MAJOR PROJECT REPORT

ON
HYDRAULIC FLOOR CRANE
Submitted in partial fulfillment of the
Requirements for the award of
Diploma in Mechanical Engineering

Submitted By : Submitted To:

Abhishek Er. Anil Sen(HOD Mechanical Engineering)
Ashish Patial
Nikhil Thakur
Ritik
Rohit Kumar
Saksham Thakur

Department of Mechanical Engineering

Atal Bihari Vajpayee Government Institute of Engineering &
Technology
Pragatinagar Shimla
Himachal Pradesh
 Abstract

This project focuses on the comprehensive design, analysis, and partial manufacturing of a
hydraulic floor crane with a lift capacity ranging from 1.5 to 2 tons. The primary goal is to
develop a robust and efficient lifting mechanism that is functional, durable, and safe for use in
various industrial applications. The design process was conducted using SolidWorks, where
the Weldment feature was employed to create a detailed structural model that adheres to the
crane's load-bearing requirements.

Structural analysis was performed using ANSYS Workbench to ensure the stability and safety
of the crane under operational load conditions. This analysis verified the strength and reliability
of the design, ensuring compliance with safety standards. Mild steel was selected as the primary
material for its excellent strength, durability, and cost-effectiveness, making it an ideal choice
for the crane’s construction.

The manufacturing process is currently in progress, with the base frame, vertical profile, and
folding plate already fabricated. These components represent a significant milestone in the
project, laying the foundation for further assembly. However, the complete manufacturing and
assembly of the crane are ongoing, with subsequent phases focused on integrating the hydraulic
system, wheels for mobility, and other essential components.

This project aims to deliver a versatile hydraulic lifting solution while prioritizing design
optimization, structural integrity, and practical usability. The next steps involve completing the
assembly and conducting rigorous testing to ensure the crane meets all performance and safety
criteria.
 Acknowledgment

We extend our sincere gratitude to our project guides, Er. Harish Jhinghta(workshop
superintendent) and Er. Nikhil Sharma(Lecturer Mechanical Engineering), for their
guidance and constructive feedback during the development of this project. Their expertise has
been invaluable in completing key components such as the base frame, vertical profile, and
folding plate of the hydraulic floor crane.

We also wish to thank Er. Anil Sen, our Head of Department, for his constant encouragement
and for providing the necessary support and resources to advance this project. His leadership
and insightful suggestions have been instrumental in our progress.

Although the project is still in progress, we deeply appreciate the assistance provided by the
Mechanical Engineering Department, which has been crucial in achieving the current
milestones.
 TABLE OF CONTENT

CHAPTER-1 1

HYDRAULIC FLOOR CRANE 1

INTRODUCTION 1
MAIN OBJECTIVES:- 2
LITERATURE REVIEW 2
APPLICATIONS AND IMPORTANCE OF HYDRAULIC CRANES 2
DESIGN CONSIDERATIONS 3
CHALLENGES IN MANUFACTURING 3

CHAPTER-2 4

OVERVIEW OF SOLIDWORKS 4

OVERVIEW OF SOLIDWORKS IN HYDRAULIC FLOOR CRANE DESIGN 4

1. ADVANCED 3D MODELING AND STRUCTURAL DESIGN 4
 WELDMENT FEATURE FOR STRUCTURAL COMPONENTS: 4
 PART MODELING: 5
2. ASSEMBLY MODELING 6
 ASSEMBLY CREATION: 6
3. STRUCTURAL AND STRESS ANALYSIS 8
 FINITE ELEMENT ANALYSIS (FEA) INTEGRATION WITH ANSYS:- 8
1. GEOMETRY IMPORT 8
2. DEFINE THE MATERIALS 8
3. MESH GENERATION 8
4. BOUNDARY CONDITIONS AND LOADS 9
5. TYPE OF ANALYSIS 9
6. SOLVE THE MODEL 9
FABRICATION AND MANUFACTURING DOCUMENTATION 10
 DETAILED ENGINEERING DRAWINGS: 10
 BILL OF MATERIALS (BOM): 10
 WELDING AND ASSEMBLY INSTRUCTIONS: 11
RENDERING AND VISUALIZATION 11

CHAPTER-3 13

MANUFACTURING PROCESS 13

STEPS IN MANUFACTURING 13
1. MATERIAL SELECTION AND PREPARATION 13
2. BASE FRAME FABRICATION 13
3. LIFTING MECHANISM INSTALLATION 13
4. ASSEMBLY 13
5. FINISHING 13
EQUIPMENT AND TOOLS USED 13
DESIGN AND ANALYSIS TOOLS: 13
FABRICATION TOOLS 13
MANUFACTURING PROCESS 14-16

CHAPTER-4 17

CONCLUSION 17
 TABLE OF FIGURES
Fig.1. 1: Hydraulic Floor Crane ................................................................................................. 2

Fig. 2. 1 Sub-Frame Structural Member Designing................................................................... 4

Fig. 2. 2 Foot Structural Member Designing ............................................................................. 5
Fig. 2. 3 Vertical profile designing ............................................................................................ 5
Fig. 2. 4 Hydraulic Jack Designing ............................................................................................ 6
Fig. 2. 5 Thread designing on bolt ............................................................................................. 6
Fig. 2. 6 Dimensions .................................................................................................................. 7
Fig. 2. 7 Detailed view ............................................................................................................... 7
Fig. 2. 8 Mesh Generation.......................................................................................................... 9
Fig. 2. 9 Analysis Results ........................................................................................................ 10
Fig. 2. 10 Bill of material ......................................................................................................... 11
Fig. 2. 11 Rendering and Visualization ................................................................................... 12

Figure 3. 1 Material cutting ..................................................................................................... 14

Figure 3. 2 Frame welding ....................................................................................................... 14
Figure 3. 3 Drilling Operation ................................................................................................. 15
Figure 3. 4 Primer coat appied for rust protection ................................................................... 15
Figure 3. 5 Final assembled hydraulic crane ........................................................................... 16
 CHAPTER-1

Hydraulic Floor Crane

Introduction

Hydraulic floor cranes play a crucial role in modern industries by providing a compact,
portable, and efficient solution for lifting and handling heavy loads. These versatile machines
are indispensable in environments where manual handling of heavy materials is impractical or
unsafe. By significantly reducing the physical effort required for lifting tasks, hydraulic floor
cranes not only improve operational efficiency but also contribute to enhanced workplace
safety by minimizing the risk of injuries related to manual material handling.

This project focuses on the design and fabrication of a hydraulic floor crane with a lifting
capacity ranging from 1 to 1.5 tons. The primary objective is to develop a reliable and user-
friendly lifting solution suitable for a variety of industrial applications, including workshops,
warehouses, and construction sites. The crane’s design emphasizes portability, allowing it to
be easily maneuvered in confined spaces. It incorporates a hydraulic mechanism for smooth
and precise lifting operations, ensuring both efficiency and control.

The design phase utilizes advanced tools such as SolidWorks for creating a detailed structural
model, with an emphasis on strength, durability, and functionality. To validate the design,
structural analysis is performed using ANSYS Workbench, ensuring the crane meets safety and
performance standards under operational loads. Mild steel is selected as the material for
construction, owing to its excellent mechanical properties and cost-effectiveness.

By integrating modern design techniques with practical manufacturing approaches, this project
aims to deliver a robust and versatile hydraulic floor crane that addresses the demands of
modern industrial lifting tasks.

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 Fig.1. 1: Hydraulic Floor Crane

Main Objectives:-
• Design a hydraulic floor crane for lifting heavy loads.

• Make the crane easy to use

• Keep the design affordable and cost-effective.

• Meet industry safety and performance standards.

• Test the crane to ensure it works reliably.

• Make sure the crane can be easily moved and operated in various settings.

Literature Review
The development of hydraulic floor cranes draws upon significant research and
advancements in the fields of mechanical design, hydraulics, and material science. A
review of relevant literature highlights the evolution of these devices, their applications in
various industries, and the methodologies employed in their design and analysis.

Applications and Importance of Hydraulic Cranes

Hydraulic cranes are widely recognized for their ability to lift and transport heavy loads
with ease, making them indispensable in workshops, warehouses, construction sites, and
manufacturing industries. Research by [Author/Source] emphasizes that hydraulic systems

2
 offer superior load control and efficiency compared to traditional mechanical systems,
ensuring smooth and precise lifting operations. The portability of floor cranes further
enhances their utility in spaces where larger lifting equipment cannot be employed.

Design Considerations

The design of hydraulic floor cranes requires careful consideration of structural stability,
load capacity, and material selection. Studies such as those by [Author/Source] underline
the importance of using lightweight yet strong materials like mild steel, which offers an
optimal balance between strength, durability, and cost. Advanced design tools like
SolidWorks enable the creation of accurate 3D models, allowing engineers to simulate and
optimize the structure for real-world conditions.

1. Structural Analysis and Safety

Ensuring safety and reliability is a critical aspect of crane design. The use of finite element
analysis (FEA) tools like ANSYS Workbench has been widely documented in the literature
for evaluating stress distribution and deformation under various load conditions. Research
highlights that incorporating FEA early in the design phase helps identify potential failure
points, ensuring the final design meets safety standards and operational requirements.

Challenges in Manufacturing
The fabrication of hydraulic floor cranes involves challenges such as maintaining
dimensional accuracy and ensuring proper assembly of hydraulic components. Studies
emphasize the importance of adhering to manufacturing tolerances and the use of advanced
welding techniques to enhance the structural integrity of the crane.

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 CHAPTER-2
OVERVIEW OF SOLIDWORKS

Overview of SolidWorks in Hydraulic Floor Crane Design

SolidWorks is a leading 3D CAD (Computer-Aided Design) software used for designing and
modeling mechanical and industrial systems. For a hydraulic floor crane, SolidWorks offers a
comprehensive suite of tools that streamline the design, analysis, and documentation process.
Here is a deeper look at how SolidWorks plays a vital role in the development of the crane.

1. Advanced 3D Modeling and Structural Design

At the core of the design process, SolidWorks enables the creation of accurate 3D models of
each component in the hydraulic floor crane. These models allow for detailed visualization
and analysis before manufacturing begins.

 Weldment Feature for Structural Components:

The Weldment feature in SolidWorks is particularly useful for designing the crane's
structural frame. It allows users to define standard profiles (like rectangular or square
tubes, angles, and beams) and automatically create a 3D model based on these
profiles. This feature also helps with:
o Standardized Frame Design: The software provides access to a library of
predefined profiles and materials that meet industry standards.
o Custom Frame Designs: Designers can easily modify dimensions and create
custom profiles to meet specific load requirements.
o Cut List Generation: SolidWorks automatically generates a cut list for the
welded components, reducing the chance of errors during fabrication and
simplifying the assembly process.

Fig. 2. 1 Sub-Frame Structural Member Designing

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 Fig. 2. 2 Foot Structural Member Designing

Fig. 2. 3 Vertical profile designing

 Part Modeling:
Each part of the crane (such as the lifting arm, hydraulic cylinder mounts, base frame,
wheels, and joints) can be individually modeled. These parts are designed with
specific material properties and dimensions to ensure they can bear the expected
loads. For example, the lifting arm must be modeled to support up to 1.5 tons of
weight while maintaining strength and stability. Parts are created with attention to
detail to ensure proper fit and function.

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 Fig. 2. 4 Hydraulic Jack Designing

Fig. 2. 5 Thread designing on bolt

2. Assembly Modeling

Once individual parts are designed, SolidWorks allows the user to assemble these parts into a
fully functional model of the hydraulic floor crane.

 Assembly Creation:
SolidWorks makes it easy to combine the individual parts into an assembly. The software
provides tools to define relationships between parts, such as alignments and mates. For
example:
o Hydraulic Systems Integration: The hydraulic system (pumps, and cylinders) can be
integrated into the design to verify how the hydraulic lift mechanism will operate in
the crane.
o Component Fit and Function: Parts such as the lifting arm, base, wheels, and
hydraulic components can be checked for compatibility, ensuring that they work as
expected during operation.

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 Fig. 2. 6 Dimensions

Fig. 2. 7 Detailed view

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3. Structural and Stress Analysis

Before manufacturing begins, it is crucial to ensure that the crane will be able to withstand
the loads and forces it will encounter during use.

 Finite Element Analysis (FEA) Integration with ANSYS:-

While SolidWorks provides basic simulation capabilities, its integration with ANSYS
Workbench allows for more advanced FEA. This enables the design team to perform:
o Detailed Stress and Vibration Analysis: ANSYS provides more accurate and
comprehensive results on how the crane’s structural components will behave under
dynamic loads, vibrations, and extreme conditions.

1. Geometry Import

 File Preparation: Ensure the SolidWorks model of the crane is correctly exported
(preferably in formats like IGES, STEP, or Parasolid).
 Import to ANSYS: Import the model into ANSYS Workbench.

2. Define the Materials

 Material Properties: Assign the appropriate material properties for all crane
components (e.g., Mild steel for the frame, high-strength steel for critical parts). Key
properties include:
o Elastic modulus
o Yield strength
o Density
o Poisson's ratio
 Material Database: Use ANSYS's material library or custom-defined materials.

3. Mesh Generation

 Mesh Quality: Generate a finite element mesh to divide the structure into smaller
elements for analysis.
o Use a finer mesh at stress concentration areas (e.g., joints, corners, holes).
o Use tetrahedral or hexahedral elements as required.
 Mesh Optimization: Check and improve element quality using mesh refinement or
controls.

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 Fig. 2. 8 Mesh Generation

4. Boundary Conditions and Loads

 Support Constraints: Define fixed or pinned supports where the crane interacts with
the ground or other structures.
 Load Application:
o Apply hydraulic force simulating the lift capacity (1–1.5 tons).
o Include gravitational loads (self-weight of components).
o Apply additional forces such as horizontal loads due to misalignment or
movement.
 Dynamic Analysis: If the crane operates dynamically, consider time-varying loads.

5. Type of Analysis

 Static Structural Analysis:

o Identify stresses, strains, and deformations under static loading conditions.
 Modal Analysis:
o Determine the natural frequencies and mode shapes to avoid resonance during
operation.
 Fatigue Analysis:
o Evaluate the life cycle of the structure under repeated loading.

6. Solve the Model

 Solver Settings: Set appropriate solver settings for convergence.

 Run Analysis: Execute the solver to calculate results.

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 Load applied 10000 Newton

Fig. 2. 9 Analysis Results

Fabrication and Manufacturing Documentation

SolidWorks does more than just help design the crane; it also aids in generating the
manufacturing documents necessary for production.

 Detailed Engineering Drawings:

SolidWorks automatically generates precise 2D drawings for each part and assembly,
including dimensions, material specifications, and welding details. These drawings
are essential for guiding the fabrication process.
 Bill of Materials (BOM):
SolidWorks creates a comprehensive BOM that lists all the components required for
the crane’s assembly. This ensures that all parts are accounted for and available
during fabrication.

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 Fig. 2. 10 Bill of material

 Welding and Assembly Instructions:

For welded parts, SolidWorks can generate welding symbols and details, making it
easier for fabricators to follow instructions and ensure proper assembly.

Rendering and Visualization

The rendering tools in SolidWorks provide photorealistic images of the crane, which can be
used for presentations or marketing purposes. These visualizations help to:

 Present the Design: High-quality rendered images can help stakeholders, including
project guides and clients, better understand the design before physical production
begins.
 Evaluate Aesthetic Aspects: The rendering tools also allow the user to evaluate the
visual appeal of the crane, ensuring that it meets aesthetic and branding requirements.

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Fig. 2. 11 Rendering and Visualization

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 CHAPTER-3
Manufacturing Process
Steps in Manufacturing

1. Material Selection and Preparation

 Selected mild steel sections for the base frame, lifting arm, and other components.
 Cleaned and cut the materials to the required dimensions using an angle grinder and
cutting machine.

2. Base Frame Fabrication

 Assembled the steel sections for the base frame.

 Joined the components using a welding machine.

3. Lifting Mechanism Installation

 Mounted the long ram hydraulic jack onto the base frame using drilling machines for
precise holes and fasteners.

4. Assembly

 Attached the lifting arm and wheels.

 Ensured proper alignment using a hydraulic press.

5. Finishing

 Removed excess material and smoothed the surfaces using an angle grinder.

Equipment and Tools Used

Design and Analysis Tools:

 SolidWorks for 3D modeling.

 ANSYS Workbench for structural analysis.

Fabrication Tools:

 Welding Machine
 Angle Grinder
 Drilling Machine
 Measuring Tape

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Figure 3. 1 Material cutting

Figure 3. 2 Frame welding

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 Figure 3. 3 Drilling Operation

Figure 3. 4 Primer coat appied for rust protection

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Figure 3. 5 Final assembled hydraulic crane

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 CHAPTER-4

CONCLUSION

Successfully designed a hydraulic floor crane using SolidWorks with weldment features.
Conducted thorough structural analysis using ANSYS Workbench. Manufacturing process is
underway with the base frame, vertical profile and folding plate completed.

 Learning Outcomes:

Improved understanding of CAD design, structural analysis, and manufacturing techniques.

Developed problem-solving skills during the manufacturing phase.

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