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2911]12]2011

nLkIC1 WA11 UNIVLkSI1 DU8AI CAMUS



GLAkLD 1kCLLL CkANL
8S9DL DLSIGN AND MANUIAC1UkL 3


1he pro[ecL ls Lo famlllarlze wlLh Lhe CLA8Lu 18CLLL? C8AnL lL ls requlred Lo deslgn geared Lrolley
carne mounLed on an lbeam of known lengLh and load raLlng and a glven seL of speclflcaLlons 1he
deslgns are produced on SCLlu LuCL v20

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CCN1LN1S AGL


1 Introduct|on 3

2 Des|gn S

3 Ca|cu|at|ons 8

4 Mater|a| kequ|rement and Manufactur|ng rocess 1S

S keference 13

6Contr|but|on 14









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Introduct|on
1rolley crane ls a llfLlng machlne generally equlpped wlLh a wlnder wlre ropes or chalns and
sheaves whlch can be used boLh Lo llfL and lower maLerlals and Lo move Lhem horlzonLally lL uses
one or more slmple machlnes Lo creaLe mechanlcal advanLage and Lhus move loads beyond Lhe
normal capablllLy of a human Cranes are commonly employed ln Lhe consLrucLlon lndusLry for Lhe
movemenL of maLerlals and ln Lhe manufacLurlng lndusLry for Lhe assembllng of heavy equlpmenL
1he deslgn show below ln flg11 shows an Cverhead 1rolley Crane 1he purpose of such mechanlcal
equlpmenL varles accordlng Lo Lhe needs of masslve verlLy of lndusLrles 1he auLomoblle lndusLry
uses overhead cranes for handllng of raw maLerlals and heavy parLs

I|g 11 1ro||ey crane des|gn]structure
1he llgure above shows Pand geared Lrolley whlch ls manually used by Lhe efforL of Lhe
operaLor 1he operaLor's efforL ls Lransferred lnLo Lhe holsL moLlon by Lhe operaLor pulllng
Lhe hand chaln 1he hand chaln Lurns a pockeLed hand chaln wheel LhaL acLuaLes Lhe Lrolley
crane mechanlsm 1hls Lype of Lrolleys are used for heavler loads load spoLLlng accuracy or
lf Lhe Lrolley ls mounLed very hlgh
1he manual overhead Lrolley crane uses gears and wheels for lLs mechanlcal operaLlon A
gear ls a roLaLlng machlne parL havlng cuL LeeLh or cogs whlch mesh wlLh anoLher LooLhed
parL ln order Lo LransmlL Lorque 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 machlne 1he mosL common slLuaLlon ls for a gear Lo mesh wlLh
anoLher gear however a gear can also mesh a nonroLaLlng LooLhed parL called a rack
Lhereby produclng LranslaLlon lnsLead of roLaLlon
1he dlrecLlon and Lhe speed aL whlch Lhe Lrolley moves along Lhe beam are dependenL on
Lhe roLaLlon of Lhe pulley AlLhough Lhe crane wlll carry a very large load Lhls pulley can be
manually operaLed and wlLh mlnlmal efforL from Lhe person operaLlng lL 1he manual
roLaLlonal power wlll be Lransformed lnLo llnear moLlon Lhrough a serles of gears wlLhln Lhe
crane Lrolley

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llgure 12


Iugure 13

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







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Des|gn

G|ven Data

Crane maxlmum load as deLalled below
8eam span as deLalled below
8eam secLlon 8S! Lo 8S Ln100361999
8eam maLerlal Ln10023 S233 wlLh a yleld sLress of 233 M9a
lacLor of safeLy 12 on yleld
8eam span (m) 4
Max|mum |oad (tones) 3

I8eam Structure



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1ro||ey Crane Des|gn



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Ca|cu|at|ons


8eam Ca|cu|at|ons

1o begln wlLh we Lake momenLs abouL Lhe rlghL end of Lhe beam

) 0 4
2
16
4
2 1 1
= + + + =

M x F
W
R M M
B

1he force equlllbrlum equaLlon
0 4
2 1
= + =
B T
W R R W F
conslderlng a secLlon of Lhe beam
)

+ + = 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 a0 M0 1herefore boLh consLanLs of lnLegraLlon are equal Lo zero
When a4

= 0 M
)

+ = 0
2
4
6
64
8 4
2
1 1
x W W
R M M
T B
(3)
When a4

= 0 M
0
6
) 4 (
3
32
6
64
8
3
1
1
=

+ + + =

x W W R
M M
T B
(4)
LquaLlon 3 2 x ln eq4
9 | 9 a g e

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

Sub for
1
R lnLo Lq3
2
1
) 4 (
32 3
4
x x
W
W M
T
B
=
Sub for
1
R and
1
M ln LquaLlon1
) 4 (
16 3
4
2
x
W
W M
T
B
=
So bendlng momenL can be shown by Lhe equaLlon
) 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 Lrolley
1he maxlmum value of Lhe bendlng momenL M appears aL x0 when Lhe Lrolley ls aL 1/3 of Lhe
beam and aL x4m when Lhe Lrolley ls aL 2/3 of Lhe beam 1herefore Lhe maxlmum bendlng ls 1809
knm wlLh Lhe '203x132x32 beam'

nook Ca|cu|at|ons
1 Shear of Pook
Shear SLress
9
F
2
= t
2 1enslle lallure
)9 / b
F
A
F

= = o

1he hook ls llfLlng a load of 3Lonnes Lherefore l29430n

1 1ear CuL/Shear of Pook
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

2 1enslle lallure of Pook
)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|ng
1oLal 3 bush bearlngs
1ens||e stress on each bush |n the four geared whee|s


Where



8equlred maLerlals and 9rocedure
1 Cear cases
MaLerlal SLeel ManufacLurlng process lormlng
2 urlven wheels
MaLerlal SLeel ManufacLurlng process lormlng
3 8ush 8earlng
O Cnly preclslon ball and roller bearlngs for all Lrolley crane assembly componenLs wlLh mlnlmum
810 llfe of 3000 hours aL full raLed load
11 | 9 a g e

O All bearlngs musL have proper lubrlcaLlon and means of lubrlcaLlng ueslgn bearlng enclosure Lo
exclude dlrL and prevenL leakage of oll or grease
MaLerlal SLeel ManufacLurlng process lndusLry SLandards

4 ShafLs
MaLerlal Coldrolled SLeel of shafLlng quallLy ManufacLurlng process Cold rolllng process
3 8olLs and nuLs
MaLerlal Plgh SLrengLh SLeel hoL dlp galvanlzed wlLh lnLernal Lhreads Lapped or reLapped afLer
galvanlzlng ManufacLurlng 9rocess lndusLry SLandards
6 LlfLlng 8lng
MaLerlal SLeel ManufacLurlng 9rocess lndusLry SLandards
7 Lquallzer 9ln
MaLerlal SLeel ManufacLurlng 9rocess Machlnlng

8 urlven Splndle
MaLerlal SLeel ManufacLurlng 9rocess Machlnlng
9 Load Pand Chaln and Caslng
O 1he pockeLs of handchaln wheels and loads wheels are deslgned Lo allow proper flL and
engagemenL for speclflc hand chaln or load chaln used on Lhe manual Lrolley crane Pand chaln
and load chaln are boLh accuraLely plLched wlLhln speclfled Lolerances Lo flL Lhe wheel pockeLs
O 1rolley crane load chaln ls manufacLured and heaL LreaLed for lLs servlce and ls noL slmllar Lo
sLandard chaln made for sllngs 1hls ls sufflclenL reason why hand or load chaln cannoL be
lnLerchanged beLween Lrolley crane producLs or why sLandard Lype chaln cannoL be lnsLalled on
Lrolley cranes as replacemenL chaln
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MaLerlal SLeel ManufacLurlng 9rocess lndusLry SLandards
10 9lnlon
MaLerlal SLeel ManufacLurlng 9rocess lndusLry SLandards













13 | 9 a g e

keference

1 hLLp//wwwmechuwaeduau/uAnoLes/gears/meshlng/meshlnghLml
2 hLLp//wwwenglneersedgecom/gear_formulahLm
3 hLLp//wwwcancocranescom/lmages/caLalogs/acco_rope_selecLlonpdf
4 hLLp//booksgoogleae/books?ld88n72L
L_g8CprlnLsecfronLcoverdqhand+chaln+Lrolleyhlensourcegbs_summary_scad
0#99A233M1
3 hLLp//courseswashlngLonedu/mengr336/daly/Cear_sLresspdf
6 hLLp//wwwanswerscom/Loplc/casLlng
7 hLLp//wwwanswerscom/Loplc/meLalformlng
8 hLLp//auLohowsLuffworkscom/gearshLm





























14 | 9 a g e

Contr|but|on


lahad khan 100 conLrlbuLlon