DESIGN AND MANUFACTURING OF FIXTURE FOR

LEVELING OF END CARRIAGE IN THE ASSEMBLY

OF END CARRIAGE-GIRDER
NIKHIL CHAVAN, ASHWINI DOSHI, PRITIBALA PEKHALE
UNDER THE GUIDENCE OF
PROF. S. S. PRABHUNE

ABSTRACT:
This paper consists of design and manufacture of fixture for the leveling of end carriage and
girder assembly which will be used to level the end carriage in the assembly of end carriage and
girder. The main aim is to design the system that will perform the leveling of the end carriage
using automation and which will be more efficient and user friendly.
The paper introduces several components used for manufacturing of mechanism. Properties of
different materials used for plates and their dimensions are discussed here. Use of mechanical
concepts and automation techniques is effectively used to increase the effectiveness and accuracy
of machining processes, which ultimately increases the productivity and replaces manpower.

INTRODUCTION: Generally on site assembly is preferred for crane assembly, as it is easy to transport the part of
the crane and assembly there than transporting the complete crane. Before the crane is dispatched
to the customer we have to make sure that it is properly leveled. The leveling of crane means the
end carriage and girder should be in one plane. This is achieved by leveling the end carriages.
The main aim of leveling is that the horizontal component of the load must be zero otherwise the
crane will be unstable to hold job at single location. In this leveling process end carriage and
girder are connected to each other through a bolted joint to MS plate is which is attached
between. This plate is already welded to the girder. End carriage and girder are assembled on the
site by bolting this plate to the end carriage. Due to this plate the end carriage and the girder both
are in same level and also all the four wheels of the end carriage is in one plane thus they rest on
leveled gantry and the horizontal component of the load is avoided.

Current procedure for leveling of the end carriage and girder assembly.
Main steps in end carriage girder assembly are as follows:
1. Place the girder on shop floor.
2. Bolting the square plate to the end- carriage at the exact centre.
3. Placing the 2 end carriages at both ends of the girder.
4. Match the centre lines of girder and both end- carriages.
5. Level the 2 wheels of one of the end-carriage.
6. With respect to these 2 wheels level the wheels of the other end-carriage. That is lifting
the lower sides by using packaging plates till 0-0 level of all four wheels is achieved.
7. After the leveling is complete the plate is tac-welded to the girder.
8. Plate is then detached from the end-carriage, and the plate is properly welded to the
girder

Required specification of the fixture.

1. The fixture should be able to move the end carriage vertically from minimum height of
300mm to 1500mm.
2. The fixture should be able to accommodate the longest end carriage i.e. 4000mm long.
3. The fixture should be able to keep the end carriage holding in elevated position for long
periods.
4. The fixture should have provision for fine adjustment of end carriage for levelling.
5. The fixture should be easy to handle. No special skills are required.

WORKING MODEL:

In this arrangement the system rest on end carriages. On these end carriages the bottom
plate is bolted and on this plate pillars are mounted. The top plate is bolted on this arrangement
and lead screw is mounted on the arrangement and is given drive by motor. In this arrangement a
third pillar is added to the avoid sagging and to provide support for the system.
In this arrangement the load transfer is almost same as above arrangement
The load is placed on the plate which is welded to the box and given drive by motor and
screw. The motor and screw are mounted on top plate. This top plate is rested on pillars. Thus
the load transfers from screw to the top plate and though the plate to pillars and to the ground.
The salient features of this arrangement are
i.

In this arrangement the toppling problem is avoided by shifting the load from corner
to the centre.

ii.

We have provided the mechanical jacks for the fine adjustments, thus removing the
limitation of spring compression.

iii.

The dead weight is not required as the system is stable for toppling

iv.

A third pillar is added at the centre which avoid the sagging problem.

Thus this system covers almost all the problems, hence this solution was finalized.

THE MATERIALS SELECTION PROCESS

1. EN-8
PROPERTIES:C 40A

%C 0.35-0.45, %Mn 0.60-0.90

TENSILE STRENGTH:-580-680, YEILD STRENGTH:-330

USES:Steel for crankshafts, spindles, shafts, automobile axle beams, push rods, connecting rods, studs,
bolts, lightly stressed gears, etc.
2. MILD STEEL

PROPERTIES:-C15 MN75 (%C:- 0.10 - 0.20,%Mn:- 0.60 - 0.90)

TENSILE STRENGTH:- 420 500, YEILD STRENGTH:- 250
USES:Especially desirable for construction purposes due to weld ability and machine ability.

PHOSPHOR BRONZE
PROPERTIES :- %COPPER:- 87 90 ,%Tin:- 9 10 ,%PHOSPHORUS:- 0.1 3
TENSILE STRENGTH:- 215 280
Possesses good wearing qualities and high elasticity. Resistant to salt water corrosion.
USES:Used for bearing, worm wheel, gears, nuts, lead screw, pump parts, etc.
CALCULATIONS
TORQUE RQUIRED TO RAISE THE LOAD

T=67844.85 N-mm

Now for DIAMETER OF SCREW

Consider stresses in lead screw
1. Tensile Stress (Direct) :-

2. Torsional Shear Stress: -

3. According To Maximum Shear Stress Theory

Solving above equation we have

= 21MM
Hence minimum required diameter is 21mm. But as it was not available in market, we choose the
one with

= 46MM
Hence the properties of screw are
D = 50MM

DC = 41.5MM
DM = 46MM
P = 8MM

FOR NUMBER OF THREADS IN CONTACT

Let the permissible bearing pressure be 5N/mm2

OR 7
Number of threads in contact Z= 7
Height of nut H = ZP
= 78
= 56MM

FOR POWER REQUIREMENT

As we have selected motor with specification as follows
Power = 0.37KW
Speed N = 1370RPM
As motor is fixed, calculate for reduction required
Assuming no power loss
Power @screw P = 0.37KW

Torque T = 67.844 N.m

here is angular speed of the screw and is given by

= N/ 0

Hence reduction required

G= 26.
Now as we have the gear box with reduction of 9 in stock.
I.E. Gg=9
Thus the reduction required is
Gs=G/Gg

PARAMETER

NOTATION

VALUES

MAJOR DIAMETER

50mm

PITCH CIRCLE DIAMETER

Dm

46mm

CORE DIAMETER

Dc

41.5mm

CORE AREA

Ac

1353mm2

FOR SCREW BODY

PITCH

8mm

HEIGHT OF THREAD

4.25mm

COEFFICIENT OF FRICTION

0.08

ANGLE OF THREAD

30

EFFECTIVE COEFFICIENT

OF

0.09

FRICTION
LEAD ANGLE

3.168

FRICTION ANGLE

5.227

TENSILE STRENGTH

Sst

450N/mm2

YEILD STRENGTH

Ssy

250N/mm2

FACTOR OF SAFETY

Nf

HIEGHT OF NUT

56mm

DIAMETER

Dn

50mm

NO. OF THREADS IN CONTACT

POWER RATING

0.37KW

RPM

1370rpm

NO OF TEETH

NP

15

PITCH CIRCLE DIAMETER

DP

61.08MM

CORE DIAMETER

DPC

45MM

WIDTH OF PINION

BP

35MM

BORE

DP

10MM

NO OF TEETH

NS

45

PITCH CIRCLE DIAMETER

DS

182.06

FOR NUT

FOR MOTOR

FOR CHAIN DRIVE

FOR PINION

FOR SPROCKET

CORE DIAMETER

DSC

95MM

WIDTH OF SPROCKET

BS

40MM

BORE

DS

20MM

FOR CHAIN

ISO NO- 08B-2

PITCH

PC

12.07MM

ROLLER DIAMETER

D1

8.51MM

WIDTH

B1

7.75MM

BREAKING LOAD

31,000N

11.1 .Comparison between the current procedure and new procedure.

11.1.1. Current Procedure
Criteria

value
CURRENT

(FOR Values(FOR NEW

PROCEDUR)

PROCEDURE)
No. of laborers

4-5

Time for single girder 2-3 hrs

1-2
20 30 min

assembly
Time

for

double 5-6 hrs

30-40 min

girder assembly
Wages

Average Rs 30/hr.

Rs 30/hr

SG RS 360/-

SG- Rs 30 /-

DG- Rs 720/-

DG- Rs 40/-

11.2. Calculations
1. Average Number of cranes manufactured per month: - 11
Single girder: - 7
Double girder: - 4
2. Amount saved per cranes: Single girder crane: - Rs 330/crane
Double girder crane: - Rs 680/crane
3. Total amount saved per month: Single girder crane: - Rs 3307= Rs2, 310
Double girder crane: - Rs 6804= Rs 2,720
Total = Rs 5,030
4. Annual saving: - Rs 5,03012= Rs 60,360
5. Total investment: - Rs 2, 12,352
No of years = Rs 2, 12,352/60,360
= 3.5 years.

12.1. CONCLUSION: We have designed and manufactured a fixture for leveling of end carriage in the assembly
of - girder and end carriage - of EOT crane.
Thus we have improved the current procedure of leveling and we have achieved
following things

1. It requires 4-5 workmen for a single job for the current procedure but now we require only
one or two persons.
2. The current procedure is not sufficiently safe as it includes the handling of the end carriages
using hooks of crane while in new procedure end carriage is rested on plate thus new
procedure is safer.
3. It takes 4-5 hours for the levelling by current procedure but now it takes only 20 30
minutes.
4. Accuracy is less of the current procedure but the new procedure is more accurate.
5. The current procedure requires skilled workmen but the levelling by new method can be
done by unskilled worker also.

13.1. FUTURE SCOPE: We can provide the arrangement for the horizontal movement by giving drive to the base end
carriages.
1. Limit switches can be provided to the fixture to restrict the maximum vertical movement
of the fixture.
2. Total levelling process can be automated with the help of programmed PLC panel using
LASER level indicators for auto levelling.
3. The fine adjustment can be achieved by motor instead of screw jack controlled by PLC
panel this will convert the total system into automated system reducing the human efforts.