhe roLaLlon of Lhe pulleyŦ AlLhough Lhe crane wlll carry a very large loadţ Lhls pulley can be
manually operaLed and wlLh mlnlmal efforL from Lhe person operaLlng lLŦ 1he manual
roLaLlonal power wlll be Lransformed lnLo llnear moLlon Lhrough a serles of gears wlLhln Lhe
crane LrolleyŦ

4 | 9 a g e


llgure 1Ŧ2


Iugure 1Ŧ3

Cears are generally used for one of four dlfferenL reasonsť
1Ŧ 1o reverse Lhe dlrecLlon of roLaLlonŦ
2Ŧ 1o lncrease or decrease Lhe speed of roLaLlonŦ
3Ŧ 1o move roLaLlonal moLlon Lo a dlfferenL axlsŦ
4Ŧ 1o keep Lhe roLaLlon of Lwo axls synchronlzedŦ







S | 9 a g e

Des|gn

G|ven Data

Crane maxlmum loadť as deLalled below
8eam spanť as deLalled below
8eam secLlonť 8S! Lo 8S Ln10036ť1999
8eam maLerlalť Ln10023 S233 wlLh a yleld sLress of 233 M9a
lacLor of safeLyť 1Ŧ2 on yleld
8eam span (m) ť 4
Max|mum |oad (tones) ť 3

IŴ8eam Structure



6 | 9 a g e



1ro||ey Crane Des|gn



| 9 a g e












8 | 9 a g e

Ca|cu|at|ons


8eam Ca|cu|at|ons

1o begln wlLhţ we Lake momenLs abouL Lhe rlghL end of Lhe beamŦ

¸ ) 0 4
2
16
4
2 1 1
= + + + =
¿
M x F
W
R M M
B

1he force equlllbrlum equaLlonŦ
0 4
2 1
= + =
¿ B T
W R R W F
conslderlng a secLlon of Lhe beamŦ
¸ )
¿
+ + = x a W
a W
R M M
T
B
2
2
1 1

Applylng of Macaulay's MeLhod
¸ )

x a W Wba a R Ma
M

x a W a W a R
a M M
T
T B
+ +

+ + + =
+

+ =
¦¦
¦
1
3 4 3
1
2
2 3 2
1
1
6
) (
24 6 2
2 6 2

When aƹ0ţ Mƹ0ţ 1herefore boLh consLanLs of lnLegraLlon are equal Lo zeroŦ
When aƹ4
¦
= 0 M
¸ )
¦
=

+ = 0
2
4
6
64
8 4
2
1 1
x W W
R M M
T B
(3)
When aƹ4
¦ ¦
= 0 M
0
6
) 4 (
3
32
6
64
8
3
1
1
=

+ + + =
¦¦
x W W R
M M
T B
(4)
LquaLlon 3 Ŷ 2 x ln eqŦ4
9 | 9 a g e

¸ ) ¸ ) x x
W
W R
T
B
+ + = 2 4
32
2
2
1

Sub for
1
R lnLo LqŦ3
2
1
) 4 (
32 3
4
x x
W
W M
T
B
=
Sub for
1
R and
1
M ln LquaLlonŦ1
) 4 (
16 3
4
2
x
W
W M
T
B
=
So bendlng momenL can be shown by Lhe equaLlonť
¸ ) x a W
a W
a R M M
T
B
+ =
2
2
1 1

So now Lhe bendlng momenL can be calculaLed for all poslLlons of Lhe LrolleyŦ
1he maxlmum value of Lhe bendlng momenL M appears aL xƹ0 when Lhe Lrolley ls aL 1/3 of Lhe
beamţ and aL xƹ4m when Lhe Lrolley ls aL 2/3 of Lhe beam Ŧ1herefore Lhe maxlmum bendlng ls 18Ŧ09
knm wlLh Lhe '203x132x32 beam'Ŧ

nook Ca|cu|at|ons
1Ŧ Shear of Pookť
Shear SLressť
9
F
2
= t
2Ŧ 1enslle lallureť
¸ )9 / b
F
A
F

= = o

1he hook ls llfLlng a load of 3Lonnesţ Lherefore lƹ29430nŦ

1Ŧ 1ear CuL/Shear of Pookť
9
F
2
= t
006 . 0 05 . 0 2
29430
x x
= t
10 | 9 a g e

!a
x
6
10 05 . 49 = t

2Ŧ 1enslle lallure of Pookť
¸ )9 / b
F
A
F

= = o
¸ )
/
9
F
b +
-
=
o

¸ )
05 . 0
006 . 0 10 235
29430
6
+
-
=
x
b
m b 0708 . 0 =
Ca|cu|at|ons of bush bear|ngť
1oLal ƹ 3 bush bearlngs
1ens||e stress on each bush |n the four geared whee|sť


Whereţ



8equlred maLerlals and 9rocedure
1Ŧ Cear cases
MaLerlalť SLeelţ ManufacLurlng processť lormlng
2Ŧ urlven wheels
MaLerlalť SLeelţ ManufacLurlng processť lormlng
3Ŧ 8ush 8earlng
O Cnly preclslon ball and roller bearlngs for all Lrolley crane assembly componenLs wlLh mlnlmum
8Ŵ10 llfe of 3000 hours aL full raLed loadŦ
11 | 9 a g e

O All bearlngs musL have proper lubrlcaLlon and means of lubrlcaLlngŦ ueslgn bearlng enclosure Lo
exclude dlrL and prevenL leakage of oll or greaseŦ
MaLerlalť SLeelţ ManufacLurlng processť lndusLry SLandards

4Ŧ ShafLs
MaLerlalť ColdŴrolled SLeel of shafLlng quallLyţ ManufacLurlng processť Cold rolllng process
3Ŧ 8olLs and nuLs
MaLerlalť Plgh SLrengLh SLeelţ hoLŴ dlp galvanlzed wlLh lnLernal Lhreads Lapped or reLapped afLer
galvanlzlngŦţ ManufacLurlng 9rocessť lndusLry SLandards
6Ŧ LlfLlng 8lng
MaLerlalť SLeelţ ManufacLurlng 9rocessť lndusLry SLandards
7Ŧ Lquallzer 9ln
MaLerlalť SLeelţ ManufacLurlng 9rocessť Machlnlng

8Ŧ urlven Splndle
MaLerlalť SLeelţ ManufacLurlng 9rocessť Machlnlng
9Ŧ Loadţ Pand Chaln and Caslng
O 1he pockeLs of handŴchaln wheels and loads wheels are deslgned Lo allow proper flL and
engagemenL for speclflc hand chaln or load chaln used on Lhe manual Lrolley craneŦ Pand chaln
and load chaln are boLh accuraLely plLched wlLhln speclfled Lolerances Lo flL Lhe wheel pockeLsŦ
O 1rolley crane load chaln ls manufacLured and heaL LreaLed for lLs servlceţ and ls noL slmllar Lo
sLandard chaln made for sllngsŦ 1hls ls sufflclenL reason why hand or load chaln cannoL be
lnLerchanged beLween Lrolley crane producLsţ or why sLandard Lype chaln cannoL be lnsLalled on
Lrolley cranes as replacemenL chalnŦ
12 | 9 a g e

MaLerlalť SLeelţ ManufacLurlng 9rocessť lndusLry SLandards
10Ŧ 9lnlon
MaLerlalť SLeelţ ManufacLurlng 9rocessť lndusLry SLandards













13 | 9 a g e

keference

1Ŧ hLLpť//wwwŦmechŦuwaŦeduŦau/uAnoLes/gears/meshlng/meshlngŦhLml
2Ŧ hLLpť//wwwŦenglneersedgeŦcom/gear_formulaŦhLm
3Ŧ hLLpť//wwwŦcancocranesŦcom/lmages/caLalogs/acco_rope_selecLlonŦpdf
4Ŧ hLLpť//booksŦgoogleŦae/books?ldƹ88n72LŴ
L_g8CƎprlnLsecƹfronLcoverƎdqƹhand+chaln+LrolleyƎhlƹenƎsourceƹgbs_summary_sƎcadƹ
0#99A233ţM1
3Ŧ hLLpť//coursesŦwashlngLonŦedu/mengr336/daly/Cear_sLressŦpdf
6Ŧ hLLpť//wwwŦanswersŦcom/Loplc/casLlng
7Ŧ hLLpť//wwwŦanswersŦcom/Loplc/meLalŴformlng
8Ŧ hLLpť//auLoŦhowsLuffworksŦcom/gearsŦhLm





























14 | 9 a g e

Contr|but|on


lahad khan 100Ʒ conLrlbuLlon

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