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General Purpose Safety CraneJared BushCurtis Blank Zane JacobKatelyn CockrellAlexandria WilliamsProfessor: Cris KoutsougerasAdvisor: Ho-Hoon LeeET 493 - 01November 17, 2016Table of ContentsAbstract pg. 3Progresspg. 4-10Deliverablespg. 11Contributionpg. 12-14Referencespg. 15Appendixpg. 16-29AbstractThe objective of this project is to design a general purpose safety crane that can be used in a variety of industries. The purpose of this project is to prove that we have gained knowledge throughout our engineering curriculum and that we can put that knowledge into perspective. Our senior project is going to involve knowledge from courses that we have taken in the past including mechanical design, strength of materials, statics and so on. The crane will be mounted onto a trailer, allowing it to be mobile. The fact that the crane will be mobile and allow to be repositioned will also make it unique. The main purpose of the crane is to allow workers painting the tops of tanker trucks to secure themselves and use the crane as an anchor point. The crane will be expected to support a load of 5000 lbs., which is the maximum weight of someone falling.Currently there are only a few cranes on the market that could compare to our design. Like our design, some cranes currently available use electric winches to lift objects and some are mounted on trailers as well. What separates our design from the cranes currently available is that our crane will use an overhead trolley that will follow the worker. This will allow the worker to move freely and not be concerned about his/her safety.ProgressOverall Crane Design:For the design of both the trailer and crane, we had to solve for static and dynamic loads. This involved finding forces on objects and determining how to go about finding what material that was best for the application. To help assist us in the design, we used programs such as MATLAB, COMSOL and AutoCAD Inventor. These programs helped us test our design to ensure everything was working properly. Specifically, in AutoCAD inventor we were able to distribute loads and run the design through a simulation.Trailer:For the design of the trailer, we will be using 4”x3”x1/4” steel tubing for the frame. The size of the trailer will be approximately 6’-8” by 10’. We decided on this size because we needed it to fit between the tires of the eighteen wheeler tanker. There will be two ten-foot tubing sections, three feet away from each other, running down the center of the trailer. There will also be two six-foot tubing sections running across the middle of the trailer, three feet away from each other and intersecting with the two ten feet tubing sections running down the middle of the trailer. We decided on a 2000 lb. double axel since it will just have to support the weight of the crane and not any loads because the jacks will be handling that. The trailer will have lights for towing, which will require an electrical hookup to a vehicle.Stability Jacks: There will be four jacks mounted to the trailer, one on each corner, to allow stability in all directions. The jacks will be extendable and constructed of tubing which will slide out of the main frame. Allowing the jacks to extend out will create a larger workspace and sturdier base. We will drill two holes in both the frame tubing and the tubing that the jacks will be attached to. The holes will be for when the smaller tubing is extended; you can insert two locking pins in the two holes. We decided to use two holes to reduce the amount of stress on the pins. Also, one hole will be drilled through both pieces of tubing so that when it is retracted a pin can be inserted to prevent the smaller tubing from sliding out while towing. The large eighteen wheeler tankers have a fifteen-foot gap between the third and fourth set of tires. This gap is where the trailer will be pulled alongside the truck. The two jacks that extend toward the tanker will extend telescopically with two pieces. We thought about having them fold instead of extend, but then they would not be able to go under the truck. The overall length of the jacks will be 14 feet. The inner piece will be 9 feet in length, 7 of which will be exposed while 2 will stay in the other section of tubing. To figure out the material and size of material needed, we had to determine the bending stress and deflection that would occur. To do this we used a free online bending stress calculator. The load, desired beam length, and moments that had been calculated at an earlier date were inputted and as a result the bending stress was given. Using the bending stress, we were able to find a suitable material to use. In addition, once we found a suitable material we ran it through a simulation on COMSOL. The jacks will be constructed of 4.5x4.5x3/16 wall A500 Square Steel Tubing. The outer piece will also be 9 feet in length, 7 of which will be exposed while 2 will stay in the inner section of tubing. It will be constructed of 4x4x5/16 wall A500 Square Steel Tubing. Each section will have an electric jack for stability. We considered using hydraulics, but the electric jacks were cheaper and more user friendly. The two jacks on the opposite side will extend three feet out at a forty-five-degree angle. They will be constructed of 4x4x5/16 wall A500 Square Steel Tubing and the jacks will also be electric. Crane:The crane will use a relatively popular jib crane design. We decided on this because we needed a large boom, but did not have the space for a large angle and the jib crane uses a 90-degree angle. The pillar of the crane will be constructed of a hollow cylindrical tubing and be 20’ in height and be mounted 2’ from the edge of the trailer. We decided on these dimensions so the boom would sit high above the worker’s head. We offset the pillar on the trailer to allow for a smaller boom length and make the crane more stable. To figure out the size of the pillar we had to calculate the bending and buckling stress. We used Euler’s Buckling Theory to find the buckling stress. We also put this into COMSOL for a simulation. The boom will be constructed of a 19’ I-Beam, which will allow us to use a trolley mechanism to contribute to the fall protection of the worker. Like the stability jacks, the bending stress in the beam had to be calculated. This was also put into COMSOL for a simulation. We researched two trolleys that we thought would work, but ultimately decided on Climbtech’s I-Beam Trolley because it was the cheaper of the two and weighed less. Climbtech’s I-Beam Trolley Anchor is designed for fall protection, rope access and work positioning. The trolley is constructed with lightweight aircraft aluminum bars and 360-degree swivel D-Ring connectors. The key features of this trolley is that it weighs 7.7 lbs., it can be mounted on a flange of 3 to 10 inches, and has a breaking strength of 5,000-pound force. An angle sensor will be attached to the trolley, to allow the trolley to move with the worker. The pillar will be able to pivot, allowing the user to turn the boom while in operation. In order to decide on a rotor, we had to calculate the moment at which the rotor will be attached to the pillar. Once that was determined we were able to find a rotor that could withstand the forces. A Rotek Brand rotor, product number A12 - 18E5, will be used. The pivoting portion of the pillar will be mounted at the top end. It will have an upper and lower mount flange. The upper mount flange will have a bolt pattern diameter of 18.874”. The lower mount flange will have a bolt pattern diameter of 14.374”. The two flanges will be connected using twenty 5/8”-11 thread. It will use a bearing system capable of operating under the required conditions. In addition, the rotating part of the pillar will have a locking system to keep the boom from swinging while in use. The boom of the crane will be mounted to the pillar using brackets. Drawings:After we had completed the overall design of the crane, we were able to construct the crane using AutoCAD Inventor. left31750029527530035500center250190003333755715000center1206500center45148500DeliverablesSeptember 2016 Pick project and assign groups (Completed)Brainstorm ideas (Completed)October 2016 Create proposal and presentation (Completed)Revise proposal and create rough design (Completed)November 2016 Finalize proposal and general design (Completed)Detailed design of stabilizer jack (Completed)Detailed design of pillar and boom (Competed) December 2016 Write final proposal and present final presentation (Completed)Next Semester:Anchoring of pillarMotorization and sensor of trolleyConnection of boom to pillarConstruction of prototypeContributionNameContributionZane Jacob Researched different styles of cranes to give us some ideas.Wrote or had some assistance in writing all of the proposals and interim report.Revised all proposals and presentation.Coordinated, collected, and emailed all weekly reports.Assisted Jared, Alex, and Katelyn in calculating the pillar height and boom length.Researched and got prices on trolleys to be used on the boom.Assisted Katelyn, Jared, Alex, and Curtis on the overall design and angles of the stability jacks.Calculated the bending stress and inertia of the stability jacks.Found a suitable steel tube that could withstand the bending stress.Got prices on the steel tubing.Researched and got prices on electric jacks to be used on the stability jacks. Katelyn CockrellResearched different styles of cranes. Assisted in writing some of the proposals, all of presentation and the interim report.Assisted Jared, Alex, and Zane in calculating the pillar height and boom length.Assisted Curtis, Jared, Alex, and Zane on the overall design and angles of the stability jacks.Assisted Jared, Curtis, and Alex in determining the position on the trailer to anchor the pillar to.Researched electric jacks.Calculated the shear stress of the pins used to connect the stability jacks. Determined the diameter and length of the pins used to connect the stability jacks.Found a supplier and got prices for the pins.Jared BushCame up with the overall design of the trailer.Assisted Katelyn, Alex, and Zane in writing the first proposal.Researched and got prices on trolleys to be used on the boom.Assisted Katelyn, Alex, and Zane in calculating the pillar height and boom length.Assisted Katelyn, Curtis, Alex, and Zane on the overall design and angles of the stability pleted rough sketch drawings with measurements.Assisted Curtis in configuring the length of the stability jacks. Researched dimensions of an eighteen wheeler trailer. Assisted Curtis, Alex and Katelyn in determining the position on the trailer to anchor the pillar to.Curtis BlankCompleted all 3D drawings on AutoCAD Inventor.Designed a 3D drawing of the trailer and ran it through simulations.Calculated the inertia and velocity.Calculated the moment load around the bearings.Researched and got prices on bearings to be used for the pivoting boom.Assisted Katelyn, Jared, Alex, and Zane on the overall design and angles of the stability jacks.Assisted Jared in configuring the length of the stability jacks. Assisted Jared, Alex, and Katelyn in determining the position on the trailer to anchor the pillar to.Alexandria WilliamsResearched and narrowed down the eligible options for adequate power supply for the hydraulic systems. Researched the measurements of 18 wheelers in order to get an exact number for each aspect of the trailer and crane. Assisted in writing the papers needed and setting up the PowerPoint for the class presentation. Helped in redesigning the crane and all of its aspects.Assisted Jared, Alex, and Zane in calculating the pillar height and boom length.Assisted Curtis, Jared, Katelyn, and Zane on the overall design and angles of the stability jacks.Assisted Katelyn, Jared, and Zane in writing the first proposal.Assisted Katelyn, Jared, and Zane in calculating the pillar height and boom length.Assisted Jared, Curtis, and Katelyn in determining the position on the trailer to anchor the pillar to.ReferencesA. (n.d.). SIMPLY SUPPORTED STRUCTURAL BEAM WITH TWO CONCENTRATED LOADS. Retrieved November 17, 2016, from Engineering Data Manual - . (n.d.). Retrieved November 17, 2016, from T., B., & O. (2014). Home. Retrieved October 17, 2016, from Trailer Images. (n.d.). Retrieved October 17, 2016, from Appendix:General Calculations Chart95251143000** The below diagrams and charts are the results of an online bending stress calculator. The forces, distances of forces, and size of beam were inputted and in return the output parameters/results were given. **Second Moment of Area – The capacity of a cross-section to resist bending.Radius of Gyration (Area) – The distance from an axis at which the area of a body may be assumed to be concentrated and the second moment area of this configuration equal to the second moment area of the actual body about the same axis.Section Modulus – The moment of inertia of the area of the cross section of a structural member divided by the distance from the center of gravity to the farthest point of the section, a measure of the flexural strength of the beam.-635-17145000*Note: P1 and P2 are positive in downward direction as shown in the figure and negative in upward direction.Please Wait...? *Note: R1 and R2 are vertical end reactions at the left and right, respectively, and positive upward. Shear forces and deflections are positive in upward direction and negative in downward direction. All moments are positive when producing compression on the upper portion of the beam cross section. All slopes are positive when up and to the right. Material(s)NameSteel, MildGeneralMass Density0.283599 lbmass/in^3Yield Strength30022.8 psiUltimate Tensile Strength50038 psiStressYoung's Modulus31908.3 ksiPoisson's Ratio0.275 ulShear Modulus12513.1 ksiPart Name(s)ASTM A6_A6M - W8 x 31 (8x8) - 228.iptBoom Base Flange.iptBoom End Cap.iptBoom Gusset.iptBoom Gusset.iptBoom Gusset.iptBoom End Cap.iptBoxing Gusset.iptBoxing Gusset.iptANSI - 12 x 0.375 - 12.iptUpper Boom Plate.ipt Operating conditions Force:1Load TypeForceMagnitude5000.000 lbforceVector X0.000 lbforceVector Y5000.000 lbforceVector Z0.000 lbforceSelected Face(s)Constraint NameReaction ForceReaction MomentMagnitudeComponent (X,Y,Z)MagnitudeComponent (X,Y,Z)Fixed Constraint:15000 lbforce0 lbforce90206.1 lbforce ft89136.1 lbforce ft-5000 lbforce0 lbforce ft0 lbforce13852.8 lbforce ft Fixed Constraint:1Constraint TypeFixed Constraint Selected Face(s) Selected Face(s) Results Reaction Force and Moment on Constraints Result SummaryNameMinimumMaximumVolume2936.47 in^3Mass832.78 lbmassVon Mises Stress0.00721782 ksi166.254 ksi1st Principal Stress-20.4174 ksi74.2412 ksi3rd Principal Stress-193.52 ksi9.50083 ksiDisplacement0 in4.58417 inSafety Factor0.180584 ul15 ul Von Mises Stress 1st Principal Stress 1st Principal Stress 3rd Principal Stress Displacement Displacement Safety Factor Material(s)NameSteel, MildGeneralMass Density0.283599 lbmass/in^3Yield Strength30022.8 psiUltimate Tensile Strength50038 psiStressYoung's Modulus31908.3 ksiPoisson's Ratio0.275 ulShear Modulus12513.1 ksiPart Name(s)pedestal base.ipt Base Gusset.iptBase Gusset.iptBase Gusset.iptBase Gusset.iptANSI - 12 x 0.375 - 168.iptSuperstructure Lower Bearing Flange.ipt Operating conditions Force:1Load TypeForceMagnitude6100.000 lbforceVector X0.000 lbforceVector Y-6100.000 lbforceVector Z-0.000 lbforce Force:2Load TypeForceMagnitude5000.000 lbforceVector X1816.248 lbforceVector Y-0.000 lbforceVector Z4658.459 lbforceConstraint NameReaction ForceReaction MomentMagnitudeComponent (X,Y,Z)MagnitudeComponent (X,Y,Z)Fixed Constraint:18085.34 lbforce-1899.27 lbforce70653.8 lbforce ft-65706.1 lbforce ft6364.28 lbforce220.844 lbforce ft-4611.01 lbforce25973.4 lbforce ft Result SummaryNameMinimumMaximumVolume2915.29 in^3Mass826.775 lbmassVon Mises Stress0.000128109 ksi29.2587 ksi1st Principal Stress-2.10199 ksi30.6146 ksi3rd Principal Stress-30.3656 ksi2.70217 ksiDisplacement0 in0.910135 inSafety Factor1.02612 ul15 ulStress XX-6.64347 ksi4.42783 ksiStress XY-7.7722 ksi9.26801 ksiStress XZ-0.912869 ksi4.89742 ksiStress YY-17.7239 ksi19.4332 ksiStress YZ-4.34079 ksi13.5421 ksiStress ZZ-11.3198 ksi14.5132 ksiX Displacement-0.000224874 in0.277285 inY Displacement-0.0554324 in0.055517 inZ Displacement-0.000162315 in0.865242 inEquivalent Strain0.00000000345221 ul0.000810477 ul1st Principal Strain-0.000000174593 ul0.000935226 ul3rd Principal Strain-0.000918586 ul0.00000183427 ulStrain XX-0.000173652 ul0.000154108 ulStrain XY-0.000310563 ul0.000370333 ulStrain XZ-0.0000364767 ul0.000195692 ulStrain YY-0.000545069 ul0.000607144 ulStrain YZ-0.00017345 ul0.000541118 ulStrain ZZ-0.000164228 ul0.000291842 ulContact Pressure0 ksi42.7549 ksiContact Pressure X-12.8054 ksi8.0062 ksiContact Pressure Y-27.253 ksi30.2962 ksiContact Pressure Z-30.0303 ksi5.90252 ksi ................
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