Advanced

Engineering
Design
Project
Introduction

Prof. Dr.-Ing. Stéphane Danjou

Dipl.-Ing. Karsten Schacky

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 1 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Scope of Project
The aim of the project is that you proof your knowledge about the
learned design rules and 3D CAD modelling capabilities in a small
individual calculation and design project.

www.tridelity.com
Scope of the project: Design a crane lifting attachment for the lifting
and crane transportation of cube shaped goods. In this individual
project you are supposed to design the gripper system, i.e. developing a
concept taking the given requirements into account, calculating selected
components and creating a fully-functioning 3D CAD model.

This is an individual project, no group work!

Deadline for final submission: 11.01.2024

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 2 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Examples of crane lifting attachments (Grippers, clamps,
traverses)

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 3 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
General Requirements
 The lifting device to be designed
consists of grab lifting clamps as
exemplarily shown in the figure.
 To enable the lifting of different good
sizes the grippers need to be capable
of adapting the distance between the
gripping surfaces.
 The system should be designed in
such a way that opening can get
locked. That means that the gripper
should not close without a load, so
that it can be lowered on the good.
When lifting, the systems closes and
generates pressure between the
contact surfaces generating (enough)
friction force to hold the good.

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 4 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
General Requirements
Required product characteristics:
 Lifting device for usage with cranes
 2-contact-surface grab system
 Attachment for crane hooks acc. to
DIN 15401
 friction-locked lifting of goods
 lifting load: max. 600 kg
 grab size 250 mm – 350 mm
 overall width max. 1200 mm

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 5 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Calculation of Components
The design requires some basic dimensions for the
given load conditions. Therefore, follow the steps
1 to 6 to design the gripper components:
1. Free body diagram for the gripper (for
maximum and minimum opening width, for
one arm only)
2. Reaction loads
3. Material selection and calculation of the pin
joints (same size for all pin joints)
4. Material selection for the arms and proof of
the maximum stresses in the arms at the pin
joints under consideration of a minimum
safety factor of 5 against plastic deformation
5. Dimensioning of the entire arm cross sections
6. Proof of the welds

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 6 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Calculation of Components
Additional information:
• For all calculations the static friction
coefficient is
µ = 0.4
• For all components a minimum safety factor
has to be ensured:
Smin = 1.5
• Material selection, open boundary conditions
and assumptions have to be defined by you
under consideration of expected operation
conditions and usability.
• Consider a load application factor KA for all
calculations.
• Use provided tables for the selection of data.

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 7 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Calculation of Components
Material data for steel components:
A RmN ReN s zd,alt,N s b,alt,N t t,alt,N
material relative
Rp0.2N (s zd,pul,N) (s b,pul,N) (t t,pul,N) material
material min. min min costs
short name
number % [N/mm²] [N/mm²] [N/mm²] [N/mm²] [N/mm²]
Mild steel, hot rolled, acc. DIN EN 10025-2

reference diameter: d = 16mm

S235JR 1.0038
S235J0 1.0114 26 360 235 140 (235) 180 (280) 105 (165) 1
S235J2 1.0117

S275JR 1.0044
S275J0 1.0143 23 430 275 170 (275) 215 (330) 125 (190) 1,05
S275J2 1.0145

S355JR 1.0045
S355J0 1.0553
22 510 355 205 (355) 255 (425) 150 (245)
S355J2 1.0577
S355K2 1.0596

S450J0 1.0590 17 550 450 220 (400) 275 (505) 165 (310)

S185 1.0035 18 310 185 - - -

E295 1.0050 20 490 295 195 (295) 245 (355) 145 (205) 1,1
E335 1.0060 16 590 335 235 (335) 290 (400) 180 (230) 1,7
E360 1.0070 11 690 360 275 (360) 345 (430) 205 (250)

N: nominal b: bending alt: alternating

zd: tension / compresion t: torque pul: pulsating

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 8 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Calculation of Components
Material data for pins:
A RmN ReN s zd,alt,N s b,alt,N t t,alt,N
material relative
Rp0.2N (s zd,pul,N) (s b,pul,N) (t t,pul,N)
material
material min. min min costs
short name
number % [N/mm²] [N/mm²] [N/mm²] [N/mm²] [N/mm²]
Tempered steel acc. DIN EN 10083-1, tempered condition

reference diameter: d = 16mm

C22E 1.1151 20 500 340 200 (340) 250 (405) 150 (235)
C25E 1.1158 19 550 370 220 (370) 275 (445) 165 (255)
1,6
C30E 1.1178 18 600 400 240 (400) 300 (480) 180 (275)
C35E 1.1181 17 630 430 270 (430) 315 (515) 190 (300)

C40E 1.1186 16 650 460 260 (460) 325 (550) 195 (320)
C45E 1.1191 14 700 490 280 (490) 350 (590) 210 (340)
C50E 1.1206 13 750 520 300 (515) 375 (625) 225 (360)
1,7
C55E 1.1203 12 800 550 320 (540) 400 (660) 240 (380)
C60E 1.1221 11 850 580 340 (570) 425 (695) 255 (400)
28Mn6 1.1170 13 800 590 320 (540) 400 (680) 240 (410)

38Cr2 1.7003 14 800 550 320 (540) 400 (600) 240 (380)
46Cr2 1.7006 12 900 650 360 (590) 450 (740) 270 (450)
34Cr4 1.7033 12 900 700 560 (590) 450 (740) 270 (480) 1,7
37Cr4 1.7034 11 950 750 580 (615) 475 (770) 285 (500)
41Cr4 1.7035 11 1000 800 400 (640) 500 (800) 300 (525)

25CrMo4 1.7218 12 900 700 350 (590) 450 (740) 270 (480)
34CrMo4 1.7220 11 1000 800 400(640) 500 (800) 300 (525)
42CrMo4 1.7225 10 1100 900 440 (685) 550 (855) 330 (565)
50CrMo4 1.7228 9 1100 900 440(685) 550 (855) 330 (565)

36CrNiMo4 1.6511 10 1100 900 440 (685) 550 (855) 330 (565)
34CrNiMo6 1.6582 9 1200 1000 480 (725) 600 (910) 360 (605) 2,4
30CrNiMo8 1.6580 9 1250 1050 500 (750) 625 (935) 375 (625) -
36NiCrMo18 1.6773 9 1250 1050 500 (750) 625 (935) 375 (625) 2,7
51CrV4 1.8159 9 1100 900 440 (685) 550 (855) 330 (565)

N: nominal b: bending alt: alternating

zd: tension / compresion t: torque pul: pulsating

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 9 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Requirements for 3D CAD modelling
 Design all individual components of the lifting device and create an assembly. If
standard parts are needed (bolts, washers etc.), use the SolidWorks toolbox.
 Additionally create an assembly drawing showing the main dimensions to
understand the function of the device. Add balloons to all items and include a bill
of material on the assembly sheet according to drawing standards. Dimensioning
according to ISO 129. Use first angle projection only.
 Look for a check mate. Create a checklist, check her/his drawing and parts list
and let her/him check yours. Submit the checkmate’s checklist, including his/her
name and student ID as well as his/her comments, with your CAD files.
 All sketches inside the assembly components need to be fully defined.
 Fully define the positions of all components by mating (don’t use ‘fix’)!
Use advanced mates e.g. for distance or angle to allow motion of assembly in
intended range!
 Of course, collisions are unacceptable (use Tools —> Evaluate —> Interference
Detection if required). Exceptions: threaded connections.

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 10 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Deliverables
 First, (interim report) submit one single PDF document in
moodle with:
first setup and the free body diagram with all calculated forces
and the tension/compression- shear and bending moment
diagrams of the arm (these will be needed later to calculate the
stresses) Deadline: 09.11.2023
 The submissions of the complete report and documents are to
be made on Moodle using the assignment activity “Design
project”. Deadline: 11.01.2024.
 Submit one single PDF document including all calculations
and figures required for the calculation part, also include the
parts of the interim report, e.g. free body diagrams etc.

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 11 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction
Deliverables
 Submit the assembly CAD model as a Pack&Go zip file (
File  Pack and Go).
o In the Pack and Go dialogue, make sure that you include
drawings, simulation results and toolbox components!
o Save as a zip file, not as a folder.
o Name the zip file by including your student ID.
 Submit the checkmate’s checklist as a PDF file.
 As a result: you are supposed to submit in total 2 PDF files and
1 zip file for the full report upload.
 Hand-written equations and comments not allowed

Prof. Dr.-Ing. Stéphane Danjou / Dipl.-Ing. Karsten Schacky

05/10/2023 12 / 12
ME 3 2702 Advanced Engineering Design | Project Introduction