WOLKITE UNIVERSITY

College of Engineering and Technology

MATERIAL HANDLING EQUIPMENT
4th Year Mechanical Engineering

By yohannes.k(M.Sc.).

1
 Material handling and equipment's
Material Handling -Definition
Materials handling can be defined as the art and science of conveying, elevating,
positioning, transporting and packaging and storing of materials regardless of
size, form and weight which effect a saving in money, time and space.
The reference of materials handling as art and science is made, because the
solution of most handling problems are not susceptible to a single definite answer
but depends largely on the experience and judgment of individual materials handling
engineer.
Material Handling is the function of moving the right material to the right
place in the right time, in the right amount, in sequence, and in the right
condition to minimize production cost.
Materials handling can be also defined as ‘the function dealing with the
preparation, placing and positioning of materials to facilitate their movement
or storage’.
2
 Cont…
 Four Dimensions of Material Handling :
1. Movement: conveyance of goods into and out of storage facilities.
2. Time: is concerned with readying goods for production or for customer
order filling.
3. Quantity: addresses the varying usage and delivery rate of raw
materials and finished goods, respectively.
4. Space: consumes place/space in the warehouse and plant.

3
 MATERIAL HANDLING-OBJECTIVES
1. Reduce Unit Material Handling Cost
 Eliminate Unnecessary Handling
Handle Material in Batch Lots
Minimize Required Handling Time
 Replace Handling Equipment as appropriate
2. Reduce Production Time
Minimize delays( when someone something has to wait or the length of the waiting time) of machine
operations
Maintain uniform and appropriate movement of material
Use Automatic Processing when appropriate

4
 Cont…
3. Reduce Overhead
Minimize Non-Productive Labor
Prevent Damage to Materials
Coordinate All Material Handling Systems.
4. Conserve Floor Space
Avoid Excessive Stock Storage
Move materials in an appropriate position to save space
Use Equipment Requiring no Floor Space

5
 Cont…
5. Prevent Accidents
Reduce Physical Load Required
Insure Handling Equipment
6. Improve Employee Morale
Provide Proper Relationship between Employee and Work.

6
 Principles of Material Handling
1. ORIENTATION PRINCIPLE: Study the system relationships thoroughly prior to
preliminary planning in order to identify existing methods and problems, physical and
economic constraints, and to establish future requirements and goals.
2. PLANNING PRINCIPLE: Establish a plan to include basic requirements, desirable option
and the consideration of contingencies for all material handling and storage activities.
3. UNIT LOAD PRINCIPLE: Handle products in as large a unit as practical unitized load
may be defined as: ‘‘A number of items, or bulk material, so arranged or
restrained that the mass can be picked up and moved as a single object,
too large for manual handling, and which upon being released will retain
its initial arrangement for subsequent movement. It is implied that single
objects too large for manual handling are also regarded as unit loads.’’
4. SPACE UTILIZATION PRINCIPLE: Make effective utilization of all cubic space
5. STANDARDIZATION PRINCIPLE: Standardize handling methods and equipment
7
wherever possible.
 Cont…

6. SYSTEMS PRINCIPLE: Integrate those handling and storage actities

which are economically viable(feasible) into a coordinated system of
operation including receiving, inspection, storage, production,
assembly, packaging, warehousing, shipping and transportation.
7. ERGONOMIC PRINCIPLE: Recognize human capabilities and limitations
by designing material handling equipment and procedures for effective
interaction with the people using the system.
8. ENERGY PRINCIPLE: Include energy consumption of material handling
systems and material handling procedures when making comparing
economic justifications.
9. ECOLOGY PRINCIPE: Minimize adverse(opposing) effects on the
environment when selecting material handling equipment.
8
 Cont…
10. MECHANIZATION PRINCIPLE: Mechanize the handling process where feasible
to increase efficiency and economy in the handling of materials.
11. FLEXIBILITY PRINCPLE: Use methods and equipment which can perform a
variety of tasks under a variety of operating conditions.
12. SIMPLICITY PRINCIPLE: Simplify handling by eliminating, reducing, or
combining unnecessary movements and/or equipment.
13. GRAVITY PRINCIPLE: Utilize gravity to move material whenever possible, while
respecting limitations concerning safety, product damage and loss.
Use roller conveyors, slides, chutes(drop) between equipment/processes.
Use ramps between varying work or floor levels.
Use sloping floor when materials movement by hand truck is mainly in one
direction.
Use spiral chutes to feed machines at different floors .
14. SAFETY PRINCIPLE: Provide safe material handling equipment and methods
9 which follow existing safety codes and regulations in addition to accrued experience.
 Cont…
15. COMPUTERIZATION PRINCIPLE: Consider computerization in materials
handling and storage systems, when circumstances warrant, for improved material
and information control.
16. SYSTEM FLOW PRINCIPLE: Integrate data flow with the physical material
flow in handling and storage.
17. LAYOUT PRINCIPLE: Prepare an operational sequence and equipment layout
for all viable system solutions, and then select the alternative system which best
integrates efficiency and effectiveness.
18. COST PRINCIPLE: Compare the economic justification of alternate solutions
in equipment and methods on the basis of economic effectiveness as measured by
expense per unit handled.

10
 Cont…
19. MAINTENANCE PRINCIPLE: Prepare a plan for preventive
maintenance and scheduled repairs of all material handling
equipment.
20. OBSOLESCENCE PRINCIPLE: Prepare a long range and
economically sound policy for replacement of obsolete equipment and
methods with consideration to after-tax life cycle costs.
EXERCISES
Section A
1. Define material handling.
2. Mention any four objectives of material handling.
3. Mention at least any eight principles of material handling.
11
 MATERIAL HANDLING EQUIPMENT
 The purpose of material handling equipment's are used to handle
heavy loads with fast speed, reliability, safety and economy.
 In order to meet the variety of requirements equipment of different
types and sizes have been developed and are being manufactured.
 Application of material handling devices is a prime consideration in
designing new plants and for modifying existing plants.
 These devices increase output, improve quality, speed up the
deliveries and therefore, decrease the cost of production. Utility of
these devices have further been increased due to increase in labor
costs and problems related to labor management.

12
 SELECTION OF MATERIAL HANDLING DEVICES
Material handling devices should be able to give maximum efficiency, economy, life and
reliability of service. Under-utilization and faulty selection of the material handling
equipment is an expensive luxury which gives rise to increase in operating costs. The
equipment should be selected according to the size, shape, weight, material to be
handled etc.
According to George Hageman, the important “Engineering and Economic” factors to
be considered in material handling installation can be classified as:
1. Factors relating to plant and operating methods
2. Factors depending on materials or parts handled
3. Factors relating to handling equipment
4. Money factors.
13
1. FACTORS RELATING TO THE PLANT & OPERATING METHODS
Is the present manufacturing or operating method permanent or temporary?
How long will the present buildings remain in service?
Is the general plant layout the best for manufacturing and handling
requirements?
What processes and departments to be tied together?
If trucks or floor type of equipment are to be used, are aisles(long pass) and
passage ways ample for conveniences in handling speed, safety and non-
interference with production? Are the floor made of water-resistant materials?
Are they leveled and smooth? Will they withstand the loads?
If overhead systems are contemplated, is the building structure strong enough
to hold them and are clearances sufficient for their installation?

14
 2. FACTORS DEPENDING ON THE MATERIALS OR PARTS
HANDLED
Kinds or nature of materials of parts handled
 Bulk or units
 Large or small
 Heavy or light
 Shape
 Rough(not smooth) or fragile( easily broken/damage)
Handled separately or in containers
Quantities handled
Continuous or intermittent flow
Under processing while moving
Distances over which transported

15
 3. FACTORS RELATING TO THE HANDLING EQUIPMENT
Capacity of equipment
Hours it will be in service daily
Size of equipment
Space requirement for operation (for trucks this factor covers, passage ways,
elevators, platform sizes etc.)
Flexibility (according to loads etc.)
Adaptability to other service
Power requirements
Ease of operation
Durability
Relationship to other handling equipment in use or contemplated
Auxiliary equipment which is required and economical to install loading platform.
16
 4. MONEY FACTORS
Initial cost of equipment
Cost of installation, re-arrangement and alterations to present equipment,
buildings etc.
Cost of maintenance, repairs, supplies etc.
Cost of power
Rate of depreciation(reduction in values or price)
Rate of oldness
Probable salvage ( save from accident) value when finally described
Cost of labor to operate
Cost of any necessary auxiliary equipment (such as charging equipment for truck
batteries, etc.)
Taxes and insurance
Interest on investment
17 License fees (for trucks that may operate on highways)
 Cont…
Rent of space (also garage rent for trucks).
Cost of supervision
Saving that the equipment will bring about in direct labor cost (number of
men released for other work).
Saving in labor burden (supervision of product)

18
 CHARACTERISTICS OF MATERIALS HANDLING EQUIPMENT
A good device (materials handling equipment) should have
following characteristics:
1. Material should not be damaged in handling
2. Capable to handle material in required quantity
3. Capable of delivering material at desired time
4. Should be able to deliver goods at right place
5. Should be safe in operation
6. Should be economical both with respect to capital outlay and
operational costs.

19
 PRINCIPAL GROUPS OF MATERIALS HANDLING EQUIPMENT

Material Handling
Equipment

Hoisting Conveying Surface &

Overhead
Equipment Equipment Equipment

Hoisting Equipment: is a group of machines with lifting gear intended for

moving loads mainly in batches.

20
 Cont…
CONVEYING EQUIPMENT: is a group of machines which may have no
lifting gear and which move loads in a continuous flow.
SURFACE AND OVERHEAD EQUIPMENT: is a machines which also
may not be provided with lifting gear and which usually handle loads in
batches.

21
 MAIN GROUPS OF MATERIALS HANDLING EQUIPMENT

Material Handling Equipment

Conveying Surface and Overhead

Hoisting Equipment Equipment Equipment

Hoisting Elevators Traction Tractionless Surface Over Head

Machine Narrow
Crane Gauge

22
 Cont…
Hoisting Hoisting Jack, Pulleys, Hoists, Monorail, Winches
Machine
Equipment
Crane Elevating, Trackless, Mobile, Bridge, Cable, Flouting,
Railway,
Elevators Vertical, Slackers, Industrial lift, Passengers' Lift, Freight
Conveying
Equipment Traction Belt, Chain, Bucket, Car type, Escalator, scrapers, Pan, Steel
plate
Tractionless Gravity, Spiral, Roller, Twin helical, Vibratory, Hydraulic,
Surface & Pneumatic
Overhead
Surface Hand-operated Truck, Powered Truck, Multi Wheel, Two
Equipment
Wheel, Platform, Lift truck, Tractors, Industrial Trailers

Narrow gauge Hand trucks, Locos, Wagons

Over Head Winches, Monorail, Haulago, Tramways, Airways (Ropeways)
23
 BULK OR UNIT LOADS
Loads can be classified as bulk or unit loads.
Bulk Loads:- Materials handled in bulk are composed of a large number of
homogeneous particles or lumps, for example: coal, ore, sand, stone, clay
Unit Loads:- may differ widely in form and weight.
Hoisting machines are intended mainly for unit loads-various parts of
machines and whole machines, elements of metal structures, hoppers and
ladles, girders, building blocks and materials, etc.[girdesrs- A beam, as of
steel, wood, or reinforced concrete, used as a main horizontals support in a
building]
Conveyors can be used to handle either bulk or only unit loads.
Surface and Overhead facilities- can be used for both bulk and unit loads.

24
 CHARACTERISTICS OF THE MAIN GROUPS OF MATERIAL
HANDLING EQUIPMENT
As a rule, the working movement in hoisting machines is intended
either for raising or lowering the load.
Some hoisting machines can also travel horizontally, turn round, move
radially, etc.
 Most of the transporting facilities shift loads in a horizontal direction
although many can also move them at various angles to the horizontal or
in a vertical direction.
 Most hoisting mechanisms are designed to perform controlled individual
typical movements, for example, of any cranes which lift the load, slew it,
hold it at rest, if required, and carry it to its destination. [slew-change
direction, move obliquely or sideways].

25
 Cont…
Transporting facilities, conveyors, trucks and telphers are moves materials
along a fixed path to perform many identical working operation. [telpher- A small
travelling car, usually driven by electricity, suspended from or moving on a overhead
rail or cable].
Identical working operations and uniform loads that they carry enable the
transporting facilities to be highly automated not only for moving but also for
loading, unloading and stacking operations.

26
 CHOICE OF MATERIALS HANDLING EQUIPMENT
Materials handling machines are manufactured in great variety of
designs. For this reason the same operation can be frequently
performed by various methods and devices.
The proper choice of a device requires not only a special knowledge of
the design and operational characteristics of the mechanism but also a
thorough understanding of the organization of production at the
enterprise.
 A transporting facility should move loads to their destinations in the
scheduled time, i.e., loads should be delivered to the departments or
enterprise in the required amounts.

27
 Cont…
The materials handling equipment should be mechanized to the fullest
possible extent so as to employ only a few workers for control, maintenance
and auxiliary jobs.
At the same time these device should not damage the loads being moved, or
encumber in any way the premises or hamper the production processes.
 They should be safe in operation and economical both with respect to
capital outlay and operational costs. [encumber- to make something hold].
Principal technical factors that can be pointed out for guidance in the choice
of the types of devices which can be expediently employed to mechanize any
handling process [expediently-quickly]

28
 Cont…

Kinds and properties of loads to be handled

Required hourly capacity of the unit
Direction and length of travel
Methods of stacking loads at the initial, final and intermediate points
Characteristics of production process involved in moving loads
Specific local conditions
Economic considerations

29
 KIND AND PROPERTIES OF LOADS TO BE HANDLED
For unit loads- their form, weight, convenient bearing surface of parts by
which they can be suspended, brittleness, temperature, etc.
For bulk loads- lump size, tendency to cake, volume, weight and the
amount of crumbling liable to occur during delivery, temperature, chemical
properties, etc. [friable- easily broken into smaller pieces,
crumble(decomposing)-to break into small pieces].
These characteristics of loads can essentially narrow down the range of
devices which can be applied in each definite case since the different
devices are not adapted equally to the various properties of loads.

30
 REQUIRED HOURLY CAPACITY OF THE UNIT
A particular unlimited hourly load moving capacity can be easily obtained
with certain types of devices, for instance, with some continuous-action
conveyors.
On the other hand, there are devices, such as power-driven trucks or
overhead travelling cranes following a definite cycle of movements with
a return idle run, which can operate efficiently only if they possess an
adequately high lifting capacity and speed at strenuous duty. [strenuous-
requiring or showing great energy and effort]

31
 DIRECTION AND LENGTH OF TRAVEL
Various types of devices can carry loads in a horizontal or vertical direction or
at an angle to the horizontal. Thus, a vertical movement or a movement close
to the vertical requires a hoist, crane, bucket or tray elevator; Horizontal
movement is provided by self propelled or hand tracks, fixed path facilities,
various types of conveyors, etc.
Some devices can easily negotiate track curves while others move only
rectilinearly, in one ramification of the load delivery stations are also very
important for the correct choice of a transporting facility. [Ramification-the act
or process of branching out or dividing into branches]

32
 METHODS OF STACKING LOADS AT THE INITIAL, FINAL AND
INTERMEDIATE POINT
Loading onto the vehicles and unloading at their destination differ
considerably because some handling machines can be loaded mechanically
while others require special auxiliary fixtures or manual power.
Thus, for example, bulk loads can be stored either in lot, in a pile, from
which they flow by gravity onto the transporting facility.
 Unit loads can be stowed directly on the ground or on pallets, stands, racks,
trays, etc., from which they are delivered to and removed from the materials
handling devices by different methods. [stowed-To place or arrange,
especially in a neat, compact way]

33
 CHARACTERISTICS OF PRODUCTION PROCESSES INVOLVED IN
MOVING LOADS
The movements of materials handling equipment are closely linked with
and depend on the manufacturing process; sometimes these movements
may even be directly involved in the performance of certain processing
operations. Such are, for example, special cranes employed in foundry,
forging and welding departments, assembly and foundry conveyors,
processing conveyors in machining, painting and other departments.

34
 SPECIFIC LOCAL CONDITION
Specific local conditions include the size and shape of the area, type and
design of the building, ground relief, possible arrangement of the processing
unit, dust or humidity conditions in the premises, presence of vapors or
gases, temperature, etc.
The choice of devices is also influenced by the considerations of a further
expansion of the enterprise, the period it will be in existence (temporary or
permanent), the kind of energy available, and problems of sanitation, safety and
operational convenience.
ECONOMIC CONSIDERATIONS
In economic evaluation of various types of devices both the total capital outlay
[outlay- An amount spent; an expenditure] and the operational cost should be
taken into consideration. The capital outlay includes the cost of equipment, the
cost of its erection(bulding) and transporting and constructing costs involved in
35 its installation and operation.
 Cont…
The difference in the cost of building and structures which can be serviced by
alternative transporting facilities should also be considered when comparing
capital outlay.
Operational costs include:
1. Wages(earning) and salaries of the personnel plus additions for social
services
2. Cost of electric power
3. Cost of lubricating, wiping, rigging and other materials
4. Cost of repairs and maintenance

36
 HOISTING EQUIPMENT (Lifting, lowering or elevating equipment)
a) Lifting and lowering equipment: These are used in the operation of lifting a
load, Handling them in suspension, Lowering and placing them at required
locations.
b) Elevating equipment: Vertical motion over fixed vertical or steep inclined
routes with continuous or with intermittent motion is followed by these
equipment.
Hoisting- [To raise; to lift; to elevate; especially to raise or lift to a desired
elevation, by means of tackle].
Tackle-[a mechanism or apparatus, as a rope and block or a combination of ropes
and brakes, for hoisting, lowering, and shifting objects or materials]

37
 HOISTING EQUIPMENT CAN BE CLASSIFIED INTO THE
FOLLOWING THREE GROUPS
1. HOISTING MACHINES
Hoisting machines are a group of periodic action devices designed as self-lifting gear, or for
hoisting and moving loads, or else as independent mechanisms of cranes and elevators. The
hoisting mechanisms are generally required to facilitate other operations, transport, assembly,
mounting on a machine tool.
The jacks, pulleys, hoists, special purpose monorail, winches, crane trolleys etc. are the
main hoisting machines.
2. CRANES
Cranes are combination of separate hoisting mechanisms with a frame for lifting or both for
lifting and moving loads which can be freely suspended on or secured to them.
3. ELEVATORS
Elevators are a group of periodic-action machines intended for rising loads or passengers in
38 guideways.
 1. HOISTS
Hoists are devices for lifting or lowering the loads suspended from a hook on the end
of retractable chains or cables.
The loads are generally supported from overhead by a hook or travelling on a track.
These devices are rugged, simple, dependable, easy to install, versatile, and
economical.
 Hoists have limitation of handling lesser loads, slow, manual operation, and fixed
path and require an overhead support.
Hourly capacity of hoisting machines can be expressed by the formula:
C = n.Q. tons/hr.
where, C = Hourly capacity of hoisting machines;
n = Number of machine cycles per hr.
Q = Weight of live load, in tons
39 When handling unit loads, Q = weight of 1 unit load
 Cont…
When handling bulk materials, Q = V.w.Ø
where, V = Capacity of grab, bucket etc. in cu m.
w = weight of one unit volume of materials in
tons/
Ø = filling factor

40
 COMPONENTS HOISTING EQUIPMENT
Hoisting equipment include following components:
o Flexible hoisting appliances (chains and ropes),
o Pulleys, pulley systems, sprockets(wheel with teeth) and drums,
o Load handling attachments,
o Stopping and braking devices,
o Drives (motors)
o Transmissions,
o Transmission components (axles and shafts, bearings, clutches
etc.)
o Rails and travelling wheels,
o Machine structures (crane frames)
o Control devices.
41
 EXERCISE
Section
1. Discuss the factors to be considered while selecting material handling equipment.
2. Discuss the different material handling equipment.

42
 TYPES OF HOISTING MACHINES
1. JACKS: The jacks are simple lifting devices which are directly applied to the
load to be lifted. The jacks are commonly employed in repair and erection
jobs to lift loads through a short distance, say 0.3 to 1.0 m. Jacks may be
classified as:
a) Rack and Lever jack b) Rack and pinion Jack
c) Screw Jack d) Hydraulic Jack

43
 Cont…

44
 Cont…
2. PULLEYS: A pulley is a small sheave or wheel with a grooved rim usually
mounted on pin on which it turns, a frame or block in which it runs and with a
with a flexible rope or chain passing through the groove.
A unit consisting of one or more sheaves mounted in a frame is known as
‘block’. Block is mostly equipped with an eye, or a hook at one or both ends of
the frame, by which objects can be attached.
In pulley system fixed or movable pulleys are connected in different
combinations.
The system of pulley block is used for lifting loads through vertical distance
and is most simple and inexpensive in cost.

45
 Cont…
This is one of the oldest systems of getting mechanical advantages.

Fig. Pulley system

46
 3. Winch
Definition and Uses
Winch is an equipment for pulling a heavy load by winding one or two
ropes on a rope drum. It is a stationary equipment which is fixed to the
floor or wall.
Winches, like hoists, are rugged and simple equipment with minimum
maintenance. Winch may be hand operated or motor powered.
Winches are used as an independent pulling equipment at construction
sites. However, they are also used as an integral part of various other
equipment like skip hoist, certain types of cranes etc.

47
 Constructional Features winch
The main component of a winch is the rope drum, supported by bearings at two ends
mounted on the winch frame. The frame may be made of cast iron or fabricated from steel
plate. The rope drum is generally single and plain, where rope is wound in multiple layers.
In sophisticated application as in a carne, the drum is grooved in two halves (double drum)
for winding two ropes simultaneously. Suitable mechanism is provided for guiding the rope
for proper laying on grooves during winding. The drum is connected to input effort through
a series of gearing of suitable reduction ratio, which determines the ultimate pull in the
rope corresponding to the torque applied at the input. In hand operated winch, the torque is
applied by a handle of suitable arm length. A ratchet-pawl type arrestor mechanism is an
essential feature for a winch. The arrestor ensures no unwinding of the drum when the input
effort is withdrawn. In power-operated winch, a motor of suitable power-torque capacity is
connected to the gear train through a coupling. In an electrically driven winch, a
magnetic or thrustor brake is used in place of pawl-ratchet mechanism for parking as
well as controlling load lowering. The coupling between the motor and drive system is used
as a brake drum on which the brake is applied. Such couplings are called brake-drum
48
coupling.
 Cont…
3. WINCH: Winches are used to lift loads vertically by winding the rope or cable on
a drum. These can be operated manually or by power to get a much greater
mechanical advantage than that obtained with the help of block and tackle (pulley
system). It is frequently used in loading heavy equipment into ships, building
construction and in similar other jobs. Capacity of a winch can be increased by
increasing the number of gear trains. These are very useful, simple and low cost
equipment for lifting heavy loads.
Ratchet brakes may be fitted on the winch to
hold a suspended load and to prevent reverse
travel of gears and thus provide safety against
accidental dropping of load.

Figure shows a Winch

49
 Cont…
POWER HOIST
The simplest is the chain hoist, which is operated by hand. There are also hoists
operated by compressed air, diesel engine, or by electric power.
The hoists are smaller to elevators except that, a hoist does not carry the
operator in it, but is operated from one or two other points.
Hoists used for - short distance horizontal hauls are suspended from trolleys
or carriers travel ling over an overhead single rail track, commonly a rolled I-
beam. In this case trollies are pushed by hand for capacity less than 1ton or they
are fitted with hand or mechanically operated drives.

50
 Cont…

51
 Cont…
ELECTRICALHOISTS: Electrical hoists capable of hoisting speeds between 5
and 25 m/min are available in capacities ranging between 0.25 and 15 tons. The
speed of their travel over a single-rail track varies depending on the distance to be
covered and the purpose the hoist serves. Electric hoists are of two types: floor
controlled and cabin controlled. A floor-controlled electric hoist has travelling
speed of 32 m/min or less. Higher speed hoists are controlled from an overhead
cabin. Such monorail hoist carrying trolleys are used for transferring loads from
shop to shop, in stock-piling and reclaiming operations, in charging cupolas, etc.
In this case, handling attachments used are: hook, lifting magnet or a grip adapted
to handle unit or bulk materials.

52
 Electric hoists: An electric motor driven hoist has one or two rope drums
for coiling and uncoiling the hoisting wire rope. The hoisting motor drives
the drum through a planetary gearing system. The gearing system with high
reduction ratio serves dual purpose of increasing torque as well as reducing
speed of hoisting. 2-speed motors may be used for obtaining two hoisting
speeds. The lower speed is employed at the start of hoisting or at the
finishing stage of lowering the load, to avoid heavy jerk on the rope and
pulley system or impact of the load with the floor. The rope is connected
with a hook).
The trolley for travelling hoist may also be powered by another motor.
Motion from the motor is generally transmitted to the wheel through three
pairs of spur gears. The motors of an overhead electric hoist is controlled by
a pendant switch box hanging from the hoist frame at a convenient height for
operation from floor level.
53
 Cont…

Electric Hoist Floor Controlled Cabin Controlled

54
 Cont…
5. WORM-WHEEL HOISTS:
In these hoists, worm-wheel arrangement is employed with two chains. There uses
two chains one is called the hand chain while the other as the load chain. The pull
applied to the hand chain is transmitted to the load chain after being multiplied by
the mechanical advantage.
·The worm is mounted on the shaft of load chain wheel and moves when this
chain is pulled, while the wheel is provided with an extended hub to which two
load sheaves are screwed.
The load chain is reeved (to pass a rope or rod through a hole, ring, pulley, or
block) over these two sheaves and the load hook is secured to both ends of this
chain. As the worm rotates the rotation is conveyed to the load sheaves through the
wheel, and this raises or lowers the load depending upon the direction of pull of the
hand chain. To pass (a rope or rod) through a hole, ring, pulley, or block.
55
 Cont…

Figure shows Worm-wheel hoists

56
 Crane

57
CRANES: Cranes have wide application in construction projects, industries and in
shipping etc. These are used for lifting the loads (may be construction materials, loose
materials, packages, containers, finished and semi finished products in industries etc.)
and placing them at desired place. For this purpose the cranes have three motions in
general, namely hoisting, derricking and slewing.
The cranes are generally electrically Operated; diesel operated or may have diesel-
electric drive. The cranes can be classified
as following classes:
1. Derrick cranes.
2. Mobile cranes.
3. Hydraulic Cranes
4. Overhead cranes, also known as Gantry cranes.
5. Traveler Cranes
6. Jib Cranes.
58
7. Tower cranes.
 1. DERRICK CRANES
Derrick crane consists of a mast, a boom, a bull wheel on which it rotates
about a vertical axis, and supporting members (also known as guys).
These cranes are very widely used in construction projects, industrial and
mufti-store building construction, plant erection, loading and unloading of
cargoes at ports, ship building etc.
When used with grabs it can handle loose materials like sand, ballast, coal etc.
The derrick cranes are supported by a number of guys.
The boom can revolve through 360° and can pass below these guys.
A bull wheel is attached to the mast and rotates it.
These are operated by either a diesel engine or by an electric motor.
The mast is generally supported by guy ropes but when this is replaced by
trussed structure it becomes stiff leg derrick .
59
 Derrick crane
Derrick is an apparatus consisting of one or two masts or fabricated strut members
supported at the bottom by a pivoting arrangement and held at the top by guys or
braces, with or without a boom, for use with a hoisting mechanism and operating
rope, for lifting and lowering a load and moving it horizontally.
Derricks are principally used in construction work for erection of technological
structures and heavy components to a height.
 Advantages of derricks are: (i) inexpensive, (ii) very easy to erect and
dismantle(to take equipment apart/separate piece), (iii) simple in design and
may be fabricated easily at the working site, (iv) a number of derricks may be
used together for manipulation of a large and/or weighty component. Derricks
may be of different types. Some of the common types of derricks have been
described below

60
 (a) Guy Derrick:
Derricks may be of different types. Some
of the common types of derricks have
been described below:
(a) Guy Derrick: A fixed derrick
consisting of a mast mounted on a turntable
and capable of being rotated, supported in a
vertical position by guys, and a boom
whose bottom end is hinged or pivoted to
move in a vertical plane with a reeved rope
between the head of the mast and the boom
point for raising and lowering the boom,
and a reeved rope from the boom point for
raising and lowering the load.

61
 (b) Gin Pole Derrick:
(b) Gin Pole Derrick: A derrick
without a boom. Its guys are so
arranged from its top to permit
leaning the mast in any direction.
The load is raised and lowered by
ropes reeved through sheaves or
blocks at the top of the mast.

62
 (c) A-frame Derrick:
(c) A-frame Derrick: A derrick
in which the boom is hinged from
a cross member between the
bottom ends of two upright
members spread apart at the lower
ends and joined at the top; the
boom point secured to the
junction of the side members, and
the side members are braced or
guyed from this junction point.

63
 Cont…
In this case the mast is supported at its upper end by two braced stiff leg, therefore
the boom crane rotates through angle of 270° to 290°.
The derrick cranes are sometimes mounted on rail wagons for quick transportation
and for working near rail lines, and are known as Wheeler cranes.
These cranes are available up to capacities of 40 tones with 25 meters boom length
and 15 meter work radius.
The Derrick cranes can be used as Tower cranes for the purpose of errection of high
industrial and residential buildings of height 100 meter or above .
 The Derrick cranes are also designed to work as Port tower cranes (for use in ports
for container and general cargo handling), as shipyard cranes (for use in ship
building and ship repairing works with longer capacities and larger working radii).
64
 2.Mobile crane
Definition: A truck or mobile crane consists of an upper carriage with front
end attachment such as a box or lattice type boom and optional jib (boom
extension). The upper carriage with attachment rotates 360° on the
undercarriage or truck chassis (carrier frame). The carrier also features the
adjustable front and rear outrigger box assemblies.
Truck (mobile) cranes are utilized in many scrap yard applications and are
equipped with wire rope suspended implements such as grapple, clamshell,
crane hook, or electric magnets.
In such applications the machines are exposed to a wide range of hazards
during normal operation, not only to the operator but also to the
maintenance personnel and others nearby.
65
 Carrier mounting of mobile crane

66
 Crawler mounting

67
68
69
 2. MOBILE CRANE
A. CRAWLER MOUNTED CRANES
 Crawler mounted cranes are highly maneuverable and have the ability to operate on
unmade ground.
 Long wide crawler mountings and wide crawler shoes give low ground bearing
pressures and they improve crane stability.
 Since these move slowly, they are used in rough terrain where truck mounted cranes
cannot travel and required to operated in a limited area.

70
 Cont…

71
 B. WHEEL MOUNTED MOBILE CRANES
Wheel mounted mobile cranes are generally truck mounted and have high
mobility, and can travel up to 70 to 75 km per hr on good roads.
These are designed for long distance travel with high road speeds.
The number of axles and drive depends upon load lifting capacity and the length
of the boom.
These cranes can operate on firm ground.
For increasing base width and to improve stability during operations, outriggers
are used.
The mobile cranes have four motions viz., hoisting, and derricking, slewing and
travelling.
Thus it has travelling motion as an extra feature as compared to Derrick cranes.

72
 C) RAIL-MOUNTED CRANES
Rail-mounted cranes are also manufactured to move on rail tracks.
Such cranes are used in steel industry, dockyards and railways .
These cranes can be driven by steam engines, by diesel engines or by electricity.
These are designed to suit the railway gauge clearances available, so as to enable
negotiating while travelling, to lift high loads such as required for salvage
operations after accidents etc.

73
 3.HYDRAULIC CRANES
Hydraulic cranes are usually truck-mounted cranes.
All operations of these cranes are hydraulically powered including extension
and retraction of out riggers, extension and shortening of boom.
The hydraulic power is supplied through oil pressure, generated by rotary oil
pumps.
Because of simplicity, quick change of boom length and easy and quick change
of angle, mobility and maneuverability of the telescopic boom, no requirement
of a separate crew for extending or shortening of the boom, these have attained
the wide popularity over conventional cable operated, latticed boom.
Besides, the operations of hoisting, slewing and derricking can be performed
Simultaneously and that too without any jerks which are unavoidable in
conventional cranes.
74
 Cont…
Craning arrangement: The crane consists of a hollow vertical post (known as
mast) to which a jib and a tie is attached as shown in Fig. 8.48. The mast is
supported on a bearing and can be revolved with its vertical axis, so that load
from all directions can be handled. The jib can be raised or lowered together
with the load.

75
 Cont…
Working: When the ram is at the end of the stroke, water under pressure is
admitted in the cylinder. This water forces the ram to go in outward direction.
While ram is making outward stroke, the Wire rope is pulled and the heavy
weight hanged with the hook will be lifted upward.
The mast can be revolved in a desired direction, for placing load, water from the
cylinder is then taken out and ram makes inward stroke. Thus the hook with load
comes down on the ground.

76
 4. OVERHEAD AND GANTR Y CRANES
These are used for handling loads over a long rectangular area in factories, power
stations, in shipyards and in workshops.
The simplest form mainly consists of (i) structural bridge support on elevated tracks and
(ii) supporting a lifting block or hoist trolley.
Control is from a cabin on the bridge or by pendant; at floor level.
Due to freedom from floor obstructions, these are widely used in erection(straight
up righting position), foundries, steel plants, power houses, shipyards etc.
The bridge consists of two main girders which are fixed at the end and supported on tram
wheels and can move on gantry rails.
The hoist trolley also known as crab is supported on these girders and is capable of
travelling across main girders.
Thus load hook has three motions viz. hoisting i.e. lifting and lowering; cross travelling
with trolley in both directions; and longitudinal traversing with the bridge in both
directions.
77
 Cont…

78
 Gantry crane

79
 5. TRAVELER (OR GOLIATH) CRANES
These have their crabs (hoisting trollies) moving on girders which are supported on legs
instead of overhead gantry tracks as used in overhead cranes.
The legs moves on tracks laid on the floor.
Since these do not need overhead gantries, hence are very useful as dock site cranes for
lifting cargoes, in shipyards and in docks etc.
6. JIB CRANES
A jib crane is a typical revolving crane.
It has a horizontal jib.
It has the appearance of an arm that extends over a work area.
A hoist is attached to the arm to provide lifting capability.
The arm can-rotate and the hoist can move along the arm to achieve a wide coverage .
It may be projected from a wall, attached to a self-supporting mast (pillar) or
mounted on a column.
80 Different types of jib cranes are shown in figures below
 Cont…..
It is a stationary crane consisting of a vertical member (called pillar or
column) from which extends a horizontal swinging arm called jib, carrying a
trolley hoist or other-hoisting mechanism.
The jib is generally made from a standard I-beam section, and can rotate in a
horizontal plane (i.e. no luffing motion) between 180° up to 360°, so that
loads can be lifted and deposited within the sector of circle having its radius
equal to the length of the boom. The extreme end of the arm is often
supported from the vertical member by a tie rod.
A normal jib crane is generally limited to a jib length of 8meters and hoist
capacity of 15tons.

81
 figure of Jib crane

82
 Jib cranes are inexpensive and widely used in manufacturing
industries for:
serving individual or a group of work places in machine shops.
loading and unloading of vehicles.
handling ladle, casting and mould in a foundry.
moving loads across shop bays and thus supplementing on overhead traveling
crane.
(A) Revolving pillar jib crane in which the pillar or vertical column consists of a
structural pipe. On the top of the column a thrust bearing of sufficient capacity is
mounted, on which the jib constructed from a standard I-beam is mounted The jib
can rotate by 360° on the fixed column. The column base is bolted to the floor/
foundation or directly grouted in foundation. A manual or powered trolley type
hoist is mounted on the jib. Stops are provided at the end of the track to prevent
over travel. See the next figure of revolving pillar jib crane
83
 Revolving pillar jib crane

84
 (B) Swinging pillar jib crane in which the jib and it’s tie rod are connected to the vertical column through
swinging fitting supports, welded with the column. The fittings allow swinging of the jib and the tie by about
180° about the fixed column.
(C) Swinging bracket supported jib crane is similar to a swinging pillar jib crane, excepting that there is no
independent vertical column. Instead, the swinging fittings are wall-bracket type which are fixed on a vertical
wall. This jib crane has maximum 180° rotation.
(D) Revolving mast jib crane is one in which the vertical column or mast is supported at the top and bottom
on bearings. The jib is bolted or welded to the column. The jib is supported by tie rod. The jib can rotate along
with its supporting column.

85
Revolving mast jib crane
 (E) Rotary girder jib crane is similar to a swinging bracket supported jib crane without a tie rod.
Instead, the end of the jib is supported from a trolley by a chain, while the trolley is supported from
a circular girder fixed to the roof or roof struts.
(F) Travelling jib crane is a special type of jib crane which consists of a cantilevered arm similar
to the bridge girder of a overhead traveling crane. One end of the girder is held from the side
wall, and supported over wheels on rails laid parallel to the wall. A motorised arrangement drives
the wheel and makes the arm to travel along the wall. The hoisting device travels along the arm.
Travelling jib crane serves the purpose of a bridge crane for lighter loads.

86
 (G) Fixed-tower hammerhead jib crane is a special type of jib crane,
which is built in capacities from 6 te to as high as 350 te. The jib of this
crane is of struss structure and looks like the head of the hammer, hence the
name. The jib is mounted on a fixed tower. The front portion of the jib
supports rail upon which one, two or three crane trolleys travel, and the rear
portion of the jib houses the machinery for hoisting, trolley travel and
slewing arrangement as well as necessary counterweight. When two trolleys
are used, they are arranged to be operated individually or simultaneously.

87
88 Figure of Fixed-tower hammerhead jib crane
 7. TOWER CRANES
 Tower cranes are used in various construction projects of high buildings, bridges, cooling
towers, television towers or power plants.
The construction of the tower crane is such that it can work and then dismantled in restricted
space. 
The tower has a truss structure welded from angle bars and channels.
Tower extension pieces are available to increase the height as per requirement. Ladders are
provided inside the whole height of the tower.
An operator's cabin is provided so as to enable full view. Jib is attached to the last highest
section of the tower .
Two sections of the jib, opposite to one another, are provided, one is saddle jib and another 1s
counter weight jib.
A saddle moves horizontally on rails provided on the saddle jib and is controlled from the
hook block.
The upper portion of the tower is fixed on the slewing head.
89
90
 Cont…

91
92
 ARRESTI NG GEARS AND BRAKES
In hoisting equipment, use of arresting gears or brakes is of paramount
importance to prevent the raised load from getting lowered of its own weight,
when the raising effort is withdrawn.
 Arresting gear is used to hold the load lifted by winches.
The common arresting gears are:
(a) PAWL AND RATCHET mechanism i.e. ratchet gearing. This comprises of
ratchet wheel and a pawl. The ratchet teeth can be arranged external or internal to
the wheel. The teeth are so designed that the ratchet wheel runs free over the pawl
when the load is being raised, but the pawl gets engaged with ratchet tooth when the
ratchet wheel tries to rotate in opposite direction (lowering direction of load).
During lower ing of load, the pawl has to be kept deliberately away from ratchet
93 path.
 Cont…
(b) ROLLER RATCHET or roller clutch is used as an arresting gear in
combination with a brake.
Brakes are used for dual purpose of holding the suspended load at rest and for
controlling the speed of lowering of load.
Some of these brakes are to be operated while some are automatic. Operated
brakes i shoe, band, cone, disk brakes etc. Centrifugal brakes and brakes
applied include by weight of the load are the automatic types.
Actuation of the operated brakes may be through pulling a handle or by
pressing a pedal which are termed as mechanical brakes. Actuation can be
through energizing magnet by AC or DC electricity (electromagnetic brakes)
or may be by hydraulic means (electro-hydraulic thruster brakes).

94
 Cont…
The electromagnetic brakes and electro-hydraulic thruster brakes can be used as
controlled brakes. Moreover, these brakes can also be used as fail safe device.
Normally these are in open condition (brake is not engaged), but actuates when
the power fails. Figure below shows line diagrams of an electromagnetic brake
and a thruster brake.

Line diagrams of an electromagnetic brake and a thruster brake

95
 Assignment – 2: 5%-individual-A
1. What are the desirable characteristics of material handling equipment?
2. What are the main groups of material handling equipment?
3. Differentiate between hoisting and conveying equipment.
4. Write all the factors to be considered during selection of materials handling
equipment.
5. Explain Principal technical factors that can be pointed out for guidance in the
choice of the types of devices which can be expediently employed to mechanize
any handling process

96
 Assignment – 2: 5% Individual-B
1. What are the components of hoisting equipment?
2. Explain Winch with a neat sketch
3. Explain Derrick crane.
4. Explain various mobile cranes.
5. Explain the features of Hydraulic crane.
6. Explain the construction and working of a hydraulic crane with a neat sketch.
7. Explain Overhead and Gantry cranes with sketches.
8. Explain various Jib cranes with sketches.
9. Explain tower crane with a neat sketch.

97
 End of chapter-2!
Read and study hardly.

98