Design optimization of Floor Cranes
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This document describes the design optimization of a floor crane. The original crane design had high deflection and bending moment issues. To address this, the researchers reduced the length of the second column from 1.2m to 1m, lowering the crane's reach from the floor. Various analyses showed the optimized design had lower deflection, bending moment, rope tension, and performed better under accelerated loads. The optimized crane was then fabricated and shown to be safer, stronger, and require less material.
![International Journal of Science and Engineering Applications
Volume 3 Issue 5, 2014, ISSN-2319-7560 (Online)
Design optimization of Floor Cranes
A. Balaji
Department of Mechatronics
Engineering
Kongu Engineering College
Erode, India
H. Jahir Hussain
Department of Mechatronics
Engineering
Kongu Engineering College
Erode, India
M.R. Faheem Ashkar
Department of Mechatronics
Engineering
Kongu Engineering College
Erode, India
Abstract: This paper inculcates a way to make the floor crane as more efficient with less material requirement. This has been achieved
by minimizing reach of the crane from the floor. The crane is assumed to be cantilever type. Also tension and acceleration in steel
ropes are analysed to ensure the safety. The optimized crane successfully passed the various analysing tests which include deflection,
bending moment, rope tension and acceleration of the loads in the rope. It also includes another method which provides the virtual user
interface for the design engineer. By providing the crane dimensions in the virtual panel, the predefined program automatically creates
the CAD modelling in the CAD software. The program is made with visual studio and Solid works macro. Finally, this work reduces
the burden on the design engineer and increases the productivity.
Keywords: cranes; floor cranes; optimization; virtual CAD model; solid works
1. INTRODUCTION
A crane is a machine which is used in material handling
processes. It is used to lift, lower and move any materials
horizontally[1]. Cranes are used in construction,
transportation, and manufacturing sections. It uses one or
more simple machines to create mechanical advantage and
thus move loads beyond the normal capability of a human[2].
Floor crane is taken into consideration in this work.
2. PROBLEM STATEMENT
Floor crane is shown in Figure 1 which has two columns for
length 1m and 1.2m. The design separates the two columns
with the distance of 0.6m. The horizontal beam for about
1.5m is defined as reach of the crane and it supports the rope.
The whole crane is fixed at the base and the counter weight is
loaded at the back. The problem is within the distance 0.6m,
the design shoots up the length for about 0.2m. Hence the
whole crane is modelled and analysed for deflection. The
result shows that the deflection at the second column is very
high.
Figure 1 CAD model of floor crane
3. VIRTUL CAD MODELING
Floor crane design varies with capacity and reach of the crane.
Depending on the reach, the length of the horizontal beam is
varied. Hence, for every time the designer has to design the
whole crane. In order to eliminate this problem, virtual CAD
modeling[3] is proposed. Designer can modify the solid works
macro in Microsoft visual basic, Microsoft visual studio for
applications to fit the need.
4. DESIGN OPTIMIZATION OF FLOOR
CRANE
In order to rectify the problem, the second column length is
reduced from 1.2 meter to 1 meter. By doing so, the reach of
the crane from the floor is reduced from 830mm to 780mm
and angle of the rope beam is reduced from 22.2 degree to
10.8 degree. This final optimized design is analysed under
various conditions to determine whether the design is safe and
efficient in comparison with the previous design. Figure 2
shows the existing and optimized design of floor crane.
Figure 2 Existing and Optimized design of crane
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![International Journal of Science and Engineering Applications
Volume 3 Issue 5, 2014, ISSN-2319-7560 (Online)
5. DESIGN ANALYSIS
5.1 Bending Moment
The column 1 and column 2 is rigidly fixed with the floor.
Hence the beam in which the work outside the floor is
considered as cantilever beam and analyzed for bending
moment. The Figure 3 shows the calculation of bending
moment. From the calculation, the bending moment in the
optimized design is reduced about 23620 N mm.
Figure 3 Bending moment calculation
5.2 Deflection
The deflection analysis of cantilever beam is analyzed which
is shown in Figure 4. The material is Mild Steel and the
details include young’s modulus is 210GPa; Poisson’s Ratio is
0.3 and density about 7.85 g/cm3[4]. From the result shown in
figure 4, the deflection of beam is reduced from 0.058mm to
0.032mm.
Figure 4 Deflection Analysis of Cantilever Beam
6. SAFETY ANALYSIS
6.1 Rope Tension Analysis
From the figure 2, the angle of the beam is changed from 22
degree to 10 degree. Based on the D’ Alembert’s principle,
the tension and acceleration in the rope is calculated for
sample loads. On resolving the forces in the figure 5, the
tension and acceleration for the existing (angle = 22.2) is
about 12N and 4.63 m/s2 and for the optimized (angle =
10.89) is about 8.34N and 5.26 m/s2 respectively.
Figure 5 Force acting on different angles
Steel rope, used for lifting load, in the floor crane is modelled
in Solid works and the sample tension is applied for the two
different angles as shown in the figure 6. The rope used is 6*7
steel ropes with nominal diameter of 32mm. The result shows
that deflection in the optimized angle is much lesser than the
existing design.
Figure 6 Rope Tension Analysis
6.2 Load with acceleration
From the rope tension analysis calculation, acceleration in the
rope is also calculated. Hence, the load with acceleration is
applied to both the existing and optimized design to check the
deflection using Solid works simulation. The result as shown
in figure 8 shows that the deflection in the optimized design is
much lesser than the existing design. Figure 7 shows the
applied initial acceleration in the rope.
Figure 7 Initial conditions in solid works
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![International Journal of Science and Engineering Applications
Volume 3 Issue 5, 2014, ISSN-2319-7560 (Online)
Figure 8 Deflection with acceleration analysis
7. RESULTS
The table 1 tabulates the advantage of optimized floor crane
design over the existing one. Based on the analysis and
results, the new optimized floor cane has been successfully
fabricated which is shown in figure 9.
Table 1 Comparative Study
ANALYSIS EXISTING OPTIMIZED
Bending
Moment
415170 Nmm 391550 Nmm
Deflection 0.0587 mm 0.0325 mm
Rope Tension High Low
Deflection
with
Acceleration
0.0527 mm 0.0427 mm
Material
Requirement
More Less
Figure 9 Optimized Floor Crane
8. CONCLUSIONS
[1] Crane would be safer (Rope tension is reduced)
[2] Crane would be stronger (Deflection and stress is
reduced)
[3] Crane would be cheaper (Material requirement is
reduced)
9. REFERENCE
[1] American Society of Mechanical Engineering
(ASME), ‘Electric Overhead Travelling Crane-
Specifications and Details’, Article 57, 2012
[2] American Society of Mechanical Engineering
(ASME), ‘Fixtures and loads for the Floor crane
design’, Article 72, 2010
[3] American Society of Mechanical Engineering
(ASME), ‘Steel Rope specifications and details’,
Article 57, 2012
[4] American Standard National Institute (ASNI),
‘Types of Material Handling Cranes- overview’,
Article 63, 2008
[5] CAD sharp Journal, ‘Solid works in Visual Studio’,
Article-13, 2011
[6] D. Saravanan, ‘Solid works 2012 for Designers’, 2nd
Edition, Wiley India Publications
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Design optimization of Floor Cranes
- 1. International Journal of Science and Engineering Applications Volume 3 Issue 5, 2014, ISSN-2319-7560 (Online) Design optimization of Floor Cranes A. Balaji Department of Mechatronics Engineering Kongu Engineering College Erode, India H. Jahir Hussain Department of Mechatronics Engineering Kongu Engineering College Erode, India M.R. Faheem Ashkar Department of Mechatronics Engineering Kongu Engineering College Erode, India Abstract: This paper inculcates a way to make the floor crane as more efficient with less material requirement. This has been achieved by minimizing reach of the crane from the floor. The crane is assumed to be cantilever type. Also tension and acceleration in steel ropes are analysed to ensure the safety. The optimized crane successfully passed the various analysing tests which include deflection, bending moment, rope tension and acceleration of the loads in the rope. It also includes another method which provides the virtual user interface for the design engineer. By providing the crane dimensions in the virtual panel, the predefined program automatically creates the CAD modelling in the CAD software. The program is made with visual studio and Solid works macro. Finally, this work reduces the burden on the design engineer and increases the productivity. Keywords: cranes; floor cranes; optimization; virtual CAD model; solid works 1. INTRODUCTION A crane is a machine which is used in material handling processes. It is used to lift, lower and move any materials horizontally[1]. Cranes are used in construction, transportation, and manufacturing sections. It uses one or more simple machines to create mechanical advantage and thus move loads beyond the normal capability of a human[2]. Floor crane is taken into consideration in this work. 2. PROBLEM STATEMENT Floor crane is shown in Figure 1 which has two columns for length 1m and 1.2m. The design separates the two columns with the distance of 0.6m. The horizontal beam for about 1.5m is defined as reach of the crane and it supports the rope. The whole crane is fixed at the base and the counter weight is loaded at the back. The problem is within the distance 0.6m, the design shoots up the length for about 0.2m. Hence the whole crane is modelled and analysed for deflection. The result shows that the deflection at the second column is very high. Figure 1 CAD model of floor crane 3. VIRTUL CAD MODELING Floor crane design varies with capacity and reach of the crane. Depending on the reach, the length of the horizontal beam is varied. Hence, for every time the designer has to design the whole crane. In order to eliminate this problem, virtual CAD modeling[3] is proposed. Designer can modify the solid works macro in Microsoft visual basic, Microsoft visual studio for applications to fit the need. 4. DESIGN OPTIMIZATION OF FLOOR CRANE In order to rectify the problem, the second column length is reduced from 1.2 meter to 1 meter. By doing so, the reach of the crane from the floor is reduced from 830mm to 780mm and angle of the rope beam is reduced from 22.2 degree to 10.8 degree. This final optimized design is analysed under various conditions to determine whether the design is safe and efficient in comparison with the previous design. Figure 2 shows the existing and optimized design of floor crane. Figure 2 Existing and Optimized design of crane www.ijsea.com 127
- 2. International Journal of Science and Engineering Applications Volume 3 Issue 5, 2014, ISSN-2319-7560 (Online) 5. DESIGN ANALYSIS 5.1 Bending Moment The column 1 and column 2 is rigidly fixed with the floor. Hence the beam in which the work outside the floor is considered as cantilever beam and analyzed for bending moment. The Figure 3 shows the calculation of bending moment. From the calculation, the bending moment in the optimized design is reduced about 23620 N mm. Figure 3 Bending moment calculation 5.2 Deflection The deflection analysis of cantilever beam is analyzed which is shown in Figure 4. The material is Mild Steel and the details include young’s modulus is 210GPa; Poisson’s Ratio is 0.3 and density about 7.85 g/cm3[4]. From the result shown in figure 4, the deflection of beam is reduced from 0.058mm to 0.032mm. Figure 4 Deflection Analysis of Cantilever Beam 6. SAFETY ANALYSIS 6.1 Rope Tension Analysis From the figure 2, the angle of the beam is changed from 22 degree to 10 degree. Based on the D’ Alembert’s principle, the tension and acceleration in the rope is calculated for sample loads. On resolving the forces in the figure 5, the tension and acceleration for the existing (angle = 22.2) is about 12N and 4.63 m/s2 and for the optimized (angle = 10.89) is about 8.34N and 5.26 m/s2 respectively. Figure 5 Force acting on different angles Steel rope, used for lifting load, in the floor crane is modelled in Solid works and the sample tension is applied for the two different angles as shown in the figure 6. The rope used is 6*7 steel ropes with nominal diameter of 32mm. The result shows that deflection in the optimized angle is much lesser than the existing design. Figure 6 Rope Tension Analysis 6.2 Load with acceleration From the rope tension analysis calculation, acceleration in the rope is also calculated. Hence, the load with acceleration is applied to both the existing and optimized design to check the deflection using Solid works simulation. The result as shown in figure 8 shows that the deflection in the optimized design is much lesser than the existing design. Figure 7 shows the applied initial acceleration in the rope. Figure 7 Initial conditions in solid works www.ijsea.com 128
- 3. International Journal of Science and Engineering Applications Volume 3 Issue 5, 2014, ISSN-2319-7560 (Online) Figure 8 Deflection with acceleration analysis 7. RESULTS The table 1 tabulates the advantage of optimized floor crane design over the existing one. Based on the analysis and results, the new optimized floor cane has been successfully fabricated which is shown in figure 9. Table 1 Comparative Study ANALYSIS EXISTING OPTIMIZED Bending Moment 415170 Nmm 391550 Nmm Deflection 0.0587 mm 0.0325 mm Rope Tension High Low Deflection with Acceleration 0.0527 mm 0.0427 mm Material Requirement More Less Figure 9 Optimized Floor Crane 8. CONCLUSIONS [1] Crane would be safer (Rope tension is reduced) [2] Crane would be stronger (Deflection and stress is reduced) [3] Crane would be cheaper (Material requirement is reduced) 9. REFERENCE [1] American Society of Mechanical Engineering (ASME), ‘Electric Overhead Travelling Crane- Specifications and Details’, Article 57, 2012 [2] American Society of Mechanical Engineering (ASME), ‘Fixtures and loads for the Floor crane design’, Article 72, 2010 [3] American Society of Mechanical Engineering (ASME), ‘Steel Rope specifications and details’, Article 57, 2012 [4] American Standard National Institute (ASNI), ‘Types of Material Handling Cranes- overview’, Article 63, 2008 [5] CAD sharp Journal, ‘Solid works in Visual Studio’, Article-13, 2011 [6] D. Saravanan, ‘Solid works 2012 for Designers’, 2nd Edition, Wiley India Publications www.ijsea.com 129