Buskerud and Vestfold University College

CRANE MECHANICAL

BACHELOR PROJECT

Mechanical Engineering

Wrote: Mario Rodriguez Estrada

Supervised: Truls A. Frednes

Printed: November 2014

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TABLE OF CONTENTS

1. INTRODUCTION 4
1.1 Objectives of the structural part 4
1.2 Objectives of the mechanical design 4

2. STRUCTURAL CALCULUS OF THE CRANE 5

2.1 Proprieties of the bars 6
2.2 Degree of indeterminacy 7
2.3. Calculus of the forces in the structure 8
2.4 Structure diagrams 10
2.5 Strain in B3 bar 12
2.6. Stress in B1 and B2 bars 12
2.7. Total stress validation using Von Misses yield 14
criterion

3. MECHANICAL EQUIPMENT 15
3.1. Engine power 16

3.2. Wire-drum speed (nt) 16

3.3. Speed of the pulleys 17

3.4. Gear ratio between engine and the small pulley 17
3.5. Incoming speed in the gear box 18

3.6. Speed ratio in the gear box 18

3.7.Dimension the incoming gear 18
3.8. The engine speed when the effect is reduced 19

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4. CONCLUSIONS: 19

5. REFERENCES AND BIBLIOGRAPHY: 20

ATTACHED: 21

I. Software calculated forces in the crane 21

II. Drawings 22

ABSTRACT:

This report explains the structural and mechanical design of a crane located in a
offshore platform.

The introduction summarizes the two main parts of the project, the structural calculus
of the crane and the mechanical design of the equipment. The report continues with
the structural calculus of the crane, both theoretical and using a software. Following,
the structural calculus and the mechanical design of the equipment are detailed.
Finally, the conclusions show that, by following the mentioned steps the objectives
have been achieved. The integrity of the crane and the possibility to be built have
been demonstrated. Regarding to the mechanical design, the suitability of the
equipment has been validated and the conditions required to meet by the gear box
determined.

The bibliography and the attachments can be found at the end.

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1. INTRODUCTION:

This project deals with the structural calculus of a mechanical crane, and the
dimensioning of the mechanical equipment. The crane is located in an offshore
platform and is used to lift boats.

This report is divided in two parts: the structural calculus of the crane and the
mechanical dimensioning of the equipment. The conclusions of the report are detailed
to finish it.

1.1 Objectives of the structural part:

The objectives of this part are to calculate the forces and stress in the crane and to
determine if the design of the crane and the material are appropriated.

To achieve the objectives the steps followed were: 1. Determine the proprieties of the
bars (inertia moment and area) which are necessary to carry the rest of the
calculations required, 2. Determine the determinacy, 3. Calculate the forces in the
structure, 4. Draw the structure diagrams, 5. Calculate the necessary strain and stress
and 6. Check the total stress and utilization U.

1.2 Objectives of the mechanical design:

The objectives of the second part are the calculus and dimensioning of the mechanical
equipment.

The steps in the second part were: 1. Calculate the engine power, 2. Determinate the
wire-drum speed, 3. Obtain the speed of the pulleys, 4. Determinate the gear ratio
between the engine and the small pulley and 5. The incoming speed on the gearbox, 6.
Calculate the speed ratio in the gear box. 7. Dimension the incoming gear, 7. Calculate
the differences when the engine effect is reduced.

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2. STRUCTURAL CALCULUS OF THE CRANE:

The crane is made of steel whit a SY = 355 MPa , and with a Working Load Limit of
5*103 Kg. It means that it is capable of lifting a mass m=5 tonnes in accordance to the
NORSOK offshore rules. The steel wire is connected to a winch, running through a
frictionless hoist as can be seen in the annexe number one.

The structure of the crane can be discretized as an structure of four bars and four
nodes as it appears in the Figure 2.1.

The calculus are handmade. Nevertheless, some results have been checked using a
simulation software based in the direct stiffness method.

Figure 2.1: Discretized structure

The B2 and B1 bars are the pillar of the crane, made of a pipe with Ø=600 mm and
thickness=10 mm. The bar B3 has a diameter of 20 mm, Length L=5m and the bar B4
has Ø=200 mm and thickness=5mm.

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The model used for de simulation with the software is shown in the Figure 2.2:

Figure 2.2: Structure model used for simulation

Two additional bars are required in the model to simulate the two small bars resulting
from the union between the pillar and the other bars.

This two small bars are modelled using the same properties of the B4 bar, because the
lack of information about them. However, this approximation is not so far from the
reality.

2.1 Proprieties of the bars:

B1 and B2 bars:

A1=A2= π(R2-r2) =π(3002-2902)= 18535,4 mm2

I1=I2= π/4(R4-r4) =π/4(3004-2904)= 806753139,5 mm4

Fig 2.3 a): B1 and B2 bars section

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B3 bar:

A3= πr2 =π102= 314,16mm2

I3= (π/4)r4 =(π/4)(104)= 7853,98 mm4

Fig 2.3 b): B3 bar section

B4 bar:

A4= π(R2-r2) =π(1002-952)= 3063,05 mm2

I4= π/4(R4-r4) =π/4(1004-954)= 14568645,06

mm4

Fig 2.3 c): B4 bar section

2.2. Degree of indeterminacy:

It is possible to know if the structure is statically determinate or indeterminate by

applying the following expression:

𝐷𝑖 = 3 ∙ 𝐵 − (3 ∙ 𝑅 + 𝑙 + 𝑙𝑠 ) (Eq.2.1)

B = number of bars

R = number of reactions

l = number of freedoms in the nodes

ls = number of freedoms in the supports

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Substituting values in the Eq.2.1 expression :

𝐷𝑖 = 3 ∙ 4 − 3 ∙ 3 + 3 + 0 = 0

This structure is therefore statically determinate allowing to obtain the forces by

means of equilibrium equations.

2.3. Calculus of the forces in the structure:

It is possible to decompose the force of the weight in two components, one vertical
and one horizontal as is showed in the Figure 2.4

Figure 2.4: External forces over the structure

Where 𝑭𝟐 = 5 ∙ 103 ∙ (cos 60) ∙ 9,8 = 24500 𝑁 and 𝑭𝟏 = 5 ∙ 103 ∙ (1 + cos 30) ∙
9,8=91435,24 𝑁

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Applying global equilibrium at the structure the reactions in the fixed support can be
obtained.

Σ𝐹𝑥 = 0

Σ𝐹𝑦 = 0 (Eq.2.2 a);b);c))

Σ𝑀 = 0

𝑭𝒙𝒂 = 24500 𝑁; 𝑭𝒚𝒂 = 91435,24 𝑁; 𝑴𝒂 = 355892,5 𝑁𝑚

Then, dividing the structure in bars and nodes all the internal forces in each element
can be calculated by equilibrium.

B1: B2: B3: B4:

𝑵𝒙𝟏 = 0 𝑁 𝑵𝒙𝟐 = 91435,24 𝑁 𝑵𝒙𝟑 = 66935 𝑁 𝑵𝒙𝟒 = 129308,68𝑁

𝑽𝒚𝟏 = 66935 𝑁 𝑽𝒚𝟐 = 24500 𝑁

𝑴𝒛𝟐 𝒙 = 𝑥 ∙ 𝑉𝑦2 + 𝑀𝑎

𝑴𝒛𝟐 𝒙 = 𝟏 = 380392,5 𝑁𝑚

𝑴𝒛𝟏 𝒙 = 𝑥 ∙ 𝑉𝑦1

𝑴𝒛𝟏 𝒙 = 𝟓 = 334575 𝑁𝑚

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2.4. Structure diagrams:

After the forces B1 and B2 in bars were calculated, the forces diagrams of the pillar can
be drawn. Normal force, shear force and bending moment force diagrams were
considered.

This diagrams are shown in Figure 2.5.

Figure 2.5: Diagrams of forces pillar

To calculate this forces and draw the diagrams can also be easily done using the
software. In the following table the results of both methods are presented ( hand
calculated and software calculated) to be compared .

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𝑵𝒙 𝑽𝒚
Theoretical 0𝑁 66935 𝑁
Bar1
Analysis ≈ 0𝑁 66935,24𝑁

Theoretical 91435,24 𝑁 24500 𝑁

Bar 2
Analysis 91435,24 𝑁 24500 𝑁

Theoretical 66935 𝑁 0𝑁
Bar 3
Analysis 66935,24 𝑁 0𝑁

Theoretical 129308,68𝑁 0𝑁
Bar 4
Analysis 129308,96𝑁 0𝑁

Table 2.1: Forces obtained comparison

As it can be seen in the Table 2.1, the values of the forces obtained with hand
calculations are really close to the values obtained with the software.

It is possible to compare the bending moment in the pillar (B1 and B2 bars) too. The
bending moment doesn't have a constant value, therefore the comparison will be
between the values in the join of the two bars.

𝑴𝒛
Theoretical 334575 𝑁𝑚
Bar1
Analysis 334676,2 𝑁𝑚

Theoretical 380392,5 𝑁𝑚
Bar 2
Analysis 380400 𝑁𝑚

Table 2.2: Values of the bending moment in the pillar.

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Again the both methods lead to nearly the same values, as it can be observed s in Table
2.2. Therefore the check was successful.

2.5. Strain in B3 bar:

The strain in bar B3 can be calculated applying the Hook Law. However, to do so, it is
necessary obtain first the stress in B3 bar.

This bar B3 is only under the effect of normal force Nx3. The stress will be determinate
by the expression Eq 2.3:

𝑁𝑥 𝑀𝑧
𝜎𝑥𝑥 = + (Eq. 2.3)
𝐴 𝑊𝑧

𝑁𝑥3 66935𝑁
𝜎𝑥𝑥 = = = 2,13 ∙ 108 𝑁 𝑚2
𝐴3 314,16 ∙ 10−6 𝑚2

Then, using the Hook Law σ=ε∙E the strain in the bar will be:

𝜎 𝑁𝑥3 (Eq. 2.4)

𝜺= = = 𝟏, 𝟎𝟏 ∙ 𝟏𝟎−𝟑
𝐸 𝐸 ∙ 𝐴3

2.6. Stress in B1 and B2 bars:

The pillar (B1 and B2 bars) are under normal force, shear force and bending moment
force. Despite the forces are not the same in B1 and B2 bars, it is only necessary
reaching the bending moment the highest value. The stress σxx can be calculated using
the Eq. 2.3 expression:

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𝑁𝑥1 𝑀𝑧1 𝑀𝑧1 ∙ 𝑦𝑚𝑎𝑥

𝜎𝑥𝑥 1 = + = 0+ ;
𝐴1 𝑊𝑧1 𝐼𝑧1

𝑁𝑥2 𝑀𝑧2 𝑁𝑥2 𝑀𝑧1 ∙ 𝑦𝑚𝑎𝑥

𝜎𝑥𝑥 2 = + = + ;
𝐴2 𝑊𝑧2 𝐴2 𝐼𝑧1

334575 𝑁𝑚 ∙ 0,3𝑚
𝝈𝒙𝒙𝟏 = 0 + = 𝟏𝟐𝟒, 𝟒𝟐 ∙ 𝟏𝟎𝟔 𝑵 𝟐
806753139,5 ∙ 10−12 m4 𝒎

91435.24 𝑁 380392,5 𝑁𝑚 ∙ 0,3𝑚

𝝈𝒙𝒙𝟐 = + = 𝟏𝟒𝟔, 𝟑𝟗 ∙ 𝟏𝟎𝟔 𝑵 𝟐
−6
18535,4 ∙ 10 m 2 806753139,5 ∙ 10−12 m4 𝒎

Because of the shear force, there are shear stress in bars B1 and B2 that can be
obtained knowing the shear force. Nevertheless, it should be noted that as they are
thin walled bars, the shear stress will be more important than in solid sections.

To determinate the shear stress it can be used the expression Eq.2.5:

𝑄 ∙ 𝑉𝑦
𝜏𝑥𝑦 = (Eq.2.5)
𝐼∙𝑒

I= Inertia moment

Q = Static moment ( first inertia moment)

e = Thickness

Vy = Shear force

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Additionally, the maximum value of the shear stress can be calculated using the
following expression:

2 ∙ 𝑉𝑦 (Eq.2.6)
𝜏𝑥𝑦 𝑚𝑎𝑥 =
𝐴

2 ∙ 𝑉𝑦1 2 ∙ 66935𝑁
𝜏𝑥𝑦 1 = = = 7,22 ∙ 106 𝑁 2
𝐴1 18535,4 ∙ 10−6 m2 𝑚

2 ∙ 𝑉𝑦2 2 ∙ 24500𝑁
𝜏𝑥𝑦 2 = = = 2,64 ∙ 106 𝑁 2
𝐴2 18535,4 ∙ 10−6 m2 𝑚

2.7. Total stress validation using Von Misses yield criterion:

The Von-Misses yield criterion was used to verify the total stress. The expression
considered for the non principal stress is the following:

𝜎𝑉𝑀 = 2 + 3𝜏 2
𝜎𝑥𝑥 (Eq.2.7)
𝑥𝑦

As there are two different bars (B1 and B2) in the pillar, the validation was carried in
both bars. It is possible to know looking at the stress calculated in the point 2.6 that
the B2 bar is more critical.

𝜎𝑉𝑀1 = (124,42 ∙ 106 )2 + 3(7,22 ∙ 106 )2 = 125,05 ∙ 106 𝑁 𝑚2 < 355 ∙ 106 𝑁 𝑚2

𝜎𝑉𝑀2 = (146,39 ∙ 106 )2 + 3(2,64 ∙ 106 )2 = 146,46 ∙ 106 𝑁 𝑚2 < 355 ∙ 106 𝑁 𝑚2

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The utilisation U can be determined as a coefficient between the yield stress and the
Von Misses stress.

U1= 125,05/355=0,35<1

U2=146,46/355=0,41<1

Therefore the integrity of the structure is justified.

3. MECHANICAL EQUIPMENT :

This section deals with the dimensioning and calculation of the mechanical equipment
required for the crane operation with a capacity of 5 Tonnes and a lifting speed of 10
cm/s.

The rotation speed of the electric motor is 𝑛m=1500 rpm. This speed is reduced by 2%.
The motor is attached to a standard gear with Dm= 200mm and Zm = 20.

The lifting wire is wound on to a drum with a diameter Dt =200mm. The pulleys of the
belt transmission have diameters of Dr1=1200mm and Dr2=300mm. And the belt
transmission has a lost effect of 6%.

Figure 3.1: Scheme of the mechanism

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3.1. Engine power:

The wire produce a force in the drum Ft = 5000 ∙ 9,8 =49000 N which generates and
this force produce a torque what can be determinate applying the expression Eq.3.1:

𝑇 = 𝑟𝑥𝐹 (Eq.3.1)

In this case, only the module is concern therefore it is possible to use a dot product.

Tt= Ft ∙ rt=49000∙0,1=4900 Nm.

The lifting speed is Vt=10 cm/s = 0,1 m/s. Consequently the power of the lifting wire
was calculated according to the equation Eq.3.2:

𝑃 =𝑣∙𝐹 (Eq.3.2)

Pt = V t∙Ft = 0,1∙49000=4900 W = 4,9 kW

The power of the engine must be the same of the power demanded in the wire:

PE = Pt= 4,9 kW

3.2. Wire-drum speed (nt):

It is easy to determine the wire-drum speed from the power or lifting speed using one
of the Eq. 3.3 or Eq.3.4 expressions:

𝑃 =𝑇∙𝜔 (Eq.3.3)

𝑣 =𝑟∙𝜔 (Eq.3.4)

𝑣 𝑃
𝒏𝒕 = = = 1 𝑟𝑎𝑑 𝑠 = 𝟗, 𝟓𝟒 𝒓𝒑𝒎
𝑟 𝑇

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3.3. Speed of the pulleys:

The speed of the pulley which is connected to the wire-drum, the large pulley, will be
the same speed of the wire-drum. Therefore the speed of the large pulley is:

𝒏𝟏 = 𝑛𝑡 = 𝟗, 𝟓𝟒 𝒓𝒑𝒎

The transmission ratio between the two pulleys can be expressed according to the
equation Eq.3.5:

𝑛2 𝐷𝑟1 (Eq.3.5)
𝑅1 = =
𝑛1 𝐷𝑟2

1200
𝑅1 = =4
300
𝒏𝟐 = 𝑛1 ∙ 𝑅1 = 9,54 ∙ 4 = 38,16 𝑟𝑝𝑚

However it is necessary to correct this value because of the fact that the belt
transmission has a lost effect of 6%.
𝑛2
𝒏𝟐′ = = 𝟒𝟎, 𝟔 𝒓𝒑𝒎
0,94

3.4. Gear ratio between engine and small pulley:

The gear ratio between the engine and the small pulley can be obtained using the expression
Eq.3.5:

𝐷𝑟2 300𝑚𝑚
𝑹𝟐 = = = 𝟏, 𝟓
𝐷𝑚 200𝑚𝑚

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3.5. Incoming speed on the gear box:

Knowing that the speed of the engine is reduced by 2%, the real speed will be:

𝒏𝒎′ = 𝑛𝑚 ∙ 0,98 = 1500 ∙ 0,98 = 𝟏𝟒𝟕𝟎 𝒓𝒑𝒎

Therefore this speed 𝑛m' is the incoming speed in the gearbox and the outgoing speed
will be 𝑛2' , then the gearbox must reduce the speed from the incoming speed to the
outgoing speed.

3.6. Speed ratio in the gear box:

The speed ratio will be the relation between these two speeds:

𝑛𝑚′ 1470
𝑹𝟐 = = = 𝟑𝟔, 𝟐𝟎
𝑛2 ′ 40,6

3.7.Dimension the incoming gear:

The two engage sprockets should have the same modulus, m, and the same pitch, p.
Both, the modulus and the pitch are related by the expression Eq.3.6:
𝑝 𝑑
𝑚= = (Eq.3.6)
𝜋 𝑍

The gear connected to the engine has a number of teeth Zm = 20 and a diameter Dm=
200mm.
Then, according to the equation Eq.3.6, the modulus will be:

200
𝒎= = 𝟏𝟎
20

Consequently, the incoming gear of the gear box should have the same modulus m=10,
thus, the diameter must be ten times the number of teeth.

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3.8. The engine speed when the effect is reduced by the system

The effect is reduced by the system by 37%, which means that the 37% of the power
produced by the engine is lost in the way to the wire-drum.
The lifting speed in the wire-drum must be the same and therefore the power as well.

The engine has to produce 37% additional power than the demanded in the wire to
meet the needs:

PE'= =4900 W /0,63 = 7,77 kW

The new engine speed is determined by the expression Eq.3.3 and considering it is
reduced by 2%:
𝑛𝑚
𝒏𝒎′′ = = (1500 ∙ 0,98)/0,63 = 𝟐𝟑𝟑𝟑, 𝟑𝟑 𝒓𝒑𝒎
0,63

4. CONCLUSIONS

Regarding to the first part of the report, the structural calculus of the crane, and
looking at the forces, the most stressed bars are B3 and the pillar (B1 and B2 bars). In
addition, the most critical section within the pillar is the join between B1 and B2 bars.
However, the integrity of the structure has been justified by calculating the maximum
stress in this section and applying the Von Misses. Therefore, it is possible to built this
crane to be used in the conditions described. Nevertheless, it would be necessary
more calculations such as stress concentrations in some parts or a buckling study to
ensure the suitability of the crane in the described conditions.

According to the second part of the report, the mechanical equipment design, it is
possible to built this equipment assuming the energy lost in the belt transmission, and
noticing that the gearbox must have an incoming gear with a determinate modulus.
The incoming speed is approximately 36 times the value of the outgoing. In the case of
the energy wasted, it will be necessary increase the engine speed in order to produce
more power and keep then the lifting speed within the proper range of values. The
gear box would have to be modified in that case.

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5. REFERENCES AND BIBLIOGRAPHY:

[1]: Ortiz Berrocal, Luis: Resistencia de materiales. Madrid, MacGraw-Hill, 2007

ISBN 978-84-481-5633-6

[2]: Garrido García, José A.: Resistencia de materiales. Valladolid, Universidad de

Valladolid, 1999 ISBN 84-776-2951-X

[3]: Cook, Nathan H. : Mechanics and Materials for Design. Singapore, Mc Graw-Hill,
1987 ISBN 0-07-012486-8

[4]: Hibbeler, R. C. : Mechanics of Materials. Singapore, Pearson, 2008 ISBN 981-06-

7994-7

[5]: Budynas, Richard G. and Nisbett, J. Keith: Shigley's Mechanical Engineering Design.
New York, MacGraw-Hill, 2008 ISBN 978–0–07–352928–8

[6]: Uicker, John Joseph: Theory of machines and mechanisms. New York, Oxford
University Press, 2003 ISBN 01-951-5598-X

[7]: Cardona Foix, Salvador; Clos Costa, Daniel: Teoría de máquinas. Barcelona,
Ediciones UPC, 2008 ISBN 978-84-8301-962-7

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ATTACHED:

I. Software calculated forces in the crane:

0,00 0,62 1,25 1,88 2,5 3,12 3,75 4,38 5,00

Bar Nx 86,58E-04 86,58E- 86,58E- 86,58E- 86,58E- 86,58E- 86,58E- 86,58E- 86,58E-04
1 04 04 04 04 04 04 04
Vy 6,69E04 6,69E04 6,69E04 6,69E04 6,69E04 6,69E04 6,69E04 6,69E04 6,69E04
Mz 43,29E-04 4,183E04 8,367E04 12,55E04 16,73E04 20,92E04 25,1E04 29,28E04 33,47E04
0,00 0,12 0,25 0,38 0,50 0,62 0,75 0,88 1,00
Bar Nx 9,144E04 9,144E04 9,144E04 9,144E04 9,144E04 9,144E04 9,144E04 9,144E04 9,144E04
2 Vy 2,45E04 2,45E04 2,45E04 2,45E04 2,45E04 2,45E04 2,45E04 2,45E04 2,45E04
Mz 38,04E04 37,73E04 37,43E04 37,12E04 36,81E04 36,81E04 36,2E04 35,9E04 35,54E04
0,00 0,62 1,25 1,88 2,50 3,12 3,75 4,38 5,00
Bar Nx 6,694E04 6,694E04 6,694E04 6,694E04 6,694E04 6,694E04 6,694E04 6,694E04 6,694E04
3 Vy - - - - - - - - -
Mz - - - - - - - - -
0,00 0,88 1,77 2,65 3,54 4,42 5,30 6,19 7,07
Bar Nx 12,93E04 12,93E04 12,93E04 12,93E04 12,93E04 12,93E04 12,93E04 12,93E04 12,93E04
4 Vy - - - - - - - - -
Mz - - - - - - - - -

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