Professional Documents
Culture Documents
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
AUTHORS
ME090330
ME090254
ME090253
ME090251
ME090248
SECTION
: 3A
GROUP
LECTURER
TABLE OF CONTENTS
Abstract
Introduction
Literature Review
Objective
Background
Specifications
Methodology
Cost Estimation
11
12
Reference
13
Appendices
10
ABSTRACT
For this project, our group will have to design a double girder bridge crane. By
referring to the Power Transmission Case Study chapter, a step-by-step solution is
studied through in order for us to obtain a design. In the design of this case, the
components of the double girder bridge crane are dependant on one another. Hence,
by knowing a few parameters, assumptions can be made to design the other parts of
the component. Throughout this project, we as a student managed to think
innovatively and critically in determining the parameters required in the design. Any
incorrect assumption made will result in a bad outcome to the design. Also, students
are trained to think meticulously as calculation for the gears, shafts and bearings must
3
INTRODUCTION
In an industrial environment that involves a massive engineering knowledge,
many types of applications have been engineered to ease the human burden. A
commonly used application is the overhead crane or bridge crane. The overhead crane
consists of parallel runways with travelling bridge spanning the gap that carries a
hoist that travels along the bridge [1]. A hoist is the lifting component of the crane that
is mounted on a trolley for horizontal movement. The end trucks are attached at right
angles to the girders and move on fixed runways. The overhead crane is powered by
electricity. This is mainly used in refinement of steel. When the metal leaves the
factory in a finished product, an overhead crane handles it. Where else, the
automobile industry uses the overhead crane to handle raw materials. Cranes come in
a variety of styles and are used with a number of attachments to facilitate load lift.
Double Girder Bridge Cranes are most frequently used where capacities over 10 tons
and/or spans of 60 to 100 feet are needed. They can be utilized at any capacity where
extremely high hook lift is required because the hook can be pulled up between the
girders. Double Girder Bridge Cranes are also ideal where high speeds and heavy
service are required. They are highly suitable where the crane needs to be fitted with
walkways, crane lights, cabs, magnet cable reels or other special equipment. EMH is
capable of building cranes for loads up to 500 tons.
LITERATURE REVIEW
The most frequently used design is the top running double girder bridge cranes
where capacities over 10 tons and spans of 60 to 100 feet are needed. They can be
utilized at any capacity where extremely high hook lift is required because the hook
can be pulled up between the girders. Double Girder Bridge Cranes are also ideal
where high speeds and heavy service are required [2]. They are highly suitable where
the crane needs to be fitted with walkways, crane lights, cabs, magnet cable reels or
other special equipment. Manufacturing companies are capable of building cranes for
loads up to 500 tons. The double girder industrial series overhead crane shows a
proven track record of reliability and quality. General workshop duty cranes range
from 5 ton to 160 ton capacity. The cranes featured are double box girder with the
hoist crab unit running on rails attached to the top flange. A feature of the double
girder crane is that it offers maximum hook height of all the crane configurations. The
double girder crane can cater for spans up to 40 meters. The crane is available with
single or double hoists pendant or radio control and inverter motor drives.
Tasks
Analysing the problem
Deciding the types of the
gearbox
Dividing the work
Design the overhead crane
gearbox
Finalising the model
Report
Presentation
Start
Duratio End
Date
n
Date
16-Jun
3 19-Jun
20-Jun
23-Jun
01-Jul
14-Jul
21-Jul
12-Aug
1
1
21-Jun
24-Jun
10
11-Jul
2 16-Jul
7 28-Jul
1 13-Aug
2-Mar
18-Sep
10-Jun
Duration (Days)
Start Date
BACKGROUND
A gearbox transmits a power of 3.728kW. The power is transmitted by gears while the
input speed of 1800 rpm is reduced to an output speed of 87 rpm. This output speed is
within the acceptable range the unit can endure.
SPECIFICATIONS
a. The gears are used as the drive components of the gearbox with a power
transmission of 5hp or 3.728kW.
b. Cost of the gearbox should be minimal.
c. The design life of the gearbox is more than 12000 hours of its continuous
operation.
d. Design the intermediate shaft with complete specification of the gears,
bearings, keys and output shaft.
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METHODOLOGY
Gears
Material Steel Grade 1 Flame-Hardened
Type Spur gears
Reason
Bearing
Material 1020 Cold-Drawn Steel
Reason
Shafts
Material 1020 Cold-Drawn Steel
Reason Has high modulus of elasticity so that deflection caused by multi-axial
stress from combination of bending moment and torque is minimized.
Keys
Material 1020 Cold-Drawn Steel
Type Woodruff Key
Reason Ductile. Keys are loaded with stress hence it will reduce failure rate.
Lubrication
Type Liquid Lubricant (Chlorofluorocarbon)
Method Grease Lubrication ( Bearing ) , Gear Oil ( Gears )
Reason
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BILL OF MATERIAL
BILL OF MATERIALS
1) GEARS
US $ 258
RM 824.34
Gear 3 Grade 1 Through Hardened US $ 170
RM 543.17
Gear 4 Grade 1 Flame Hardened
US $ 258
RM 824.34
Gear 5 Grade 1 Flame Hardened
US $ 258
RM 824.34
2) SHAFT
3) BEARING
4) LUBRICANT
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13
14
15
16
B) GEAR 2
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C) GEAR 3
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D) GEAR 4
19
E) GEAR 5
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F) INTERMEDIATE SHAFT
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G) OUTPUT SHAFT
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23
ASSEMBLY OF GEARBOX
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CONCLUSION
As a conclusion, we have achieved the objective of the project. We are able to
design a double girder bridge crane, which consists of gears, rolling element bearing,
shaft and keys. We have learned to assume some parameters before designing the
gearbox such as its number of teeth on its gear, the diameter and length of the shaft
and number of bearings needed in order for the gearbox to withstand a power
transmission of 3.7285kW. Moreover, we have learned how to make correct and
precise calculations in order to produce gearbox that is optimized for its functional
use. In this project, the intermediate shaft is designed as shown in Figure 2(a), Also,
the specification of the gear has a minimum safety factor of 1.86 that is for Gear 3.
The keys have a length of 3.73mm and bearing is chosen from SKF Internet catalog as
shown in analysis. The specifications of this project are successfully followed. We
have designed a gearbox where its component can last to more than 12000 hours of its
continuous operation. Most importantly, we have learned to work as a team and
discuss problems with our teammates in order to tackle problems efficiently. At last,
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we want to thank our machine design lecturer Dr. Omar Suliman Zaroog for guiding
and helping us throughout this project.
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REFERENCE
[1] Overhead Crane. (20 August 2014). Retrieved from
http://en.wikipedia.org/wiki/Overhead_crane
[2] Product- Double Girder Crane. (20 August 2014). Retrieved from
http://www.multicrane-asean.com/double_girder.html)
[3] Richard G. Budynas, J. Keith Nisbett (2011). Shigleys Mechanical Engineering
Design. McGraw Hill.
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APPENDICES
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