ISSN: 2277-9655

[Mundhe* et al., 6(3), March 2017] Impact Factor: 4.116

IC™ Value: 3.00 CODEN: IJESS7

IJESRT
INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH
TECHNOLOGY
DESIGN DEVELOPMENT AND OPTIMISATION OF OVERHEAD CRANE
Shubham R. Bhagat, Varun H. Danke, Sagar S. Kolte, Vikram K. Mundhe*,
Prof. Nilesh V. Dhumal
*
Department of Mechanical Engineering, Suman Ramesh Tulsiani Technical Campus , India

DOI: 10.5281/zenodo.439200

ABSTRACT
Optimization is one of the techniques used in designing sectors to arrive at the best designing conditions which
is a very essential need of the industry toward designing of quality products at low costs. This paper is aimed at
finding the optimal conditions using which beam and columns can be designed for crane system manufacturing.
The following set of calculations are specific to our industry. For this application we considered various beam
sections and found them to be ineffective in terms of cost and material usage. So we did a few iterations using
different sections and optimized the design for best material utilization.
KEYWORDS: Overhead Crane, load carrying capacity, beam optimization, column design.

INTRODUCTION
A 'crane' is a type of machine, generally equipped with a hoist, wire ropes or chains, and sheaves, that can be
used both to lift and lower materials and to move them horizontally or vertically. It is mainly used for lifting
heavy things and transporting them to other places. It uses one or more simple machines to create mechanical
advantage and thus move loads beyond the normal capability of a man. Cranes are commonly employed in the
transport industry for the loading and unloading of freight, in the construction industry for the movement of
materials and in the manufacturing industry for the assembling of heavy equipment. In material handling,
the cranes play a vital role in modern manufacturing industries.

MATERIALS AND METHODS

Design of components of the overhead crane system:
The overhead crane consists of the following components:
1. Beam for the chain hoist
2. Columns for the crane
3. The chain hoist mechanism
4. Channel for the chain hoist
5. Channels supporting the beam

Design of beam for chain hoist:

The existing chain hoist will be transferred to a new beam which will move on channels situated over
the columns in the workplace.
The beam has to withstand bending and shear forces which will be caused due to the load being lifted
by the chain hoist.

The dimensions of the work place are :

Length = 25m
Width = 12m
Height = 5.4m
The beam will be as long as the total width of the workplace and the bearings at the side will facilitate
linear movement along the length of the place.

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[Mundhe* et al., 6(3), March 2017] Impact Factor: 4.116
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Beam
Channel

Column

Layout of the workplace

Design of beam :
The material selected for the beam is Fe 410. This material is used in 90% manufacturing works as it is cheap
and readily available.
The material properties are :
 Ultimate tensile strength (σu) = 410 MPa
 Yield tensile strengt (σy) = 220 MPa
 Young’s modulus (E) = 210 GPa
 Considered FOS over yield =2
 Allowable bending stress (σb) = 110 MPa

Available Data:
Total weight on beam (W) = 3000kg = 29430N≈30000N
Total length of beam (L) = 12m = 12000mm
Total moment acting(M) = WL/4
= 9x10^6 N-mm
Required section modulus (Z) = M /σ b
= 818.181 x 10³ mm³
For ISMB 200x100 (with plate of dimension 650mmx 20mm welded to it)
I xx = 1.787 x 10^9 mm4
Deflection of beam (δ) = WL³/48*E* I xx
= 12.12 mm

Calculated values for selected beam section in AutoCAD

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Optimized section of beam selected

Design of column:
By Euler’s formula,
For, 1 end fixed and 1 end free column,
Pc = π²E* I c/4* Lc ²
where, Pc = Buckling load,
E = 205 GPa,
Lc = Length of column.
and I c = Moment of inertia of considered column section.
= 7.88 x 10^6mm^4
Pc = π² x 205 x 10^3 x 7.88 x 10^6/ ( 4 x 5400²)
= 136688N
Considering FOS = 5 ( as safety is a primary concern , an FOS of 5 is selected.)
Safe load = Pc /FOS = 136688/5 = 27337.6 N
≈ 2.786 tonne
Total maximum load on 1column = (Load on beam /2)+ Beam weight + (Total load of channel/5)
= 3000/2+1000+1000/5
= 2700kg < Safe load
Therefore, The considered I-section is safe and design is proper.

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 ISSN: 2277-9655
[Mundhe* et al., 6(3), March 2017] Impact Factor: 4.116
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Existing
column

Optimized
column
section

New I section used for columns

RESULTS AND DISCUSSION:

Formulae:
WL
M= (1)
4

³/¿
δ = WL ¿ (2)
48∗E∗I xx

W b = w b*L (3)

π ² E∗I c
Pc = (4)
4∗Lc ²

Safe load = Pc /FOS (5)

Iterations for beam design:

Sr.No Details Notation Units Iteration I Iteration II Iteration III Iteration IV
. (ISMB 500) (ISMB 450) (ISMB 250) (cad 400)
1 Load W Kg 3000 3000 3000 3000
2 Span L Mm 12000 12000 12000 12000
3 Allowable σb kg/ 11 11 11 11
bending mm ²
stress
4 Moment M kg-mm 9000000 9000000 9000000 9000000
5 Moment of I xx mm 4 4.52E+08 3.04E+08 1.03E+08 4.24E+08
Inertia
6 Deflection Δ Mm 11.3780025 16.91729323 50.101 12.12

7 Weight of wb kg/m 210 72.4 37.3 37.3

the beam/ m

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[Mundhe* et al., 6(3), March 2017] Impact Factor: 4.116
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8 Weight of Wb Kg 2520 868.8 447.6 1115
the beam

CONCLUSION
By selecting single I section we have defelection above safe limit. So ,to reduce deflection we select 2 I section
with plate welded on its flange as our beam. By selecting this design we optimize weight of beam as well as size
of the beam.

REFERENCES
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IJDR, Vol.6, Issue 05, pp. 7821-7823, May 2016.
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[5] Steel Work Design and Analysis of a mobile floor crane ISSN 2231-0843 ,Article no. BJAST.23079
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Ebieladoh.( Department of mechanical engineering Nnamdi Azikiwe University, Nigeria)

BOOKS:
Strength of Materials, S.S.Rattan.
Design Data Book, V.B.Bhandari
Material science and metallurgy, S.V.Kodgire.

CATALOGUES
BIS – Design of hot rolled steel beams, columns, channels and angle sections.
IS 808:1989 , Addition 4.1 ( 1992-07)

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