UNIVERSITI TENAGA NASIONAL

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

MEMB312 MACHINE DESIGN

SEMESTER 1, 2014/2015
DESIGN OF DOUBLE GIRDER
BRIDGE CRANE

AUTHORS

TUNKU ATIQAH BINTI TENGKU HAMNET

ME090330

VISHNU A/L VEVAKANANDAN

ME090254

VINOTH A/L KARUPPAN@SURESH

ME090253

VIJAY A/L NAGANDRAN

ME090251

TANESHWAREN A/L SUNDARAM

ME090248

SECTION

: 3A

GROUP

LECTURER

: DR. OMAR SULIMAN ZAROOG

TABLE OF CONTENTS

Abstract

Introduction

Literature Review

Objective

Background

Specifications

Methodology

Cost Estimation

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Analysis and Calculations

- Speed, Torque and Gear Ratios
- Gear Specifications
- Shaft Layout
- Design for Stress
- Deflection Check
- Bearing Selection
- Key Design
- Lubrication Plan
CREO Parametric 2.0
- Bearing
- Gear 2
- Gear 3
- Gear 4
- Gear 5
- Intermediate Shaft
- Output Shaft
Conclusion

12

Reference

13

Appendices

10

ABSTRACT
For this project, our group will have to design a double girder bridge crane. By
referring to the Power Transmission Case Study chapter, a step-by-step solution is
studied through in order for us to obtain a design. In the design of this case, the
components of the double girder bridge crane are dependant on one another. Hence,
by knowing a few parameters, assumptions can be made to design the other parts of
the component. Throughout this project, we as a student managed to think
innovatively and critically in determining the parameters required in the design. Any
incorrect assumption made will result in a bad outcome to the design. Also, students
are trained to think meticulously as calculation for the gears, shafts and bearings must
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be precise as it is crucial to know the right dimensions of the component. An

inaccurate reading will unable the design to run properly. Analysis and calculation are
done on every component of the double girder bridge crane so that design is
optimized for its functional use. In the design, the gearbox transmits a power of
3.728kW. The power is transmitted using a pair of gears where the input speed is 1800
rpm and the output speed is reduced to 87 rpm, which is within the acceptable range
of speed the components can uphold.

INTRODUCTION
In an industrial environment that involves a massive engineering knowledge,
many types of applications have been engineered to ease the human burden. A
commonly used application is the overhead crane or bridge crane. The overhead crane
consists of parallel runways with travelling bridge spanning the gap that carries a
hoist that travels along the bridge [1]. A hoist is the lifting component of the crane that
is mounted on a trolley for horizontal movement. The end trucks are attached at right
angles to the girders and move on fixed runways. The overhead crane is powered by
electricity. This is mainly used in refinement of steel. When the metal leaves the
factory in a finished product, an overhead crane handles it. Where else, the
automobile industry uses the overhead crane to handle raw materials. Cranes come in
a variety of styles and are used with a number of attachments to facilitate load lift.
Double Girder Bridge Cranes are most frequently used where capacities over 10 tons
and/or spans of 60 to 100 feet are needed. They can be utilized at any capacity where
extremely high hook lift is required because the hook can be pulled up between the
girders. Double Girder Bridge Cranes are also ideal where high speeds and heavy
service are required. They are highly suitable where the crane needs to be fitted with
walkways, crane lights, cabs, magnet cable reels or other special equipment. EMH is
capable of building cranes for loads up to 500 tons.

LITERATURE REVIEW
The most frequently used design is the top running double girder bridge cranes
where capacities over 10 tons and spans of 60 to 100 feet are needed. They can be
utilized at any capacity where extremely high hook lift is required because the hook
can be pulled up between the girders. Double Girder Bridge Cranes are also ideal
where high speeds and heavy service are required [2]. They are highly suitable where
the crane needs to be fitted with walkways, crane lights, cabs, magnet cable reels or
other special equipment. Manufacturing companies are capable of building cranes for
loads up to 500 tons. The double girder industrial series overhead crane shows a
proven track record of reliability and quality. General workshop duty cranes range
from 5 ton to 160 ton capacity. The cranes featured are double box girder with the
hoist crab unit running on rails attached to the top flange. A feature of the double
girder crane is that it offers maximum hook height of all the crane configurations. The
double girder crane can cater for spans up to 40 meters. The crane is available with
single or double hoists pendant or radio control and inverter motor drives.

Tasks
Analysing the problem
Deciding the types of the
gearbox
Dividing the work
Design the overhead crane
gearbox
Finalising the model
Report
Presentation

Start
Duratio End
Date
n
Date
16-Jun
3 19-Jun
20-Jun
23-Jun
01-Jul
14-Jul
21-Jul
12-Aug

1
1

21-Jun
24-Jun

10
11-Jul
2 16-Jul
7 28-Jul
1 13-Aug

2-Mar

18-Sep
10-Jun

Analysing the problem

Deciding the types of the gearbox
Dividing the work
Design the overhead crane gearbox

Duration (Days)
Start Date

Finalising the model

Report
Presentation

Figure No. 1(a) Orthogonal View of Double Girder Bridge Crane

Figure No. 1(b) Double Girder Bridge Crane

Figure No. 1(c) Double Girder Bridge CraneOBJECTIVE

To design a double girder bridge crane that consists of bearings, gears, shafts and
keys.

BACKGROUND
A gearbox transmits a power of 3.728kW. The power is transmitted by gears while the
input speed of 1800 rpm is reduced to an output speed of 87 rpm. This output speed is
within the acceptable range the unit can endure.
SPECIFICATIONS
a. The gears are used as the drive components of the gearbox with a power
transmission of 5hp or 3.728kW.
b. Cost of the gearbox should be minimal.
c. The design life of the gearbox is more than 12000 hours of its continuous
operation.
d. Design the intermediate shaft with complete specification of the gears,
bearings, keys and output shaft.

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METHODOLOGY
Gears
Material Steel Grade 1 Flame-Hardened
Type Spur gears
Reason

1) High wear resistance and internal damping. This is crucial as gear

experiences high stress between its teeth.
2) Low cost hence economical to produce
3) Ease of machining

Bearing
Material 1020 Cold-Drawn Steel
Reason

1) Smooth finish to reduce friction and aid the rolling of shaft.

2) High machinability and corrosion resistance.
3) Can withstand boundary lubrication.
4) Can support high loads and high temperature.

Shafts
Material 1020 Cold-Drawn Steel
Reason Has high modulus of elasticity so that deflection caused by multi-axial
stress from combination of bending moment and torque is minimized.
Keys
Material 1020 Cold-Drawn Steel
Type Woodruff Key
Reason Ductile. Keys are loaded with stress hence it will reduce failure rate.
Lubrication
Type Liquid Lubricant (Chlorofluorocarbon)
Method Grease Lubrication ( Bearing ) , Gear Oil ( Gears )
Reason

1) Suitable for any gear system that is open or enclosed, as long as it

runs at low speed.
2) Good lubricants, good thermal stability.

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BILL OF MATERIAL
BILL OF MATERIALS
1) GEARS

Gear 2 Grade 1 Flame Hardened

US $ 258
RM 824.34
Gear 3 Grade 1 Through Hardened US $ 170
RM 543.17
Gear 4 Grade 1 Flame Hardened
US $ 258
RM 824.34
Gear 5 Grade 1 Flame Hardened
US $ 258
RM 824.34

2) SHAFT

1020 Cold Drawn Steel Shaft US $ 532 632

RM 1099.79 - RM2014.30

3) BEARING

1020 Cold Drawn Steel Bearing US $ 86

RM 274.78

4) LUBRICANT

SAE Gear 140 Lubricant US $ 35

RM 111.83

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ANALYSIS AND CALCULATIONLUBRICATION

PLAN
Lubrication is one of the methods applied to decrease wears of components.
This is by applying grease on the surface of object that lies in between the surfaces of
another object that moves in respect to one another. When lubrication is applied, it
removes heat generated from the friction during operation that can cause wear and
tear of component. Since gear is the smallest component, it transmits the largest load
and will defect faster. By properly selecting the correct and proper lubricant it will
minimize the downtime of the gear system hence increasing productivity and reducing
maintenance and repair cost. This makes the object to have a longer lifespan.
Surface fatigue occurs when the lubricant film on the gear wheel teeth is
insufficient to protect the surfaces from the stress. The consequence of this is pitting
formation will occur on the surface of contact region. Hence, it is important to know
the suitable lubricant that will be sufficient to use in between the gears. This can be
found by applying the following equation to find the suitable selection of the
lubrication.
Viscosity, 40 = 7000/Vt0.5
The maximum velocity occurs at the lowest pitch line velocity which is at the
output (stage 2), which is 279.22 ft/min. Substituting the value into the equation, we
obtain a value of 419 cst. By referring to the chart on Figure 3(a), at 419 cst the most
suitable lubricant to use is SAE GEAR 140 lubricant at 40C temperature. Hence,
SAE Gear Oil is used as lubricant.

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Figure 3(a) Chart of Grade System for Lubricants

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CREO PARAMETRIC 2.0 - DESIGN OF DOUBLE GIRDER BRIDGE CRANE

A) BEARING

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B) GEAR 2

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C) GEAR 3

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D) GEAR 4

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E) GEAR 5

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F) INTERMEDIATE SHAFT

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G) OUTPUT SHAFT

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H) EXPLODED VIEW OF GEARBOX

23

ASSEMBLY OF GEARBOX

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CONCLUSION
As a conclusion, we have achieved the objective of the project. We are able to
design a double girder bridge crane, which consists of gears, rolling element bearing,
shaft and keys. We have learned to assume some parameters before designing the
gearbox such as its number of teeth on its gear, the diameter and length of the shaft
and number of bearings needed in order for the gearbox to withstand a power
transmission of 3.7285kW. Moreover, we have learned how to make correct and
precise calculations in order to produce gearbox that is optimized for its functional
use. In this project, the intermediate shaft is designed as shown in Figure 2(a), Also,
the specification of the gear has a minimum safety factor of 1.86 that is for Gear 3.
The keys have a length of 3.73mm and bearing is chosen from SKF Internet catalog as
shown in analysis. The specifications of this project are successfully followed. We
have designed a gearbox where its component can last to more than 12000 hours of its
continuous operation. Most importantly, we have learned to work as a team and
discuss problems with our teammates in order to tackle problems efficiently. At last,

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we want to thank our machine design lecturer Dr. Omar Suliman Zaroog for guiding
and helping us throughout this project.

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REFERENCE
[1] Overhead Crane. (20 August 2014). Retrieved from
http://en.wikipedia.org/wiki/Overhead_crane
[2] Product- Double Girder Crane. (20 August 2014). Retrieved from
http://www.multicrane-asean.com/double_girder.html)
[3] Richard G. Budynas, J. Keith Nisbett (2011). Shigleys Mechanical Engineering
Design. McGraw Hill.

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APPENDICES

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