INDEX

TOPIC PAGE NO

Abstract

List of Figures

List of abbreviations

1. INTRODUCTION..................................................................................... [1-4]

1.1 Introduction of Mini Boom Crane ............................................................... 2

1.2 Literature review of crane ............................................................................ 3

1.3 Hoist device .................................................................................................. 3

1.4 Working........................................................................................................ 4

2. HISTORY ............................................................................................... [5-13]

2.1 History of cranes .......................................................................................... 6

2.2 TYPES........................................................................................................ 11

2.2.1 Truck-mounted ..................................................................................... 11

2.2.2 Rough terrain ........................................................................................ 12

2.2.3 Floating crane ....................................................................................... 12

2.2.4 Pick and carry crane ............................................................................. 12

2.2.5 Telescopic handler................................................................................ 12

2.2.5 Tower Crane ......................................................................................... 13

3. COMPONENTS .................................................................................... [14-34]

3.1 Induction motor .......................................................................................... 15

3.1.1 Basic Working Principle of an Induction Motor .................................. 16

3.1.2 Single Phase Induction Motor .............................................................. 16

3.1.3 Working of single Phase Induction Motor ........................................... 18

3.1.4 Remote controlled uptown switch ........................................................ 19

 3.1.5 63 amp 3 pole MCB ............................................................................. 19

3.1.6 Isolator switch ...................................................................................... 21

3.2 Gear box ..................................................................................................... 21

3.2.1 Types of Gearbox ................................................................................. 22

3.3 Pulley.......................................................................................................... 24

3.3.1 Types of Pulley..................................................................................... 24

3.4 Bearings...................................................................................................... 26

3.4.1 Ball Bearings ........................................................................................ 26

3.4.2 Self-aligning roller ball Bearings ......................................................... 27

3.5 clutch .......................................................................................................... 28

3.5.1 Types of clutches .................................................................................. 28

3.6 Steel rope .................................................................................................... 29

3.6.1 Materials ............................................................................................... 29

3.6.2 Terminology about Cross section AA .................................................. 29

3.6.3 Wire Rope End Connectors (fittings, end attachments, terminals) ...... 29

3.7 Bolts and nuts ............................................................................................. 33

3.7.1 Types of bolts ....................................................................................... 33

3.8 Mild Steel C sections ................................................................................. 34

3.9 Lifting hook ................................................................................................ 34

4. OPERATIONS PERFORMED DURING FABRICATION ............ [36-40]

4.1 Cutting ........................................................................................................ 36

4.3 Grinding ..................................................................................................... 37

4.4 Drilling ....................................................................................................... 38

4.5 Lathe ........................................................................................................... 39

5. TOOLS AND EQUIPMENTS ............................................................. [41-47]

 5.1 Cutting wheel ............................................................................................. 42

5.2 Grinding wheel ........................................................................................... 42

5.3 Drill bits...................................................................................................... 43

5.4 Hammer ...................................................................................................... 43

5.5 Spirit level .................................................................................................. 44

5.6 Welding rod ................................................................................................ 44

5.7 Welding helmet .......................................................................................... 45

5.8 Wrench ....................................................................................................... 45

5.9 Screwdriver ................................................................................................ 45

5.10 Hacksaw ................................................................................................... 46

5.11 G-Clamp ................................................................................................... 46

5.12 Measuring tape ......................................................................................... 47

6. MAINTANANCE AND LUBRICATION .......................................... [48-51]

6.1 Lubrication ................................................................................................. 49

6.1.1 Grease ...................................................................................................... 49

6.1.2 SAE-140 .................................................................................................. 50

6.2 Painting....................................................................................................... 51

7. ANALYSIS ............................................................................................ [52-68]

7.1. Analysis of miniboom crane ..................................................................... 53

7.1.2. Principle of operation of a squirrel cage motor................................... 53

7.1.2. Speed Regulation and Percent Slip ..................................................... 54

7.1.3. Speed Regulation and Percent Slip ..................................................... 55

7.1.4. Power Factor ....................................................................................... 57

7.1.5. Reversing Rotation .............................................................................. 58

7.1.6 Speed Control ....................................................................................... 58

 7.1.7 over all Calculation of the motor ......................................................... 59

7.2 STEEL ROPE ........................................................................................... 60

7.2.1 Steel wire suspensions ropes for lifts, cranes and hoists: .................... 60

7.2.2 Diameter of the wire and Area of wire rope: ....................................... 61

7.2.3 Factor of safety for wire ropes: ............................................................ 61

7.2.4 Wire rope sheaves and drums .............................................................. 62

7.2.5 Stress in wire ropes .............................................................................. 62

7.2.6 Bending stress when the rope winds round the sheave or drum .......... 63

7.2.7 Stresses during starting and stopping ................................................... 63

7.2.8 Over all Calculation of the steel rope .................................................. 65

7.2.9 Variation of speed by variable loads .................................................... 67

8. CATIA V5 ............................................................................................. [69-80]

8.1.2 Modules Used While Designing Components ..................................... 71

8.1.3 Part Design Module.............................................................................. 72

8.1.4 Commands Used While Designing ...................................................... 73

8.1.5 Drafting Module ................................................................................... 75

8.2 Design of Crane Hook ................................................................................ 78

8.3 Design of a jib ............................................................................................ 78

8.4 Design of a pulley ...................................................................................... 79

8.5 Design of boom .......................................................................................... 79

8.6 Design of base ............................................................................................ 80

9.RESULT .......................................................................................................... 83

10. CONCLUSION............................................................................................ 85

11. Bibliography………………………………………………………. 87
 ABSTRACT

The project is to design the mini boom crane using the CATIA V5 and Analysed with
the design calculations. It is needed to analyse crane structures. The analysis is done with the
maximum load can be applied on crane. The motor and wired rope has their own maximum load
that can be supported. It was found that the stresses of the analysis is still in the range of the yield
strength of the mild steel. And we have calculated the Motor and steel rope capacities at the
different loads conditions within the factor of safety limits.

This is about crane; it is a device that efficiently moves goods vertically between
floors of a building, vessel, or other structures. They are generally powered by electric
motors that either drive traction cables or counterweight systems like a hoist, or pump
hydraulic fluid, to raise a cylindrical piston in the form of a jack.

We have designed the various components of mini boom crane using CATIA V5 P3
work bench. As compared and analysed with applied loads, the crane operated under the safe
limits. So, this design is still in the safe condition.
 LIST OF FIGURES
S.NO FIGURE NUMBER PAGE NO
1 2.1.1 7

2 2.1.2 7

3 2.1.3 9

4 2.1.4 10

5 2.2.1 11

6 2.2.2 12

7 2.2.3 12

8 2.2.4 13

9 2.2.5 13

10 3.1 15

11 3.1.2.1 17

12 3.1.2.2 17

13 3.1.4 19

14 3.1.5 19

15 3.1.6 20

16 3.2 21

17 3.2.1.1 22

18 3.2.1.2 23

19 3.2.1.3 23

21 3.3.1.1 24

22 3.3.1.2 25

23 3.3.1.3 26

24 3.4.1 27

25 3.4.2 28

20 3.3 24
26 3.5.1.1 28

27 3.5.1.2 29

28 3.6.2.1 29

29 3.6.2.2 30

30 3.6.2.3 30

31 3.6.2.4 31

32 3.6.3.2.1 32

33 3.7 32

34 3.8 34

35 3.9 34

36 4.1 36

37 4.2 37

38 4.3 38

39 4.4 39

40 4.5 40

41 4.5.1 40

42 5.1 42

43 5.2 42

44 5.3 43

45 5.4 43

46 5.5 44

47 5.6 44

48 5.7 45

49 5.8 45

50 5.9 46

51 5.10 46

52 5.11 47
53 5.12 47

54 6.1.1 50

55 6.1.2 51

56 6.2 51

57 7.1.1 53

58 7.1.3.1 56

59 7.1.3.2 56

60 7.1.4 57

61 7.1.5 58

62 8.1 70

63 8.1.2 71

64 8.1.3 72

65 8.1.4.1 73

66 8.1.4.2 73

67 8.1.4.3 74

68 8.1.4.4 74

69 8.1.4.5 75

70 8.1.5 76

71 8.2 77

72 8.3 78

73 8.4 78

74 8.5 79

75 8.6 80
 List of abbreviations
Short Name : Abbreviated Name

Cm : Centimetre

Mm : Millimetre

HP : Horse power

Rpm : Revolution per minute