MESFI INDUSTRIAL ENGINEERING plc.

FACULITY OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT DESIGN DEVELOPMENT OF PORTABLE LIFTING CRANE IN PRODUCTION SHOPS

CASE STUDY IN MESFIN INDUSTRIAL ENGINEERING plc. HDVL Bu Production MEKELLE,
ETHIOPIA

Prepared By

 Robel Kalayu Debre Markos univerity

 Dawit Ngusse DebreMarkos University
 Dawit Tsegabrhan Asossa University

 Sumitted to; Mr. Kiflom

Supervisor of HDVL Bu Production
Contents
Abstract....................................................................................................................................................3
Keywords.................................................................................................................................................3
1. Introduction......................................................................................................................................4
1.1 Background...............................................................................................................................4
1.2 Definition of portable crane...........................................................................................................5
2. LITERATURE REVIEW.................................................................................................................7
3. Statements of problems......................................................................................................................10
4. Objectives of the research project.....................................................................................................11
4.1 General objectives........................................................................................................................11
4.2 Specific objectives........................................................................................................................11
5. Methodology......................................................................................................................................12
6. Material Selection.............................................................................................................................12
6.1 Material for vertical column.........................................................................................................12
6.2 Material for the boom and base plate...........................................................................................12
6.3 Material for the crane hook..........................................................................................................12
6.4 Material for Bolt...........................................................................................................................12
6.5 Material for the Pins.....................................................................................................................12
7.Design analisis....................................................................................................................................13

2
 1. Introduction
1.1 Background
The development of lift machine or crane has reached through different time starting the first crane
for lifting heavy load was invented by ancient Greeks in the late 6 th century BC. The heydays of crane
in ancient times come during Roman Empire when construction activity soared and buildings reached
enormous dimensions. The Romans adapted the Greeks cranes and developed it further.
The simplest Romans crane is the trespasses, which consists of a single beam jib, a winch, a rope,
and a block containing three pulleys. Having this mechanical advantage of 3:1, it has been calculated
that a single man working the winch could raise 150kg [as estimated in each of the pulley carrying
capacity of 50 kg which gives 3pulles*50kg=150kg in here it is assumed that 50kg represent the
maximum effort of a man can exert. Over a long time period heavier crane type featured five pulleys
(pentaspastos) or in case of the largest one a set of three by five pulleys (polyspestos) and came with
two, three, or four masts depending on the maximum loads.
The polyspestos when operated by four men at both side of the hoist could readily lifts 3000kg
(3 ropes*5 pulleys*4 men*50kg=3000kg)
If the winch was replaced by a trade wheel, the maximum load could be doubled to 6000kgs, because
the trade wheel have much bigger mechanical advantages due to its higher diameters. This means
comparing with the construction of Egyptian pyramid where in 50 men are needed to move 2.5 tons of
stone up the ramp (50kg per persons). The lifting capability of the Roman polyspastos is proved to be
60 times higher than the Egyptian system of lifting stones.
During the high middle age the trade wheel was introduced on large scale after the technology had
fallen in the Western Europe with dismiss of Western Roman Empire.
The earliest reference to the trade wheel reappears in the archival literature in France about 1225.
Generally vertical transport could be done more safely and inexpensively by crane than customary
method. Typical areas of application were harbors, mines, and in particular building sites where the
trade wheel crane played a pivoted role in the construction of lofty Gothic cathedrals.
In contrast to the modern cranes, middle age cranes and hoists –much like to their counter parts in
Greece and Rome were primarily capable of a vertical lift, not used to move loads for considerable
distance horizontally as well. It is not worthy that middle age cranes rarely featured ratchets or brakes
to forestall the loads from running backwards. This curious absence is explained by a high friction
force exercised by middle age trade wheels, which normally prevented the wheel from accelerating
beyond control.

3
 With the onset of the industrial revolution, the first modern cranes were installed at Harbors for
loading cargo.
In 1838, the industrialist and business man sir William Armstrong designed a hydraulic water
powered crane .His design used a ram in a closed cylinder that was forced down by a pressurized fluid
entering the cylinder. Thus the valve on the cylinder regulates the amount of fluid intake relative to
the load on the crane [1].
1.2 Definition of portable crane
Portable lifting equipment is a large component of any mechanical shop. This can be achieved
through the use of forklifts, chain lifts, etc. While motor-powered equipment is expensive and
requires maintenance and fuel, manually operated lifts are inexpensive and do not require much or
any maintenance. Ease of maneuverability is a big issue for most shops along with variable terrain.
The portable crane is a product selected into the application of design axiom for this project.
Portable crane is a small crane that can be broken down into several parts for ease of transportation. It
must be assembled and bolted into a place where to be used effectively. Portable crane designed for a
whole range of floor lifting job. They are transportable and require no external power. They can be
used where no overhead lift is available and relatively short lift required. It also increase efficiency
and productivity while decreasing operator bending and risk of back injury. The portable crane is
widely used in mechanical engineering filed for assist any heavy duty job.
There are various types portable crane that are available in the market with a various function and
features.
Now a day scholars related to this fieldcategorizes the type of portable crane are divided into 3 types
accordingly let’s brief them
A. Types of portable crane
Thus cranes are broadly categorized into three
1) Overhead crane
2) Fixed cranes and
3) Mobile crane
1) Overhead crane
It is being used in a typical industrial shop. The hoist is being operated via a wired push button
station to move system and load along any direction .un overhead mechanism crane is also known as
abridge crane where in the hook and by line mechanisms runs along two widely separated rails.
Overhead crane is typically consists of lifter single beam or double beam construction. It can be built
by using typical steel beam or more complex box grinder type. Double Grinder Bridge is more typical
when there is a need for heavy capacity system of 10tons and above.

4
 The basic components of overhead cranes are the hoist to lift the item, the bridge, a trolley to move
along the bridge. Most of the time over head cranes are applicable in steel manufacturing industry and
vehicle/truck production industry
2) Fixed cranes
Fixed cranes are preferable in order to insure the ability to carry heavy reaches greater heights due to
increased stability. These types of cranes are characterized by the fact that their main structures does
not move during the period of use. However many can still be assembled and disassembled. The
structure basically is fixed in one place. There are many different types of fixed cranes such as Tower
cranes, self-erecting, telescoping, Hammerhead, Gantry cranes, Deck cranes, jib cranes, and bulk
handling cranes. However most of them are used under construction sites. Only few of them like jib
cranes Gantry and deck cranes are used in mechanical engineering operations.
3) Mobile cranes
For effective and versatile operation cranes can also made to be mobile. Mobile cranes are designed
in different manner in order to be used on the road, rail, water and air. There are many different kinds
of mobile cranes. That are truck mounted, side lifter, rough terrain, all terrain cranes, pick, and carry
cranes, telescopic handler crane crawl crane, pail road cranes, floating Aerial crane and also portable
crane.

5
 2. LITERATURE REVIEW
In our assess the projected make before we have tried to see the projects from those
 LK Goodwin CO. is a material handling Equipment Company that sells many types of hoist’s
and cranes for certain applications. Looking through their list of portable hoists, a 2 ton has a
cost around $2500 for a non-adjusting height crane and would have an equivalent rating to the
one being designed. These hoists come with casters but the trolley and chain hoist must be
purchased separately. Below is an example of a basic portable gantry hoist design.

Figure 1: Basic “A” frame gantry hoist (LK Goodwin 2012)

 This design is relatively easy to assemble while it is lying down but would most likely require
two people to stand up. Using two people to stand up the hoist after assembly seems to be an
unavoidable factor in the design.
 The Cal Poly Rose Float club has a gantry hoist (3 ton Capacity) which was quickly examined
to get a different idea of how the column and frame could be designed. After looking at the
frame it was easy to see that the legs were designed poorly; they were built with 3”X6”X3/16”
rectangular tube which is strong but the “A” frame design means the legs will start deflect due
to the resolving bending moment and the rectangular tube was oriented to bend about its
weaker axis seen in Figure 2. This also allows for someone to be underneath the frame when
it could potentially fail making it a severe safety hazard. The hoist beam is an S15X42.9 and
spans around 26ft without support of the compression flange making its L b value 26ft as
shown in Figure 3. Adding support (drawn in Figure 3) would reduce the travel of the trolley
slightly but would improve the overall safety of the design by reducing the beam’s L b value.
This is a very long length to span without supporting the compression flange and using the
AISC Steel Manual page 3-82 the beam’s L p=4.41ft and Lr=16.8ft. Since Lb>Lr the critical

6
 force Fcr was calculated and found to be 15,100 lbs which means the 3 ton capacity is
allowable.

Figure 2: Rose Float “A” frame gantry hoist

Figure 3: Rose Float gantry hoist, no support of the compression flange

 The AISC Steel manual will be the book used to help calculate the maximum load the beam
available can handle and how much the beam will deflect with the assumed load on it. The
compression flange is the main factor to design around when using a beam whether it is an “S”
or “I” beam. This can also be used for the column calculations to find what point load will
cause the columns to buckle. Shigley’s Mechanical Engineering Design book shows how to
calculate the loads on the beam supports and gussets along with the Mohr’s circle to find the
max shear and normal stresses. This will help find the Factor of Safety for the frame of this
design.

7
 Figure 4: Jet 3.2-ton hoist (CPO Jet Tools 2013)

 BISHOFTU AUTOMOTIVE INDUSTRY they have designed portable crane that’s helpful in
providing materials and transporting materials from one place to other using hydraulic system

Fig 5: portable crane (2017)

 Regarding to our project we are focusing on modification and design development of portable
crane with hydraulic system and to improve the capacity of lifting equipment with help of
selected materials that can be easily usable at Mesfin Industrial Engineering department of
production.

8
 3. Statements of problems
In MESFIN INDUSTRIAL ENGINEERING plc. there are seven departments from material
preparation to final production which is final desired product. From those departments we have
visited most of them and there we have observed many problems and challenges that should be solved
to improve effective work, time and economically. For example HDVL Bu Production department
there are only overhead cranes and most all shops.Additionally inFTU, FTR, some components like
lower torque rod, v-torque rod, fuel tank …etc. are carried by man power to be assembled.
All of the components are transported from store to the shop by using fork lift and this needs cost
for fuel consumption, not easily accessible specially with fork lift, and transporting needed
equipment’s from nearby the shops to transport needs fork lift In addition to this electrical power is
needed to operate the crane ,this means if there is no electrical power the factory is obliged to wait for
the electrical service during this time workers are expected that they are working and this is another
loss of cost for the man power.

9
4. Objectives of the research project
The project is going to held by the guides of general and specific objectives.
4.1 General objectives
The general objective of the research project is to design and develop moveable lifting crane to lift
heavy loads that is beyond the capacity of human being applying only small force in the HDVL Bu
production shops.
4.2 Specific objectives
Detailed objectives we going to focus on are
 To design analytically the portable lifting machine lift slightly heavy objects that can’t be carried
by single worker
 To determine the overall cost of the crane production
 Finally, to documentation of the research project

10
 5. Methodology
The methodology incorporated in design and development of portable crane in the production shop of
MESFIN INDUSTRIAL ENGINEERING plc. Department of HDVL Bu Production is indicated as
follows;
• Observation in different departments and shops such as; material preparation, production of
tanks, assembling high track Vehicles, Power house, raw material usage and management
• Problem identification specifically in Bu production shops
• Data source specifically regarding the company identification, collection and analyze;
• Development of suitable system configuration It should have moveable wheel attached base,
hydraulic link, basic vertical column, and connections
• Design analysis of each components of the portable crane
• Development of working crane prototype for the application

6. Material Selection
Material selection is a means of selecting material that best suited for the member of machine to be
designed. As a designer material selection should be done carefully in order to design each
components, that will serve till the end of service life. The basic considerations done in selecting
materials are; Strength, Machinability, Toughness, Ductility, Hardness…etc. for each components of
the crane.
6.1 Material for vertical column
Load that the vertical column subjected to is compressive, and material for the column is selected to
be cast iron, because it has low cost, good casting, and high compressive stress. It is primarily made
of carbon and iron with carbon content of 1.7% to 4.5%
6.2 Material for the boom and base plate
Since the load applied on these components is high the material used to make these components
should be strong and hard, thus the best material suited for is steel which has carbon content of up to
1.5% which results in an increased strength and hardness.
6.3 Material for the crane hook
Thus the crane hook is subjected to both tensile and compressive stress, and wrought iron is
selected for it, because it is malleable tough and ductile material. It has carbon content of0.02%,
0.12% silicon, 0.018% of phosphorus, 0.07%of slag, and the remaining is iron [2].
6.4 Material for Bolt
The material for the bolt is subjected to tensile and shearing stress and mild steel best fit the criteria
to resist these stresses and is selected as a material for bolt.

11
6.5 Material for the Pins
In our project pins are subjected to tensile and shearing. The material selected for the pin should be
ductile and we have selected mild steel.

12
7. Design Analysis the Parts

A. Design of vertical column

Vertical column is modeled as a strut or short compression member thus it is exposed to a
compressive stress and this stress is the sum of simple stress component and flexural (bending)
components [2].

σc= P / A MC)+/ I

= P / A (PecA+ )/ IA

Figure 1. Vertical column

Therefore: c=0.15m/2, e=1.6m
The column cross section subjected to compression
stress is

Figure 2. Cross Section of Vertical Column

The area of column cross section is

A =[0.15*0.13)-(0.116*0.136) ]m2= 3.724*10−3m2

Moment of Inertia
Ixx=[(0.15*0.13)3 −(0.136*0.116)3] /12
=0.97725*10-5

Iyy=[(0.13*0.15)3 −(0.116*0.136)3 *10−5 ] /12

13
 Iyy=1.22089*10−5m4

NOTE: Buckling always occur about the axis having minimum radius of gyration or least moment
of inertia, therefore in our case buckling occur along horizontal direction (Ixx).

K = Ixx / A= 0.97725*10 −5 / 3.724*103

= 0.051226891 m

σc= Pvc/ A(1+ ec / k2)

P = (3000) (9.81m / s2)

= 29.43 KN
Pvc= P / (cos12o)
= 30.1 KN
σc= 30.1KN /1.911*10− 3m2 [1+(1.6m)(0.075m)] / (0.051226891)m2
=15.751*106N/m2 [1+ 45.72832]

= 794.024*106N/m2

σc= 736.013MPa

 Referring to text book of machine design by KHURMI and GUPTA, The maximum value
of crushing stress (σc) that will develop in cast iron is given to be 400MPa to 1000Mpa.
Since the induced compressive stress due to the applied load is not greater than the
maximum crushing stress developed in the cast iron.
Therefore the vertical column is designed safe.
B. Design of Boom
The boom is modeled as simply supported beam, and it is subjected to a bending stress due to
bending moment developed at the fixed end where it is pinned with the vertical column.

Figure 3. Boom connected with

σb= M / Z

Where:

14
 • Z = section modulus
• M = Bending Moment at point A
• σb = Bending stress
Since the boom is hollow rectangular cross section, the area of boom to which the effect of load P
induces the stress is:

A =1.6(0.12-0.108)
A = 0.0192m2

Figure 4 Boom section vie

• Moment of Inertia
Ixx=1.6(0.12* 0.108) /12 m− 4
Ixx= 6.24384*10−5m4

• Distance from neutral axis extreme fiber (c), is;

c = (0.12) / 2m

c=0.06m

• Section Module(z)

z = I / c =[ 6.24384*10−5 / (0.06)]m4

z =1.04064*10−3m3

• Bending Moment , M is;

M = P*L, L=length of boom

= 29.43KN *1.6m
M=47.088*103Nm
σc= M / Z

= 47.088*103Nm / 91.0406*10−3m3)

σc= 45.25Mpa

15
NOTE: The material selected for the boom is standard steel Fe E-520-Indian standard designation,
and it has a minimum yield stress of 520Mpa and the allowable bending stress is;
σb=Sy / n,
n = factor of safety − which is assumed to be 4
= 520Mpa / 4
σb= 130Mpa, Allowable bending stress.

Since the allowable bending stress developed is greater than the induced bending stress due to the
load applied, then the boom is designed safe.
C. Design of crane hook
Hook is the component which is fixed with the boom and it is used for hanging the load on the
boom which moves up and down in lifting the load.

Figure 5. Plane view of crane hook

Figure 5.1. Cross section of crane hook

(From Shigley’s “Mechanical Engineering design”, 8th edition –Table 3.4)

16
 rc=ri+ h / 2
and
rn=h / ln(ro/ri).
Due to the applied load the hook is subjected to tensile and compression stress with moment
M=P*rc.
•Normal stress

σ= P / A + My/[Ae(rn −y)], rn−y=r

But rc= 3cm+4cm/2 = 5cm

rn=4 / ln(7 / 2) = 4.72 cm
e =rc − rn=(5−4.72)cm

e=0.0028 m

Cross sectional area at which the load act is,

A = 2cm*4cm=8cm2

A=8*10 −4m2.

Moment due to the load applied, M = P * rc, => 29,430N*0.05m = 1471.5 Nm.
→ Substituting r from 3 to 7 we can determine the stress developed in compression and tensile side.
For r = 3cm

σ= 29430N /8*10−4 + 1471.5Nm(0.0472−0.03) / ( 8*10−4 (0.0028)(0.03))

σ= 413.4215 Mpa.

For r = 4cm

σ= 29,430N / (8*10−4) + 1471.5(0.0472−0.04) / ( 8*10−4 (0.0028)(0.04))

σ=155.0255Mpa.

For r = 5cm

σ= 29,430 /8*10−4 + 1471.5(0.0472−0.05) / (8*10−4 (0.0028)(0.05))

= 0Mpa

For r = 6cm

σ= 29,430 /8*10−4 +1471.5(0.0472−0.06) / (8*10−4 (0.0028)(0.06))

σ= −103.3557Mpa

For r = 7cm

17
 σ= 29,430 /8*10−4 +1471.5(0.0472−0.07) / (8*10−4 (0.0028)(0.07))

σ= −177.1806Mpa.

NOTE, since the induced tensile and compressive Stress are less than for the crane hook, i.e.
wrought iron which have a stress of 250MPa to500MPa and 300MPa under tensile and compressive
respectively, then hook is designed safe. The ultimate tensile and compressive stress of the material
that is selected
D. Design of base plate
Base plate /Truck serve as a base for carrying all the weight of the proposed design project. In
addition it carries the load by all the components of the crane .It is composed of four bars and each of
them is modeled as a beam.

Figure 6. Base plate

Bar 1 and Bar 2 are side bars on which the center connecting bar is supported over. And the other is
end bar which is provided at the back end of the two side bars to give extra strength.
To know the stress developed in these components first we should know the all loads applied and
let’s first calculate all the masses of all the other components. Masses of vertical column:

Figure 6.1. Vertical column

• Volume vertical column

V = A*L

= [(150*130) − (136*1160)](1800 )
V = 6,703,200mm3
V = 0.0067032m3.

18
 Since the material for the vertical column is made from cast iron, the mass density of cast iron is
7250kg/m 3.

ρ= m / V, m=ρV

= (7250kg / m 3 )*(0.0067032m3 )

mv = 48.6kg, mass of Vertical column

Mass of Boom:

Figure6.2. Boom cross section The volume of the boom is

V = A*L

= [(1200*1200)−(1060*1060)] (1600)= 0.00506062mm3.

The boom is made of standard steel, and the mass density of steel is 7850kg/m3

ρ= m / V,m=ρV

=(7850kg / m3)(0.00506062m3)
m = 39.7kg, mass of boom
Mass of vertical column support:
V = A*h

V= [(60*70) − (52*62)] (1200)

V= (4200−3224)*1200

V = 0.0006048mm3.

Figure6.3. Vertical Column support

19
 The material for the support is selected to be cast iron, which have mass density of 7250kg/m 3.

ρ= m / V, m= ρV=7250*0.0006048
m = 4.4kg, mass of vertical column support.

Mass of crane hook

The cross sectional area of crane hook is assumed to be equal to thin circular plate of 6cm inner
diameter and 14 cm outer diameter having a thickness of 2cm.
V = A*t

=[π(do2 di2 )]/−4(t)

=π/ 4(7cm2 −3cm2) (2cm)

V = 62.832*10−6m3.
Since the material for crane hook is wrought iron, which have mass density of 7780kg/m3,

m =ρ*V= (7780) (62.832*10−6)kg, m = 0.5kg.

The mass of other components like hydraulic tank with the fluid, hydraulic cylinder , pin , bolts
with nut, all in one are estimated to be 25kg.Additionally the design is proposed to lift a load of
3000kg ,and the total mass applied on the base plate is,

mT= (48.6+39.7+4.4+ 0.5+25+ 3000 )kg

= 3,118.2kg

PT=mT*g
= 3,118.2kg*9.81m / s2 =3058954kN.
Center connecting bar:

Figure 6.4. Center connecting Bar

Due to the load P the bar is subjected to equal bending moment at both end of the plate. At both end
there are two reaction forces to encounter the bending of beam due to the load applied. And these are
equals to half the load applied.
R =15.294771kN

20
A = (200*80) − (193*73) mm2

A =1900mm2 =0.0019m2.

Section Modules

Z = (200*803−186*663 )

= 5.69*10−5m3

• Moment at the two end of bar

MA, B = (PT *L)/ 4

= 30.58954KN*0.516_m) / 4

M = 3.946051KNm

σb= M / Z

= 3,940.51Nm / 5.96*10−5m3

=661.159*105 N / m2

σb= 66.1159MPa, Induced stress.

The material selected for the center bar of the base plate is standard steel of Indian standard
designation FeE520, having yield strength of 520N/mm2. Taking the factor of safety equals 4.

σ= Sy / n= 520 /4 = 130 N / mm2.

Since the induced stress is less than the ultimate bending stress, then the bar is designed safely.
E. Design of pins
Pin 1
Due to the load applied at the end of the boom and the load by the boom itself, the pin that connect
the vertical column and the boom is subjected to shearing stress. The shearing force applied on the pin
that connects the vertical column with the boom can be obtained using the principle that summation of
moment on the pin that connects the actuator and boom is zero.

ΣMB = 0

0.7(RC) = 0.1(W) 0.9(P)

• W = (39.7Kg)(9.81m/s2)

W = 389.457N
• P =29.43KNRC =(38.9457 26,487)+/ 0.7
= 37,894.208N
21
 RC = 37.894208KN, Shear force on pin 1.

Figure 7. Pins of portable crane

Since the pin is subjected to high tensile and shearing stress, the material for the pin should be
ductile. And the material selected is mild steel. From Indian standard designation of steel (Mechanical
Engineering design by KHURMI and GUPTA, 8 th edition) - Table 2.5 we have selected Fe 690 which
has minimum tensile strength of 690N/mm2 and minimum yield strength of 410N/mm2.

τMax= σy / 2(n)

τMax= 25.625MPa.

Figure 8. Pin supporting vertical column and Boom

Thus the pin will be subjected to double shear and then the pin is designed as follow.
τ= P / 2A, P=Shear force,
A = Area subjected to shear stress
A = RC /2τ
πd2 / 4 = Rc / 2τ,
d= 2Rc /πτ
= (2*37.894208*1000N) 0.5 / (π*25.625N / mm2)
= 30.6827mm,

Say d = 32mm, Diameter of pin at lower extreme.

22
 When the actuator is at its upper extreme, the pin that is used to connect the vertical column with
the boom is designed as follow. Reaction at point C is obtained by applying the principle that
summation of moment about point B is zero.

RC (0.7) cos71.45°
= W (0.1) cos71.45°+ P (0.8) cos71.45°
RC = 389.45(0.1) (0.31813) + (29,430)(0.8)(0.31813) / 0.7((0.31813)
= (12.389+7490.0527) / 0.222691

RC =33,689.92N

d = [2*RC] 1/2 /π*t

= (2*33,689.92) / (π*25.625)

d= 28.93mm, diameter of the pin when the actuator is at its upper extreme.

Taking the larger of the two is safe, and the pin that connects the vertical column and the boom
should be 32mm of diameter. The length of pin is slightly made to exceed the width of vertical
column, that is

L = (150+15)mm
L =165 mm
Similar way;
For pin 2, d = 28mm
Pins for the Actuator, d = 74mm
F. Design of Hydraulic system
Hydraulic cylinder or also known as linear hydraulic motor is a mechanical actuator that is used to
give a unidirectional force through a unidirectional stroke. Hydraulic cylinders get their power from
pressurized hydraulic fluid, which is typically hydraulic oil. Design of hydraulic cylinder consists of
design of cylinder, design of piston rod, hinged pin, design of flat end cover design of piston,
Design of Cylinder
The main function of cylinder is to retain the working fluid and to guide the piston. Hydraulic
cylinder usually made of cast steel or cast iron, But for our design purpose we select cast steel
because of high heat resistance, easily machine able and low cost.
The values taken for our design are;

σt= permissible tensile stress

= 80N / mm2
p = maximum pressure inside the Cylinder
23
 = 3.5N / mm2
F = load that is applied on the actuator

= 212,615.4189 N.

Then, inner diameter of the cylinder is (di):-

F = p*di2 / 4 *p
di=(√4P /p*p) = (√4*212615.4189N / p*3.5N / mm2)
= 280mm, say,

•Thickness of the cylinder;

Let, t= thickness of the cylinder

t = ri{( √σt+p) / (σt− p) −1}

Where, ri = di/2= 280mm/2=140mmt= ^>PP^¥1PP2 + 3.5N/mm2)/ 80N/mm2

- 3.5N/mm2] - 1}t = 9.22mm.
• Outer diameter of the cylinder
Let, do = Outer diameter of the cylinder

do= di + 2t = 280mm + 2(9.22mm)

= 298.44mm.

The cylinder head may be taken as flat circular plate whose thickness may be determined from the
following relation.
Let, th = is the thickness of the head

σc= allowable circumferential stress in N / mm2

= 30 to 50Mpa.

Take, σc = 40Mpa (for our design purpose)

th= di(c*p /σc)

Where, C = constant = 0.1

th = 280mm (√0.1*3.5N/mm2)/ 40N/mm2 = 26.2mm.

• And the length of cylinder is:-

L = 2*do
= 2*298.44mm = 596.88 mm

24
Design of Piston:
Piston is moved by a fluid, or it moves the fluid which enters the cylinder. The most commonly
material used for piston is cast iron, cast aluminum, forged aluminum, cast steel, and forged steel. But
the material we selected for our design purpose is cast iron.
Piston is consists of the following parts, Head or crown, Piston ring, Skirt, Piston pin, Piston head:-
The thickness of piston head (tH), according to Grashoff’s formula is given by:-

tH=√(3P)(Do) /16σt , p = Maximum pressure,

Do = Outer diameter of the piston,

σt= tensile stress,=38MPa.

Note: The outer diameter of the piston is assumed to be equal to the inner diameter of the cylinder.
Therefore the outer diameter of the piston is 280mm.

t H = √(3*3.5*280) / (16*38) = 4.8mm,say, tH= 5mm

Piston rings:
The piston rings are used to impart the necessary radial pressure to maintain the seal between the
piston and cylinder bore. The radial thickness (tr) of the ring may be obtained by considering the
radial pressure between the cylinder wall and the ring.

tr= Do [(3√*pw ) / (σt )]

Where
• Do = Outer diameter of piston
• Pw = pressure on the wall of cylinder, limited to
0.025 to 0.042N/mm2
• σt = Allowable tensile stress in Mpa, it may be taken 85MPa to 110MPa for cast iron rings.

tr= 280mm (3*0.035√ ) / (90)

tr= 9.56mm.

And also the axial thickness of the piston ring (ta) is:-
ta = 0.7tr to tr
= 7mm to 9.56mm, adoptingta =8.5 mm.

We also know that the minimum axial thickness of the piston ring is:

ta= Do /10nr ,
Where nr = No of rings = 4

t = 280mm /10(4) = 7 mm.

25
 Thus the axial thickness of the piston ring as calculated (i.e. ta = 7mm) is satisfactory.
The distance from the top of the piston to the first ring groove, i.e. the width of the top hand:-

b1 = tHto1.2 t H
= 5mm to 6mm, taking, b1 = 5.5 mm.
And the width of the other hand of the ring
b2= 0.75ta to t a
= 6.63mm to 8.5mm, taking, b2 = 7.5 mm.
We know the gap between the free ends of the rings:

G1 = 3.5tr to 4tr
= 33.46mm to 38.24 mm.
And the gap when the ring is in the cylinder,

G2 = 0.002Do to 0.004Do
= 0.56mm to 1.12mm, let 's adopt

G1 = 36mm, and G2 =1 mm.

Piston Barrel:
It is a cylindrical portion of the piston. The maximum thickness (t 3) of the piston barrel may be
obtained from empirical relation:

t3 = 0.03Do+b+4.5,

Where
b = radial depth of piston, and it is taken to be 0.4mm greater than the radial thickness of piston ring
I.e. b = tr + 0.4mm
Therefore, t3 = 0.03DO + tr +4.9

t3 = 0.03(280) +9.56 +4.9

= 22.86 mm,
Say t3 = 23 mm.

And the piston wall thickness (t4) towards the open end is decreased and should be taken as:-
t4 = 0.25t3 to 0.35t3
= 0.25(23) to 0.35(23)mm
= 5.75 to 8.05mm, Adopting
t4 = 8 mm.

26
G. Lifting system
Here the system is used to lift the load up and down as required. Thus the system works by allowing
a certain amount of fluid to pass through the hose. The system is made of three basic components.1.
Electrical system box
2. Solenoid coils
3. Electric motor
Electrical system box:
This system box include power indicator, switch indicators, raising indicator, switch, and push
buttons for raising the piston rod up and down. When the push buttons are pressed, electrical energy
will turn the solenoid and the respective valves will be opened forcing the pressurized oil to pass
through the hose.
Solenoid coils:
It is used to close and open the rising and lowering valve, when we press up and down push button.
There are different types of solenoid; of these we used electrically actuating double acting coil.
Electric motor:
The motor is used to compress and pump the oil from the oil tank to the actuator through the hose.
Motor specification:
Power 3000W
Speed 2830/3620rpm
H. Lifting height
• The maximum height that the crane can lift is obtained as follow

Figure9. Height of the crane at maximum height From cosine low:

107.62 =1722 +702 −2 (172) (70) cos (a)

α= cos−1 [0.9512]

27
 α= 17.96 °
From sin low:

Sin17.96°/107.6 = Sinβ/ 70

β= Sin−1 [0.20056]

β=11.57°
θ=180°− (17.96+11.57) °
θ=150.46°
M=160Sin (60.46) ° =139.2cm
N=107.6cos12=105.24cm°
K = 53cos12° =51.84cm
H = M +N +K =296 cm
H = 2.96 m

Figure10. Designed portable crane at maximum height

• Minimum height that the crane can pick up objects from is obtained as:

Figure11. Height of the crane at lowest height

From Cosine law:

28
 θ= Cos−1 [(107.6)2 (70)2 − (107)2] /2(107.6) (107.6)

θ= 70.49 °

M =160*cos (82.49) ° =20.99

h =160cos12−M°

h =135.5 cm

Figure12. Designed portable crane at lowest height

I. Result, Advantage, and Disadvantage
A portable crane designed and developed its prototype here in MESFIN INDUSTRIAL
ENGINEERING.
Ethiopia is electric motors driven and moveable by wheels in the flours of the machine shop. It can
also use as transporting objects from place to place in a shop replacing overhead crane. The operation
is simple press to make the motor ON, very simple and suitable for the purpose.
Disadvantage of the portable crane may its using of electric power that its application impossible in
the area where no electricity.

3. Conclusion and Recommendations

For many years cranes have been designed for lifting heavy objects with different capacity in
different work sites. Portable cranes are of one type of cranes designed for lifting objects which are
beyond the capacity of human being. As MESFIN INDUSTRIAL ENGINEERING is one of the
companies where in many different lifting operation is practicable.
Of this lifting operation by using portable and moveable crane which is not being use before, we
have identified that there is the need for using portable crane to lift up objects these are beyond the
capacity and difficult of human power. Thus this paper provides the design of each part of portable
crane. And the design analysis for each part is checked that it is safe accordingly the size of each parts
of the crane.

29
 The maximum carrying capacity 3 ton, and maximum lifting height is estimated as greater than
greater than 2.96m from the ground run by using 3KW electric motor rotating 2830/3620 rpm.
We recommend that anybody who interested to modify the current design of the portable crane for
the production workshop of our design can make this work base study or can use as reference.

Symbols and Descriptions

A Cross sectional area

Aw Area of wire
b Width / depth
C Stiffness constant
c Distance b/n axis and end fiber
d nominal diameter
dc Core diameter
dh Diameter of hinged pin of piston
di Inner diameter
dp Diameter of piston
do Outer diameter
dr Diameter of rope
dw Diameter of wire E Modulus of elasticity
e Eccentricity
G GAP
M Bending moment
m Mass
n Factor of safety /load factor P Pressure
rc Radius at neutral axis
rn Radius at eccentricity
Sut Ultimate strength
Sy Yield strength
T Torque
t Thickness
V Volume
Wcr Buckling load
Z Section modulus
σb Bending stress
30
σc Compressive stress
σc Circumferential stress
σt Tensile stress
τ Shear stress
π pie≈3.14159265
µ Coefficient of friction

ρ Density

31