Wall Mounted Jib Crane (H-Type)

Mechanical System Design

Department of Mechanical Engineering

 Executive Summary

Jib crane is a machine that is used to lift heavy loads of greater than 1 ton. There are two main

kinds of jib cranes like Column Jib cranes and Wall mounted Jib cranes. Column jib cranes are

the cranes which utilize a vertical column that is fixed on the Earth with the help of nuts and

bolts. Wall mounted jib cranes do not contain vertical columns rather they have brackets that are

used to fix the crane beam with the wall. Jib Cranes are further divided into three different kinds

on the basis of beam used i.e. C-Type Jib cranes, H-Type Jib Cranes and T-Type Jib cranes. Our

Project is to design an “H-Type” Jib crane. Talking about H-Type jib cranes, these cranes have

an H-Type beam on which the trolley is mounted.

Some required specifications, given by the client, have been utilized to design a particular jib

crane. The designed H-Type jib crane has maximum capacity of 1850 kg, a span length of 7.25

meters, maximum height of 8 meters and slewing angle is 300 degrees. Travelling mode is

manual i.e. the movement of trolley is controlled manually whereas slewing mode is motor

controlled i.e. left right turning movement of the beam shall be controlled by motor. After

considering all parameters, it has been calculated that hoist motor should have a power of 68 kW

or higher to lift the maximum desired capacity load.

 Table of Contents
Executive Summary ........................................................................................................................ 2

1. Problem Definition.................................................................................................................. 9

1.1. Problem Scope.................................................................................................................. 9

1.2. Technical Review ............................................................................................................. 9

1.3. Design Requirements ..................................................................................................... 10

2. Design Description................................................................................................................ 10

2.1. Overview ........................................................................................................................ 10

2.2. Structural Components ................................................................................................... 11

2.3. Applied forces to the supported structure ...................................................................... 11

2.3.1. Loading Calculations .................................................................................................. 12

2.4. Moment and Shear diagrams .......................................................................................... 14

2.5. Deflection in the Beam ................................................................................................... 15

2.6. Trolley Design ................................................................................................................ 16

2.7. Beam Structure ............................................................................................................... 18

2.8. Pivot Assembly .............................................................................................................. 20

2.9. Hoist Assembly .............................................................................................................. 23

2.9.1. Trolley Hoist ........................................................................................................... 24

2.9.2. Hoist Selection Factors ........................................................................................... 24

2.9.3. Selected Hoist ......................................................................................................... 26

 2.9.4. Hoisting Equipment ................................................................................................ 26

2.9.5. Hook Assembly........................................................................................................... 26

2.9.6. Gear Assembly ............................................................................................................ 27

2.9.7. Rope Drum .................................................................................................................. 27

2.9.8. Ropes........................................................................................................................... 28

2.9.9. Selection of Electric Motor ......................................................................................... 29

2.10. Detailed Description ................................................................................................... 29

2.11. Drive Assembly .......................................................................................................... 30

3. Welding Analysis .................................................................................................................. 31

3.1. General Instructions: ...................................................................................................... 31

3.2. Welding Design .............................................................................................................. 32

3.2.1. Types of Weldings Used ......................................................................................... 33

3.3. Beam Bracket Construction: .......................................................................................... 34

3.4. Bottom Bracket Construction ......................................................................................... 34

3.5. Tie Rod ........................................................................................................................... 36

3.6. Crane Rail (Steel Supported Rail) .................................................................................. 37

3.6.1. DIN “A” BURBACK rail ....................................................................................... 37

3.6.2. Installation of rail .................................................................................................... 38

4. Hoist Motor ........................................................................................................................... 39

4.1. Selection of Motor .......................................................................................................... 39

5. Bearing Analysis (Slewing Bearing) .................................................................................... 40

5.1. Material .......................................................................................................................... 41

5.2. Components.................................................................................................................... 41

5.3. Functioning and Analysis ............................................................................................... 42

5.4. Attachment Bolts ............................................................................................................ 43

6. Cost Analysis ........................................................................................................................ 43

6.1. Trolley and Hoist Set...................................................................................................... 44

6.2. H Beam ........................................................................................................................... 44

6.3. Slewing Bearing ............................................................................................................. 45

6.4. Welding and Bolts .......................................................................................................... 46

6.5. Tie Rod ........................................................................................................................... 46

7. Conclusion ............................................................................................................................ 47

APPENDICES .............................................................................................................................. 50

9. Bill of Material ...................................................................................................................... 50

10. ASTM BTH Standards ....................................................................................................... 51

11. Manufacturing Details ....................................................................................................... 54

11.1. H-Beam Manufacturing .............................................................................................. 54

11.2. Hoist Manufacturing ................................................................................................... 54

11.3. Hook Manufacturing................................................................................................... 55

11.4. Trolley Manufacturing ................................................................................................ 55

 11.5. Tie Rod Manufacturing .............................................................................................. 56

11.6. Bearing Manufacturing ............................................................................................... 56

12. Cost Estimate ..................................................................................................................... 57

12.1. Trolley and Hoist ........................................................................................................ 57

12.2. H Beam ....................................................................................................................... 57

12.3. Slewing Bearing ......................................................................................................... 58

12.4. Welding and Bolts ...................................................................................................... 58

12.5. Tie Rod ....................................................................................................................... 58

13. Drawings ............................................................................................................................ 59

13.1. Bracket Exploded View .............................................................................................. 64

13.2. Crane Exploded View ................................................................................................. 65

List of Figures

Fig. 01: General Parts and Description of a Jib Crane .................................................................. 10

Fig. 02: Structural Concept of H-Type Jib Crane ......................................................................... 11

Fig. 03: Application of Forces ...................................................................................................... 12

Fig. 04 (a, b): Force Analysis........................................................................................................ 12

Fig. 05: Bending moment and Shear Force diagrams ................................................................... 14

Fig. 06: Moment of Inertia Calculation ........................................................................................ 15

Fig. 07: Push girder trolley-Single pin .......................................................................................... 16

Fig. 08: Crane trolley with 4 vertical flange wheels ..................................................................... 16

Fig. 09: Schematic Diagram for the cross-sections of an H-Beam ............................................... 18

Fig. 10: Moment Diagram of Crane Cantilever Beam .................................................................. 18

Fig. 11: Bracket Dimensions [In inches] ...................................................................................... 20

Fig. 12: Plumbing pivot mounting assembly ................................................................................ 21

Fig. 13: Orienting Bearing, Figure: Installing boom welding ...................................................... 21

Fig. 14: Installing upper pivot mounting assembly ...................................................................... 21

Fig. 15: Installing friction brakes on wall-mounted pivot assembly ............................................ 22

Fig. 16: Adjusting the secondary arm on wall-mounted pivot assembly...................................... 23

Fig. 17: Double girder crane hoist ................................................................................................ 23

Fig. 18: Hoist Assembly ............................................................................................................... 25

Fig. 19: Flow diagram for Crane Support Structure Design ......................................................... 30

Fig. 20: Drive Assembly ............................................................................................................... 31

Fig. 21: Single-flare-bevel-groove welds ..................................................................................... 33

Fig. 22: Single-flare-V-Groove Weld ........................................................................................... 33

Fig. 23: Joint Penetration Welds in Shear (Used for making rails runway) ................................ 33

Fig. 24: Beam Bracket Construction ............................................................................................. 35

Fig. 25 [a, b]: Bottom Brackets assembling with welding, bolt and bearing positions ................ 36

Fig. 26: Tie Rod with right hand threads on both ends ................................................................. 36

Fig. 27: Junction details ................................................................................................................ 37

Fig. 28: A soft mounted rail .......................................................................................................... 37

Fig. 29: BURBACK over steel support installation...................................................................... 38

Fig. 30: Welded joints in rails ....................................................................................................... 39

Fig. 31 (a): Motor Data of the drawings (Appendix) .................................................................... 39

Fig. 31(b): Dimensional Drawings ............................................................................................... 40

Fig. 32: Components of slewing bearing (Appendix)................................................................... 41

Fig. 33: Bolts positions in bearing and their lengths .................................................................... 43

List of Tables

Table 01: Specimen Standard Design Parameters ........................................................................ 19

Table 02: Sheaves and Drum Standard Values ............................................................................. 28

Table 03: Chemical Composition of E7018 Soldering Stick ........................................................ 32

Table 04: Mechanical Composition of E7018 Soldering Stick .................................................... 32

Table 05: Calculations for Welding Process ................................................................................. 32

Table 06: Some standard channel thicknesses .............................................................................. 34

Table 7: Flat bar welding .............................................................................................................. 37

Table 8: BURBACK over Steel Support Parameters ................................................................... 38

Table 09: Hoist Motor standards................................................................................................... 39

Table 10: Selection of bearing ...................................................................................................... 40

Table 11: Minimum Mechanical Characteristics of Bearing ........................................................ 42

Table 12: Track diameters and corresponding thicknesses........................................................... 42

Table 13: Standard Tolerances (ISO 286-2 Standard) .................................................................. 43

 1. Problem Definition

1.1. Problem Scope

While working in industry, especially in mechanical field, we deal with a lot of heavy load.

Heavy loads include any machinery with engine power mechanism, any vehicle like car, trolley

or van. This is the case when we intentionally use cranes for moving them when these things are

not movable on their own. Moreover, we also deal with accidents everywhere. When huge loads

are disturbed accidently, then cranes are also employed to deal with these accidently fallen loads.

Jib cranes are basically kind of overhead cranes. These cranes have a large horizontal arm and

are fixed with the wall, or earth via long column, to lift a load in a particular defined range of the

arm. These types of cranes have a big application that these are highly used for construction

purposes. Hospitals, Banks, Plazas etc are all constructed by the assistance of jib cranes. These

are also called as tower cranes.

1.2. Technical Review

When I talk about technical review, then I am going to deal with the structural components and

its technical specifications. Main structural components of the crane are boom or a particular

type of Beam, tie rod, brackets, gusset and trolley. Length of boom is called span and it is usually

6 to 8 meters, I have 7.25 m in my case. Bolts and welding are also used while assembling these

components. Technical design and detail of each component shall be discussed in further

sections of this report.

 1.3. Design Requirements

I am going to design a “Wall-mounted Jib Crane” with H-type.

2. Design Description

2.1. Overview

Actually, a unique power drive (electric) with built in adjustable clutch is used to power the

crane. There is a “VFD” Controller Rotation Panel attached to the motor. Slewing power is

transmitted by gears i.e. pinion and ring gear. Collector rings and cable grip is provided for the

given rotation i.e. 300 degrees. The hoists and trolleys of jib cranes are slow moving with a

manual travelling mode whereas slewing is motor controlled. Brackets shall be used to connect

crane on the wall.

Fig. 01: General Parts and Description of a Jib Crane (Design Concepts for Jib Cranes, n.d.)
 2.2. Structural Components

The main components with some specified details are highlighted below:

Fig. 02: Structural Concept of H-Type Jib Crane (H Beam Design, n.d.)

2.3. Applied forces to the supported structure

When we talk about wall-mounted jib crane, then there is no need to use mast. Only wall

brackets are used where there are two kinds of forces exerted; pull on one bracket and thrust on

the other. As applied load is towards down, hence tie rod will tend to extend itself which will

exert a pull on bracket. A thrust will be generated on the other bracket to accommodate this pull.
 Fig. 03: Application of Forces (Design Concepts for Jib Cranes, n.d.)
2.3.1. Loading Calculations

(a)

Angle between tie rod and boom is kept low; let us assume it to be 10 degrees, then;

(b)

Fig. 04 (a, b): Force Analysis (Design Concepts for Jib Cranes, n.d.)
Here,

A = Span = 7.25 m

P = Maximum load = 1850 kg = Resultant

Acting at top hinge only;

1 𝐴
𝐹𝐻 = [𝑊𝑙𝑖𝑓𝑡𝑒𝑑 + 𝑊𝐵𝑜𝑜𝑚 + 𝑊𝑇𝑟𝑜𝑙𝑙𝑒𝑦 ] 𝑐𝑜𝑠 ( ) , … … … (1)
2 𝐵

𝐵
𝑈𝑠𝑖𝑛𝑔, tan 𝜃 =
𝐴

𝐵 = 𝐴 tan 𝜃 = (7.25𝑚) × tan 10 = 1.278 𝑚

𝑩 = 𝟏. 𝟐𝟕𝟖 𝒎

Hence, using equation (1);

7.25
𝐹𝐻 = (18148.5) × 𝑐𝑜𝑠 ( )
1.278

𝑭𝑯 = 𝟏𝟕𝟖𝟕𝟐. 𝟕𝟖 𝑵

Now, for vertical forces, we can write:

1 𝐴
𝐹𝑣 + 𝐹𝑏 = [𝑊𝑙𝑖𝑓𝑡𝑒𝑑 + 𝑊𝐵𝑜𝑜𝑚 + 𝑊𝑇𝑟𝑜𝑙𝑙𝑒𝑦 ] ( ) , . … … … … (2)
2 𝐻𝑜𝑖𝑠𝑡 𝐸

Let us assume that sum of lifted weight, boom weight and trolley weight is equal to the capacity

of the crane and is given as (1850 x 9.81) N. Also let us consider A=E, hence we can write:

𝑊ℎ𝑒𝑟𝑒, 𝑭𝒗 = 𝑷𝒔𝒊𝒏 (𝟏𝟎) = 𝟏𝟖𝟏𝟒𝟖. 𝟓 𝐬𝐢𝐧(𝟏𝟎) = 𝟑𝟏𝟓𝟏. 𝟒𝟓 𝑵

 𝐹𝑣 + 𝐹𝑏 = 1850 × 9.81 𝑜𝑟 3151.45 + 𝐹𝑏 = 1850 × 9.81

𝑭𝒃 = 𝟏𝟒𝟗𝟗𝟕. 𝟎𝟓 𝑵

2.4. Moment and Shear diagrams

Considering impact factor of 1.3, we can write bending moment as:

𝐼𝑚𝑝𝑎𝑐𝑡 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑀𝑜𝑚𝑒𝑛𝑡 = 1.3 × 𝑃𝑦 × 𝐴

Where
P y = Maximum vertical load = P sin 𝜽 = 18148.5 (sin 10) = 3151.45 N
A = span length = 7.25 m
𝑰𝒎𝒑𝒂𝒄𝒕 𝑩𝒆𝒏𝒅𝒊𝒏𝒈 𝑴𝒐𝒎𝒆𝒏𝒕 = 𝟏. 𝟑 × 𝟑𝟏𝟓𝟏. 𝟒𝟓 × 𝟕. 𝟐𝟓 = 𝟐𝟗𝟕𝟎𝟐. 𝟒𝟐 𝑵𝒎
Maximum Shear force is constant due to a point load and hence given as:
𝑉𝑚𝑎𝑥 = 𝑃𝑦 = 18148.5 sin(10) = 3151.45 𝑁

Maximum bending moment can be written as

𝑀𝑚𝑎𝑥 = 𝑃𝑦 𝐴 = 3151.45 × 7.25 = 22848.013 𝑁

Fig. 05: Bending moment and Shear Force diagrams (Shear forces and Bending Moment
Diagrams, n.d.)
 2.5. Deflection in the Beam

Considering boom section as an H-beam section, we can label and write the moment of inertia:

Fig. 06: Moment of Inertia Calculation (H Beam Moment of Inertia, n.d.)

2𝑏𝐻 3 + 𝑑ℎ3
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 =
12
Width and thickness can be taken equal and equal to 0.5’, hence B = H = 0.1524 m, thickness is

taken as 0.5 inch, hence b = 0.0127 m, h = 2b = 0.0254 m, d = 0.127 m

2𝑏𝐻 3 + 𝑑ℎ3 2(0.0127)(0.1524)3 + (0.127)(0.0254)3

𝐼= =
12 12
𝐼 = 7.66 × 10−6 𝑚4
Material = ASTM A36 Steel
Modulus of Elasticity = E = 200 GPa
Using deflection formula for cantilever beam, maximum deflection with full load is:
𝑃𝐴3
𝑢𝑚𝑎𝑥 =
3𝐸𝐼
(18148.5)(7.25)3
𝑢𝑚𝑎𝑥 =
3(200 × 109 )(7.66 × 10−6 )
𝑢𝑚𝑎𝑥 = 1.505 𝑚
This value is much greater than expected; hence tie rods are essential for this kind of crane.

When we will use tie rod, then load will be divided into components. Vertical component will be

responsible for the deflection:

 ′
𝑃𝑦 𝐴3 18148.5 𝑠𝑖𝑛(10)(7.25)3
𝑢𝑚𝑎𝑥 = =
3𝐸𝐼 3(200 × 109 )(7.66 × 10−6 )
𝒖𝒎𝒂𝒙 ′ = 𝟎. 𝟐𝟔𝟏 𝒎 = 𝟐𝟔𝟏 𝒎𝒎

Boom will undergo 261 mm of deflection when loaded fully, which is acceptable.

2.6. Trolley Design

Trolley could be a unit that carries the hoisting mechanism that travels on the bridge rails in the

direction perpendicular to the Crane runway. Crane trolley frame is actually the basic structure of

the trolley on that the hoisting and traversing mechanisms are mounted.

Fig. 07: Push girder trolley-Single pin (Hoist and trolley full catalog, n.d.)

Fig. 08: Crane trolley with 4 vertical flange wheels (final load distribution trolley beam two-

crane picks)
Here,

𝑍𝑗 = 𝑤ℎ𝑒𝑒𝑙 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑓𝑜𝑟𝑐𝑒𝑠

𝑙 = 𝑐𝑟𝑎𝑛𝑒 𝑠𝑝𝑎𝑛

𝑏ℎ = 𝑟𝑎𝑖𝑙 ℎ𝑒𝑎𝑑 𝑤𝑖𝑑𝑡ℎ

𝑤𝑏 = 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑔𝑢𝑖𝑑𝑒 𝑚𝑒𝑎𝑛𝑠

𝑑𝑗 = 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑔𝑢𝑖𝑑𝑒 𝑚𝑒𝑎𝑛𝑠 𝑡𝑜 𝑡ℎ𝑒 𝑤ℎ𝑒𝑒𝑙 𝑗

𝑊ℎ𝑒𝑟𝑒, 𝐹𝑜𝑟𝑐𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑔𝑢𝑖𝑑𝑒 𝑚𝑒𝑎𝑛𝑠 = 𝑌𝐹 = ∑ 𝑌𝑗

𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑟𝑒𝑐𝑜𝑚𝑚𝑒𝑛𝑑𝑒𝑑 𝑡𝑟𝑜𝑙𝑙𝑒𝑦 𝑡𝑟𝑎𝑐𝑘 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑣𝑎𝑙𝑢𝑒 = 𝑠𝑔𝑚𝑖𝑛 = 4 𝑚𝑚

𝐹𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒, 𝑤𝑒 𝑘𝑛𝑜𝑤 𝑡ℎ𝑎𝑡, 𝑆 = 𝑍1 + 𝑍2 + 𝑍3 + 𝑍4

𝑆𝑑 = 𝑍1 𝑑1 + 𝑍2 𝑑2 + 𝑍3 𝑑3 + 𝑍4 𝑑4

𝑆𝑑𝑑 = 𝑍1 𝑑1 2 + 𝑍2 𝑑2 2 + 𝑍3 𝑑3 2 + 𝑍4 𝑑4 2

𝑆𝑑
𝐻𝑒𝑛𝑐𝑒, 𝑏=
𝑆𝑑𝑑

𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝐿𝑎𝑡𝑒𝑟𝑎𝑙 𝑓𝑜𝑟𝑠𝑒 𝑎𝑡 𝑡ℎ𝑒 𝑔𝑢𝑖𝑑𝑒 𝑚𝑒𝑎𝑛𝑠 𝐹𝑦 = 𝑌𝐹 = 𝑢𝑓 (𝑆 − 𝑆𝑑 𝑏)

Where, “u f” is friction slip coefficient. This is a design procedure for the trolley. Some selected

standard values have been mentioned in the table attached in appendix (Table 01, Table 03).
 2.7. Beam Structure

Let us consider an H-Beam with the following nomenclature:

Fig. 09: Schematic Diagram for the cross-sections of an H-Beam (H Beam Calculations, n.d.)

Fig. 10: Moment Diagram of Crane Cantilever Beam (H Beam Calculations, n.d.)

Where, d=depth, b= width, t w = web thickness and t f = flange thickness. Minimum wing plate

thickness can be obtained as:

Where, Z0 is Plastic Modulus and S0 is Section modulus of the beam. These can be found by:

Let us consider that Ls is length of welding zone and L b is length of span i.e. 7.25 m, hence

𝐿𝑏
𝐷𝑒𝑚𝑎𝑛𝑑 𝑀𝑜𝑚𝑒𝑛𝑡 = 𝑀𝐷𝑒𝑚𝑎𝑛𝑑 = 𝑀
𝐿𝑏 − 𝐿𝑠 𝑝

Where, M p is plastic moment and it can be measured by using:

𝑀𝑝 = 𝐹𝑦 𝑍0

Where, “F y” is a yielding stress of steel.

Table 01: Specimen Standard Design Parameters (ASME B16.21-2011 (Revision of ASME

B16.21-2005) Nonmetallic flat gaskets for pipe flanges, n.d.)

Some standard values for the H-Beam structure are given in the appendix (Table 04 and Table

05)
 2.8. Pivot Assembly

Pivot assembly is very essential towards boom installation. Here are some steps required to make

pivot assembly for boom installation:

Fig. 11: Bracket Dimensions [In inches] (Hoist and trolley full catalog, n.d.)

Determine the position of upper pivot mounting assembly on the support structure, and drill bolt

holes. Quickly bolt the upper pivot mounting assembly to the support structure (don’t use lock

washers).

Determine position of lower pivot mounting assembly by dropping bob (by others) through pivot

holes

Drill bolt holes and bolt lower pivot mounting assembly to support structure. Don’t force bolts

till boom assembly is put in.

Remove the upper pivot mounting assembly from support structure.

 Fig. 12: Plumbing pivot mounting assembly (Hoist and trolley full catalog, n.d.)

Clean pivot pins with a clean, dry cloth. Slide the bearings on pivot pins. Ensure to orient

bearings properly.

Lift boom weldment up and insert lower pivot pin into lower pivot mounting assembly

Fig. 13: Orienting Bearing, Figure: Installing boom welding (mediathek, n.d.)

Place higher pivot mounting assembly on higher pivot pin of boom assembly Bolt higher pivot

mounting assembly to support structure.

Fig. 14: Installing upper pivot mounting assembly (Hoist and trolley full catalog, n.d.)
At 45° intervals, make sure pivot pins of crane are plumb. Shimming of higher and/or lower

pivot mounting assembly is also needed (shims included).

Once pins are plumb and shimmed, tighten all mounting bolts to manufacturer’s specifications.

Carefully swing boom through entire journey and guarantee boom is obvious of obstructions and

doesn't drift. If boom drifts, support structure is also inadequate and/or pivot mounting assembly

might not be aligned

Attach 2 brake pads to the lower pivot mounting assembly by using two 1/4” socket head cap

screws, lock washers, and lock nuts.

Fig. 15: Installing friction brakes on wall-mounted pivot assembly (mediathek, n.d.)

Adjust brake by alteration 2 lock nuts to get the desired motility resistance of the first arm.

To adjust the secondary arm, loosen the set screw and jam nut.

Adjust set screw for desired motility resistance.

Tighten the jam nut.

 Fig. 16: Adjusting the secondary arm on wall-mounted pivot assembly (mediathek, n.d.)

2.9. Hoist Assembly

A hoist may be a device used for lifting or lowering a load with the help of a drum or lift-wheel

around that the rope or chain is wrapped. Cranes and Hoists are somewhat interchangeable things

since the particular lifting mechanism of a crane is usually stated as a hoist. Hoists could also be

integral to a crane or mounted in a fixed position, temporarily or permanently. Once a hoist is

mounted to a self-propelled trolley on a single rail system, 2 directions of load motion are

available i.e. forward or reverse, up or down. Once the hoist is mounted on a crane, 3 directions

of load motion are available i.e. right or left, forward or reverse, up or down.

The hoist mechanism may be a unit consisting of a motor drive, coupling, brakes, gearing, drum,

ropes, and cargo block designed to lift, hold and lower the most rated load. Hoist mechanism is

mounted on the trolley.

Fig. 17: Double girder crane hoist (Hoist and trolley full catalog, n.d.)
 2.9.1. Trolley Hoist

An electric hoist and high running motorized self-propelled vehicle i.e. trolley combined in one

unit provides correct load positioning during a kind of applications. Wheels, drives and

management packages are unremarkably designed specifically for the appliance. Out there to be

used on category A through D cranes having capacities from five tons to thirty tons with normal

lifts of a hundred feet or additional.

Common Applications: Moderate service together with significant machine retailers, metal

fabricating plants and steel reposition.

Selection Considerations: Sturdy, welded steel frame; back-geared limit switches; variable

hoist and self-propelled vehicle speeds and controls; heat treated wheels; heavy-duty crane rated

motors; double reeving for true vertical lift; heavy-duty, long bearings.

2.9.2. Hoist Selection Factors

1) The load to be upraised together with below-the-hook lifting, load supporting, and

positioning devices.

2) Physical size of the load.

 Holding and orienting devices.

 Design for centre of gravity (control & stability).

 Lift – the vertical distance the load will be affected.

3) Clearance concerns

 Headroom

 Obstacles to be cleared throughout the load transfer.

 Design for vertical raise needed together with device height.

4) Lifting Speed concerns

 Distance the load is to be raised and down

 Frequency of usage

 Required positioning accuracy

 Nature of the load being upraised

5) Hoist duty Cycle concerns based mostly on:

 Number of lifts per hour

 Total range of lifts per shift

 Maximum range of starts and stops per hour

 Number of shifts per day

 Average distance load is raised and down

 Average weight to be upraised

 Maximum weight to be upraised

 Frequency of lifts with most weight.

Fig. 18: Hoist Assembly (Hoist and trolley full catalog, n.d.)
 2.9.3. Selected Hoist

Hoist Name: Overhead Electric Wire Rope Hoist

Standard: ASME-HST-4
2.9.4. Hoisting Equipment

Sheaves

A “Sheave” may be a grooved wheel or pulley-block used with a rope or chain to vary direction

and purpose of application of an actuation force.

Load Block

Load Block is associated with an assembly of hook, swivel, bearings, sheaves, pins and frame

suspended from the hoisting ropes. In a "short type" block, the hook and also the sheaves are

mounted on a similar member, referred to as the swivel. However, in a "long type" block, the

hook and also the sheaves are mounted on separate members.

The supporting member for the sheaves is termed as the sheave pin and also the supporting

member for the hook is termed as the trunnion.

2.9.5. Hook Assembly

1) Load blocks and hook assembly shall be non-sparking, non-corroding kind, fictional of AISI

kind304, 18-8 chrome-nickel, corrosion-resistant steel or a bronze alloy of appropriate strength

and section for the rated capability load. Hook material will be cast steel for non-hazardous

areas.

2) Hook assembly for electrical hoists shall be carried on antifriction bearings to allow free

swivel below rated-capacity load while not twisting load chain or wire.
3) Every hook assembly shall embrace a machined and rib shaft and swivel nut with an efficient

lockup device to stop nut from backing off.

4) Every hook shall have an elastic device safety latch.

2.9.6. Gear Assembly

1) Gear shafts shall be factory-made from high-carbon steel or steel, machined and ground for

correct work and splined for fitting to the union gear.

2) Gear-train assembly shall be carried on antifriction bearings and encircled within the hoist

frame casting.

Assembly shall operate during a sealed oil tub.

3) Frame casting shall be supplied with lubrication fittings and review ports.

2.9.7. Rope Drum

Selection of rope will be made in line with the quality knowledge out there in appendix (Table

02).

1) Rope drum shall be hardened steel or special-grade forged iron.

2) Drum shall have correct, machine-cut grooves, move full depth of wire-rope radius, with

rounded corners of dimension as needed for the indicated raise. Groove diameter and pitch

centers shall be not but 1/32 in. (0.79mm) bigger than diameter of rope.
Table 02: Sheaves and Drum Standard Values (ASME B16.21-2011 (Revision of ASME B16.21-

2005) Nonmetallic flat gaskets for pipe flanges, n.d.)

2.9.8. Ropes

In selecting hoisting ropes, the Crane manufacturer's recommendation shall be followed. The

rated load divided by the quantity of components of rope shall not exceed twenty % of the

nominal breaking strength of the rope.

1) Wire rope for normal applications shall be further versatile, preformed, and improved, plow

steel, 6 by37, fiber-core wire conformist to FS RR-W-410, Type I, Class 3.

2) Wire rope for single-line application shall be performed, improved plow steel, 18 by 7, fiber-

core, non-rotating wire conformist to FS RR-W-410, Type IV, and sophistication a pair of.

3) Wire rope for non-corroding, non-sparking hoist application shall be performed, AISI kind

304, 18-8 corrosion-resistant steel, 6 by 19, bright end, conformist to FS RR-W-410, Type I,

Class 2.

4) Wire rope shall have a FOS (Factor of Safety) of not less than five, based on the minimum

final strength of the fabric used, for different classes of cranes like A and B cranes, and a factor

of safety of six for Category C cranes.

5) Not less than 3 wraps of rope shall stay on the drum once the hook is in its extreme low

position and make sure that one extra rope flip will be accommodated once the hook is at its

higher limit of hoisting (i.e. the rope shall not overlap once the hook is at its highest point).

2.9.9. Selection of Electric Motor

Let us assume that lifting speed varies from 50 to 130 mm/s.

2𝜋𝑁𝑇
𝑃𝑜𝑤𝑒𝑟 = 𝑷 =
60

Speed of drum = ω = 4 x 0.13/R = 2N

For drum rotating angular speed ω, we can write:

𝑃𝑜𝑤𝑒𝑟 = 𝑷 = 𝑇𝜔 = 𝑃𝐴𝜔 = (18148.5)(7.25)(4𝑥0.13)

𝑷𝒐𝒘𝒆𝒓 = 𝑷 = 𝟔𝟖𝟒𝟏𝟗. 𝟖𝟒𝟓 𝑾𝒂𝒕𝒕 = 𝟔𝟖. 𝟒𝟐 𝒌𝑾

2.10. Detailed Description

There is a particular procedure that must be followed before making a crane structure. There are

some considerations which are of primary importance and these can’t be ignored. Primary level

requirements include the codes and standards, loading, the steel structure design, clearances and

Earthworks. Earth works must be done on the soil to make sure that it can bear heavy loads.
 Fig. 19: Flow diagram for Crane Support Structure Design (Thompson, n.d.)

2.11. Drive Assembly

There are two requirements that must be fulfilled before selecting wall bracket jib crane:

1) There should be a structurally adequate wall, column or truss to support the crane. Note

that the responsibility for determining if the support is adequate or not, rests entirely on

the customer. Information on the loading of the support by the crane can be found by

checking the manufacturer’s guides for cranes e.g. WB100.

 2) There should be sufficient clearance (nominally 3 inches) above the tie rod throughout its

arc.

Before selecting wall brackets, tie rod, drive motor and rotation arm, we should know the

mechanism to be utilized for making the drive assembly. General mechanism can be seen in the

figure below:

Fig. 20: Drive Assembly (Wall mounted jib crane, n.d.)

3. Welding Analysis

3.1. General Instructions:

 All welds should have 4 mm fillet

 All bolts should be M16 or higher

 Gusset Plates must be 8 mm thick

 Internal bracing shown 65 x 50 x 6 to use common section (Size can be reduced if others

available)

 All sections should be in grade 43 steel

  Purlin supports: 70 x 70 x 6 with 2 x 6 Ø holes.

3.2. Welding Design

(Structural Fabrication Materialsof crane = CCT38 and ASTM A36 Steels)

Type of Welding = Automatic Welding (Electric Arc Welding)

Welding Quality = Uniform metal welding of chemical composition is high

Electrodes = Low-Hydrogen Welding Electrodes (Welding rods must be thoroughly dry)

Soldering Stick (Standard E7018)

Table 03: Chemical Composition of E7018 Soldering Stick (Book, n.d.)

Table 04: Mechanical Composition of E7018 Soldering Stick (Book, n.d.)

Table 05: Calculations for Welding Process (Book, n.d.)

3.2.1. Types of Weldings Used

Fig. 21: Single-flare-bevel-groove welds (Design for Welding, n.d.)

Fig. 22: Single-flare-V-Groove Weld (Design for Welding, n.d.)

Fig. 23: Joint Penetration Welds in Shear (Used for making rails runway) (Welding

guidlines, n.d.)
3.3. Beam Bracket Construction:

 It connects tie rod to the beam near end of span.

 It consists of a formed clevis fastened to the tie rod, and bolted to the formed beam

channel.

 Design does not rely on any tension welds

 Pivot bolt is in double shear

3.4. Bottom Bracket Construction

1) Bottom bracket accepts the downward and compressive forces which actually crane

applies, yet provides optional ease of rotation and resistance to drift the boom.

2) It has a formed channel which is bolted to the supporting structure.

3) It has two beam connecting plates that are welded to a steel tube, which contains two

bronze bushings.

4) The bolts that connect the plates to the beam are in double shear, with a minimum

dependency on welds in carrying the load.

5) The beam bracket assembly normally rests on an oil-impregnated bronze thrust washer

and is held in a formed wall channel by using a pivot bolt assembly that is in double

shear.

6) A grease fitting is also provided for field lubrication.

Table 06: Some standard channel thicknesses (Welding guidlines, n.d.)

Fig. 24: Beam Bracket Construction (Behavior of welded CFT column to H-beam connections

with external stiffeners, n.d.)

(a)
 (b)

Fig. 25 [a, b]: Bottom Brackets assembling with welding, bolt and bearing positions

(Behavior of welded CFT column to H-beam connections with external stiffeners, n.d.)

3.5. Tie Rod

i. A single tie rod made up of ASTM A36 and right hand threaded at each end is used.

ii. Tie rod offers ease of leveling

iii. It assures that the bottom bracket and H-Beam will be loaded evenly.

iv. The design of single tie rod is superior to a double tie rod arrangement that depends on

even adjustments of the two tie rods, which can increase installation time as well as costs.

Fig. 26: Tie Rod with right hand threads on both ends (abus overhead cranes, n.d.)
3.6. Crane Rail (Steel Supported Rail)

Table 7: Flat bar welding (Design for Welding, n.d.)

Fig. 27: Junction details (Design for Welding, n.d.)

3.6.1. DIN “A” BURBACK rail

Fig. 28: A soft mounted rail (Wall mounted jib crane, n.d.)
Rail profile must fulfill the requirements of DIN 536 and should have minimum tensile strength

of 650 MPa.

Length of each portion should be big enough in order to reduce the number of junctions.

3.6.2. Installation of rail

Fig. 29: BURBACK over steel support installation (Wall mounted jib crane, n.d.)

Table 8: BURBACK over Steel Support Parameters (Thompson, n.d.)

 Fig. 30: Welded joints in rails (Design for Welding, n.d.)

4. Hoist Motor

4.1. Selection of Motor

Standard: Crane and Hoist Duty Motors Type MC Foot Mounted (B3) TEFC Series
Type of Frame: Frame 355L
Table 09: Hoist Motor standards (crane hoist duty motors catalog, n.d.)

Fig. 31 (a): Motor Data of the drawings (Appendix)

 Fig. 31(b): Dimensional Drawings (crane hoist duty motors catalog, n.d.)

5. Bearing Analysis (Slewing Bearing)

Slewing Bearing is a main component used in jib cranes. It is responsible to reduce friction in

slewing. When crane slews or turns at a certain angle like 300 degrees in our case, this bearing

turns out to be an essential part to help this rotation. It basically contains two rings, one inside

and one outside. A lubricant is added between these two rings to reduce friction.

Table 10: Selection of bearing

 5.1. Material

Steel is used as a basic manufacturing material. Different alloys of steel are prepared for better

strength. These materials are specially prepared for this purpose.

5.2. Components

Fig. 32: Components of slewing bearing (Appendix)

5.3. Functioning and Analysis

Table 11: Minimum Mechanical Characteristics of Bearing

Table 12: Track diameters and corresponding thicknesses

 Table 13: Standard Tolerances (ISO 286-2 Standard)

5.4. Attachment Bolts

Where,

Fig. 33: Bolts positions in bearing and their lengths (Appendix)

6. Cost Analysis

Cost estimation for each part of the crane will be done according to the companies recently

manufacturing these parts. Complete cost and product details shall be provided in this section

along with their references from reliable sources.

 6.1. Trolley and Hoist Set

Trolleys with complete hoist are easily available in market. It can be selected by visiting

companies who produce different kinds of crane trolleys. We have got a similar hoist and trolley

assembly which also includes hoist motor as well as hook assembly.

CD Electric Wire rope hoist has only one normal speed whereas MD Electric wire rope hoist

gives two speeds i.e. normal and low speed. At a low speed, it can do precise loading and

unloading.

Reference:https://www.alibaba.com/product-detail/2-ton-3-ton-5-

ton_1491014450.html?spm=a2700.7724838.2017115.32.4b0e4059nOE9Fo

6.2. H Beam

We have found some companies who manufacture H-Beams of different dimensions. We can

easily select one beam of our desired dimensions. The minimum price we can get for a 7.25 m

long H beam is $550.

The selected company produces H-Beams with lengths 6m to 12 m and flange width of 100 mm

to 900 mm hence we can get our desired beam section here.

Reference:https://www.alibaba.com/product-detail/China-manufacturer-construction-structural-

H-beam_60772883253.html?spm=a2700.7724838.2017115.126.4b0e4059nOE9Fo

6.3. Slewing Bearing

Reference:https://www.alibaba.com/product-detail/hydraulic-marine-crane-jib-crane-

slewing_1950500507.html?spm=a2700.7724838.2017115.1.39b02f0a28cETe&s=p
 6.4. Welding and Bolts

Reference:https://www.alibaba.com/product-detail/high-pressure-stud-bolt-arc-

welding_60509355067.html?spm=a2700.7724838.2017115.28.39b02f0a28cETe&s=p

6.5. Tie Rod

Reference:https://www.alibaba.com/product-detail/Formwork-parts-Self-color-Galvanizing-

steel_60624521291.html?spm=a2700.7724838.2017115.11.64867cd0RWsClm&s=p
 7. Conclusion

Some required specifications, given by the client, have been utilized to design a particular jib

crane. The designed H-Type jib crane has maximum capacity of 1850 kg, a span length of 7.25

meters, maximum height of 8 meters and slewing angle is 300 degrees. Travelling mode is

manual i.e. the movement of trolley is controlled manually whereas slewing mode is motor

controlled i.e. left right turning movement of the beam shall be controlled by motor. After

considering all parameters, it has been calculated that hoist motor should have a power of 68 kW

or higher to lift the maximum desired capacity load.Detailed Engineering Drawings were made

and are attached in the Appendix. All drawings were made in SolidWorks 2016. Main

components, which were considered in making drawings, were H-Beam, Trolley Assembly and

Hoist Assembly, Tie rod, Wall Brackets and Fasteners like nuts and bolts. Standard dimensions

were used and all dimensions can be seen mentioned in the drawing files.

8. References

[1] abus overhead cranes. (n.d.). Retrieved from www.abuscranes.com:

https://www.abuscranes.com/download/ac79cd9ff7e1eb9da9d1c851bc67fb50/abus_overh

ead_cranes.pdf

[2] ASME B16.21-2011 (Revision of ASME B16.21-2005) Nonmetallic flat gaskets for pipe

flanges. (n.d.). Retrieved from b-ok: http://b-ok.xyz/book/2075926/2c6bb0

[3] Behavior of welded CFT column to H-beam connections with external stiffeners. (n.d.).

Retrieved from ar.booksc.org: http://ar.booksc.org/book/3023206/ad4efd

[4] Book, E. (n.d.). ASM Metals Handbook, Vol 02 Properties and Selection: Nonferrous

Alloys and Special-Purpose Materials. Retrieved from b-ok: http://www.b-

ok.xyz/book/542821/aaeeae

[5] crane hoist duty motors catalog. (n.d.). Retrieved from

http://www.bharatbijlee.com/media/13634/crane_hoistdutymotorscatalogue.pdf

[6] Design Concepts for Jib Cranes. (n.d.). Retrieved from Scribd:

https://www.scribd.com/document/356475547/Design-Concepts-for-Jib-Cranes-pdf

[7] Design for Welding. (n.d.). Retrieved from lecturer.ppns.ac.id:

http://lecturer.ppns.ac.id/munir/wp-content/uploads/sites/14/2015/09/71005378-Design-

for-Welding.pdf

[8] final load distribution trolley beam two-crane picks. (n.d.). Retrieved from www.iti.com:

https://www.iti.com/hs-fs/hub/78935/file-705583916-pdf/docs/~final_load_distribution_-

_trolley_beam__two-crane_picks_042914r1.pdf

[9] H Beam Calculations. (n.d.). Retrieved from ar.booksc.org:

http://ar.booksc.org/s/?q=H+beam+calculations&t=0

[10] H Beam Design. (n.d.). Retrieved from ar.booksc.org:

http://ar.booksc.org/s/?q=H+beam+design&t=0

[11] H Beam Moment of Inertia. (n.d.). Retrieved from

https://www.pinterest.co.uk/pin/349169777339870818/
[12] Hoist and trolley full catalog. (n.d.). Retrieved from www.cmworks.com:

https://www.cmworks.com/Public/11144/Hoist%20and%20Trolley%20Full%20Catalog.

pdf

[13] how to calculate the load capacity of a jib crane. (n.d.). Retrieved from hunker:

https://www.hunker.com/12462977/how-to-calculate-the-load-capacity-of-a-jib-crane

[14] mediathek. (n.d.). Retrieved from www.gis-ag.ch: https://www.gis-

ag.ch/mediathek/pdf/englisch/05-laufkran-englilsch/laufkrane_en.pdf

[15] Shear forces and Bending Moment Diagrams. (n.d.). Retrieved from

notendur.hi.is: https://notendur.hi.is/mvg1/ch4.pdf

[16] Thompson. (n.d.). Structural Design. Retrieved from scholar.sun.ac.za:

https://scholar.sun.ac.za/bitstream/handle/10019.1/1904/Thompson,%20G.B.pdf?sequenc

e=1

[17] wall mounted cantilever jib cranes. (n.d.). Retrieved from cisco eagle:

http://www.cisco-eagle.com/catalog/category/4343/wall-mounted-cantilever-jib-cranes

[18] Wall mounted jib crane. (n.d.). Retrieved from Supporting Structures:

http://smakmanutention.com/products/supportings-structures/Wall-mounted-Jib-crane/

[19] Welding guidlines. (n.d.). Retrieved from homepages.cae.wisc.edu:

http://homepages.cae.wisc.edu/~me349/lecture_notes/welding_guidelines.pdf
 APPENDICES

9. Bill of Material

Sr. No. Name of Component Quantity Material

1. Crane Hook 1 Wrought Iron

2. Trolley 1 Cast Iron Body

3. Hoist 1 Carbon Steel

4. H-Beam 1 Carbon Steel

5. Tie Rod 1 Mild Steel

6. Bolts and Nuts (for each hole) Alloy steel

7. Rope 1 Steel Wires

8. Slewing Bearing 1 Carbon Steel

9. Case Hardened Cast

Internal Gears 2
Iron
10. ASTM BTH Standards

Table I: Basic Crane Data

Table II: Selection of rope

 Table III: Push Girder Trolley Standard Dimensions

Table IV: Suggested Wing Plate widths Table V: Plastic Shear Forces

Table VI: minimum effective Throat for Partial joint Penetration groove welds in steel
Table VII: Hoist Motor Data
11. Manufacturing Details

11.1. H-Beam Manufacturing

11.2. Hoist Manufacturing

11.3. Hook Manufacturing

11.4. Trolley Manufacturing

11.5. Tie Rod Manufacturing

11.6. Bearing Manufacturing

12. Cost Estimate

12.1. Trolley and Hoist

12.2. H Beam
12.3. Slewing Bearing

12.4. Welding and Bolts

12.5. Tie Rod

13. Drawings
13.1. Bracket Exploded View
13.2. Crane Exploded View