Kathmandu University

School of Engineering
Department of Mechanical Engineering
(Design and Manufacturing)

PROJECT PROPOSAL ON DESIGN

AND FABRICATION OF MINI
PORTABLE CRANE

Submitted by:

Mukti Mishra 026076-19

Sabal Katuwal 026071-19
Sajal Maskey 026075-19
Sandeep Gauli 026065-19
Shahil Adhikari 026061-19

October-17, 2020
 PROJECT EVALUATION

DESIGN AND FABRICATION OF MINI PORTABLE

HYDRAULIC CRANE

By

Mukti Mishra 026076-19

Sabal Katuwal 026071-19

Sajal Maskey 026075-19

Sandeep Gauli 026065-19

Shahil Adhikari 026061-19

This is to certify that I have examined the above Project report and have found
that it is complete and satisfactory in all respects, and all revisions required by
the report examination committee have been made.

Department of Mechanical
Engineering Er. Chiranjeevi Mahat
Project Supervisor

January 2021
 ACKNOWLEDGMENT

I would like to express our sincere gratitude to our supervisor Mr.Chiranjeevi Kunwar for your
guidance and support for completing the project. We are equally thankful to all our team members
who were supportive and enthusiastic throughout the project completion.

We came to know about the many new things. The guide and support from the supervisor was really
helpful to build up our skills and ideas. We are really thankful to him.

I would also like to express deepest gratitude to coordinator Mr.Binay KC for giving valuable time ,
suggestions and resources during this project.
 ABSTRACT

The main objective of this project is to design the simple hydraulic crane using the basic principle of
the liquid pressure principle. Even though there are many other mechanisms that occur during its
working period. We have included description of terms, assumptions, cost analysis, designs, grant
chart and so on in this report. We have created the design of the hydraulic crane in solid works
making the assumptions. We have studied the basic principle of the liquid pressure and transfer of
forces while doing this project. We have also studied the factors that affect the efficiency of the
crane. The main purpose of our project was to increase efficiency. The goals of our project was to
make it efficient and affordable. We have also included the design of our hydraulic crane in this
paper.
 TABLE OF CONTENTS

Acknowledgement…………………………………………
Abstract…………………………………………………….

CHAPTER 1 INTRODUCTION

1.1 Background ........................................................................................ 1-2

1.2 Objectives. .............................................................................................2
1.3 Significance............................................................................................2
1.4 Limitations…………………………………………………………….2

CHAPTER-2 METHODOLOGY

2.1 Literature Review...................................................................................3

2.2 Theoretical/Conceptual Framework...................................................... 4
2.21 Material Selection… .................................................................. 4-5
2.22 Parts…...........................................................................................5
2.3 Study Design ...................................................................................... 5-6
2.4 Conceptual Design ................................................................................ 7

CHAPTER-3 DESIGN AND CALCULATIONS

3.1. Design Analysis the Parts ……………………………………………9

3.2. Design of vertical column ………………………………………….9-10

3.21. Moment of Inertia…………………………………………….10-11
3.3 Design of Boom…………………………………………………..…11-12
3.31 Moment of Inertia………………………………………….…12-13

3.4. Design of crane hook ………………………………………………..13

3.41 Mass of crane hook ……………………………………………..14

3.5. Design of base plate ……………………………………………..……14-15

 3.51 Mass of vertical column…………………………………………..15-16

3.52 Mass of Boom………………………………………………….…16-17

3.6. Lifting Heights…………………………………………….…………..18-20

CHAPTER-4 GANTT CHART ............................................................... 20

CHAPTER-5 COST ESTIMATION ....................................................... 21

CHAPTER-6 EXPECTED OUTCOMES...........................................21-22

CHAPTER-7 WORK ACCOMPLISHED………………………………22

REFERENCES ........................................................................................23
 LIST OF FIGURES

Figure 1
Conceptual Design Of Hydraulic Crane Lifter
(3D model). ...................................................................................................... 7-8

Figure 2
Orthographic Views of Mini hydraulic crane
........................................................................................................................... 9

Figure 3

Dimension of vertical column………………………………………………..10

Figure 4

Design of Boom……………………………………………………………….12

Figure 5
Crane hook design………………………………………………………………13

Figure 6
Base plate………………………………………………………………………..15
Figure 6.1 Broom cross section……………………………………………16
Figure 6.2 Center connecting Bar ………………………………………….17

Figure 7
Max Lifting Height……………………………………………………………….19

Figure 8
Min Lifting Height…………………………………………………………………20
 LIST OF TABLES

Table 1
Features ............................................................................................... 5

Table 2
Cost Estimation................................................................................... 22
 Chapter 1 Introduction

1.1 Background

The basis for all hydraulic systems is expressed by Pascal's law which states that “The pressure
exerted anywhere upon an enclosed liquid is transmitted undiminished, in all directions, to the
interior of the container”. This principle allows large forces to be generated with relatively little
effort. A hydraulic lift is a machine that uses pressurized liquid to transfer pressure in a confined
space. The fluid pressure is moved from one end of the hydraulic device to the other undiminished
– allowing the force to be magnified by moving it from a smaller piston to a larger one. The
hydraulics concept is used in many systems and can be used in devices as diverse as the car brakes
and the human circulatory system. [1]

Hydraulic lifting devices are commonly used for lifting, moving and pushing activities in the
mining, building and steel industries and in material handling equipment. Since the 1950s,
applications of hydraulic systems have been initiated in the industry and this type of control has
become the standard for the operation of industrial equipment. Modern automation technology has
a very important position for hydraulic systems today. The explanation for this is that hydraulic
systems are quick, flexible and effective for power transmission. The key feature of the hydraulic
system is the transmission of power as the power is shifted from one form to another. Since these
hydraulic systems are widely used in manufacturing and manufacturing plants, it is also important
that they are reliable and efficient equipment to achieve the desired results, such as the transmission
of large quantities of forces using smaller components, which ensures a good power strength and
a precise positioning of the equipment with a consistent power output. These systems operate
smoothly with reversal function possibility and can work well in high temperature environment
conditions. These systems are thus cost considerably to provide the above functions and therefore
the same system is modified using a simple rack and pinion mechanism to lower its cost and
allowing further research and modification in it to make it able to provide all the above functions
with the same efficiency.

Hydraulics are similar to pneumatic systems in use. Unlike pneumatics, hydraulics use liquids
rather than gases. Hydraulic systems are capable of higher pressures: up to 10,000 pounds per

1
square inch (psi) vs. 100 psi in pneumatics systems. This pressure is due to the incompressibility
of liquids, which allows a greater transfer of power with increased efficiency, as the energy is not
lost to compression, except in the case where the air reaches the hydraulic lines. Fluids used in
hydraulics can also lubricate, cool and transmit power. Pneumatics, which is much less
multifaceted, require oil lubrication separately, which can be messy with air pressure. Pneumatics
are simpler in design and control, safer (with less fire risk) and more efficient, partly because the
compressibility of the gas-absorbing shock will protect the mechanism. [2]

1.2 Objective
The general objective of the research project is to design and produce portable and moveable
lifting crane based on Pascal’s law.

1.3 Significance
Hydraulic lifts are used in a variety of different applications. Some of them are listed below:
1. They can be found in automobile, shipping.
2. Construction, waste removal, mining, and retail industries as they're an effective means of
raising and lowering people, goods and equipment.

1.4 Limitations
There are some drawbacks in hydraulic lift and they are shown below:

1. Contamination of the atmosphere by waste oils (danger of fire or accidents).

2. Aversion to dirt.
3. The danger of undue pressure (severed lines).
4. Temperature dependence (change in viscosity).
5. High heat producing.
6. It usually cannot travel at speeds higher than 150 feet per minute (on larger travels). [3]

2
CHAPTER 2-METHODOLOGY

2.1 Literature Review

The development of lift machines or crane has reached through different times starting the first
crane for lifting heavy loads was invented by ancient Greeks in the late 6th century BC. The heyday
of cranes in ancient times came during Roman Empire when construction activity soared and
buildings reached enormous dimensions. The Romans adapted the Greeks cranes and developed it
further. [4]
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 [3pulles*50kg=150kg],
assuming that 50kg represents the maximum effort a man can exert.
In contrast to the modern cranes, middle age cranes and hoists –much like their counterparts 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. [4]
With the onset of the industrial revolution, the first modern cranes were installed at harbors for
loading cargo. In 1838, the industrialist and businessman 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.

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2.2 Theoretical/Conceptual Framework

The principle of transmission of fluid-pressure or Pascal’s law is the principle in fluid mechanics
that states that the pressure change at any point in a confined incompressible fluid is transmitted
throughout the fluid such that same change occurs everywhere. The law was established by French
mathematician Blaise Pascal in 1653 and published in 1663. This principle is stated mathematically
as:
∆𝑝 = 𝜌𝑔(∆ℎ)

Here, ∆𝑝 is the hydrostatic pressure (given in pascal in the SI system), or the difference in
pressure at two points within a fluid column, due to the weight of the fluid;
ρ is the fluid density (in kilograms per cubic meter in the SI system);
g is acceleration due to gravity (normally using the sea level acceleration due to gravity, in
meter per second squared);
∆ℎ is the height of fluid above the point of measurement, or the difference in elevation
between the two points within the fluid column (in meters). [5]
The major application of Pascal’s law is in the field of hydraulics. Hydraulic system is a drive
technology where a fluid is used to move the energy. Hydraulic systems use an incompressible
fluid, such as oil or water, to transmit forces from one location to another within the fluid. The
main reason for using hydraulics is the high power density and secondly the simplicity coming
from using few components to realize complex and fast moving machines with a high degree of
safety. Thus they are mainly used when a high power density is needed or load requirements
change rapidly. [6]

2.21 Material selection

Material selection is a means of selecting material that best suited for the member of the machine
to be designed. The basic considerations done in selecting materials are; Strength, Machinability,
Toughness, Ductility, Hardness…etc. for each component of the crane.
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%

4
 ● 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.
● 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 of 0.02%, 0.12% silicon, 0.018% of phosphorus,
0.07%of slag, and the remaining is iron
● Material for Bolt The material for the bolt is subjected to tensile and shearing stress and
mild steel best fits the criteria to resist these stresses and is selected as a material for bolt.
● 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. [4]

2.22 Parts
We have divided the hydraulic mini crane into three major frameworks. They are:
1. Frames and structures.
2. Jack or hydraulics.
3. Wire sheet, hook and pulley.
Table 1 Features

Description Measures
Maximum load bearing capacity 100kg
Lifting height 6ft to 7ft
Distance of its reach 4.5 to 5ft

2.3 Study design

● Literature review
● Design the prototype in the correct manner.
● Consult with respective supervisor and coordinator for budget estimation and materials.
● Identify and finalize the required tools.
● Collect the required tools and materials.
5
 ● Manage the materials in correct shape and size.

● Fitting of frame smoothly and creatively.

● Fabrication
● Test the product at University.
● If any defect on the product, correction of design and product.

The above schematic diagram represents the study design flowchart.

6
 2.4 Conceptual design

We worked on Solidworks to design and analyze our preliminary model by taking

note of theories and mathematics.

7
 Fig 1- Isometric View of Mini Hydraulic Crane

The above figures show the conceptual design of mini portable crane.

8
 Chapter-3 Design and Calculations

3.1. Design Analysis the Parts

Figure 2 - Orthographic Views of Mini hydraulic crane

3.2. Design of vertical column

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

σc = P /A + MC) /I

= P / A + (PecA) / IA

9
 Therefore: c=0.03m/2 e=1.45 m.
The column cross-section subjected to compression stress is

Figure 3- Dimension of vertical column

The area of column cross-section is

A = 35.14-26.73𝑐𝑚2
= 8.41* 10−4 𝑚2
Moment of Inertia

Ixx = [0.06*0.063 -0.052*0. 0523 ]/ 12

= 4.7069 *10−7 𝑚4

Iyy = [0.06*0.063 --0.052*0. 0523 ] / 12

= 4.7069* 10−7 𝑚4
10
Therefore Ixx= Iyy

Since the moment of inertia of both axis is the same.

Radius of gyration (K) = √𝐼𝑥𝑥 / 𝐴 = √(4.7069 ∗ 10−7 )/8.41 ∗ 10−4 = 0.02365 m

P = (100)*(9.81m / s2 )
= 981 N
= 0.981 KN

Pvc = P / (cos18.92°)

=1025.98 N

Compressing stress (σc )= Pvc/A(1+ec/k^2)

=1025.98/8.41* [10^-4 (1+ (1.45*0.03)/( 0.02365)2 ]

= 96098901.58 pa

= 96.099 MPa

σc = 96.099 MPa

Since the induced compressive stress due to the applied load is not greater than the maximum crushing
stress(1000 MPa) developed in the cast iron. Therefore the vertical column is designed safe.

3.3 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.

11
 Fig 4: Boom connected with

σb =M/Z

Where:
• 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 = 1.4236(0.7-0.6)
A = 0.14236 m2

• 3.31 Moment of Inertia:

I = 1.4236(0.7^3-0.6^3)/12 m4
I =0.015066m4
1. Distance from neutral axis extreme fiber (c), is;
12
 c = (0.7)/2m = 0.35m
2. Section Module(z);
z = I / c = [0.015066 / (0.35)] m4
z = 0.04305 m3
3. Bending Moment , M is;
M = P*L, L = length of boom;
= 981 N *1.4236 m = 1395.96 Nm

σc = M / Z
= 1395.963Nm / 0.04305 m3
σc = 32426.55 pa
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.

3.4. 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.

Fig 5-Crane hook design

NOTE: The choice of crane hook is done such that induced tensile and compressive Stress are
comparatively lesser. Hence, The ultimate tensile and compressive stress of the material is selected.

13
3.41 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

=[πd d]/−4(t)

=π/4(7cm2 3cm2)(2cm−)

V=62.832*10 m.

Since the material for crane hook is wrought iron, which have mass density of 7780kg/m ,

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 15kg.Additionally the design is proposed to lift a load of 100kg ,and
the total mass applied on the base plate is,

mT =(8.83 +14.53 +0.5 +15 +100)kg = 140kg (approx.)

PT=mT*g
=140 kg*9.81m/s2 =1.36 kN

3.5. 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.

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Figure 6. Base plate

Bar 1 and Bar 2 are side bars which transfers all the load to the ground. It isdirectly connected to the
vertical column.

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

3.51 Mass of vertical column :

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• Volume vertical column
So, V=A*L
=35.14-26.73*145.25
= 1221.5525cm3
= 0.0012215525m3
Since the material for the vertical column is made from
cast iron, the mass density of cast iron is 7250kg/m3.

So, ρ = m / V, m = ρ* V
= 7250 * 0.0012215525m3
= 8.86 kg
mv = 8.86 kg = the mass of the vertical column.

3.52 Mass of Boom:

The volume of the boom is

Figure 6.1 . Boom cross section

Let's consider a rectangular boom so area of boom is:

A= (0.7^2-0.6^2)

= Approx. 0.13 m^2

V = A*L
= 0.13 * 1.4236

= 0.185068 m^3

16
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 = 14.53 kg, mass of boom

Center connecting bar:

Figure 6.2 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 = 1.36/2 kN = 0.68 kN

The area of base cross-section is

A = (35.14-26.73)𝑐𝑚2
= 8.41* 10−4 𝑚2
Section Modules

I = a4/12
I= 1.08*10-6
y= a/2
y=0.03 m3

section modulus(Z) = I/y

= 3.6* 10-5 m

Moment at the two end of bar M A , B = ( PT * L ) / 4

17
 = (1.36 * 0.42)/4

= 0.1428 KNm

σb = M/Z

= 0.1428/3.6 *10-5

=3900000.667

=3.967 MPa

Therefore, σ = 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/mm . Taking the factor of safety equals 4.

σ=Sy/n

=520/4

=130N/mm

Since the induced stress is less than the ultimate bending stress, then the bar is designed safely.

3.6. Lifting Heights

The maximum height that the crane can lift is obtained as follow:

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 Fig 7-Max Lifting Height

From cosine law:

103.32² = 120² + 30.34² - 2 (120)(30.34)cos(a)
a = cos-1 [0.6379]
= 48.93ᐤ

From sin law:

Sin48.93° / 103.32 = Sinß / 30.34
ß = Sin-1 [0.2412]
ß = 12.57°
θ= 180°- (48.93 +12.57)°
θ = 118.5°

M = 104.46cm

N = 103.32cos18.92°

19
 = 97.6546 cm
K = 41.93cos18.92°
= 39.66 cm

H = M + N + K = 241.7746 cm

The minimum height that the crane can pick up objects from is obtained as:

Fig 8 -Min Lifting Height

θ = Cos-1 [(103.32)2 + (30.34)2 - (88.68)2 ] / 2 (103.32)(103.32)

θ = 53.48°
M =142.36 cos(85.04)°
=43.06
h = (103.32+41.93)cos18.92°- M
h = 94.06 cm

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Chapter- 4 Gantt Chart

21
 Chapter 5 Cost Estimation

Table 2 Cost Estimation:

S.N. ITEMS QUANTIT PRICE (per COST (in NRs.)

piece)
Y
1 Jack 1 1500 1500
2 Crane Hook 1 600 600
3 Steel Wire Rope 3meters 200 600
4 Metal Sheets (provided by TTC) - - 1,800
5 Miscellaneous (nuts, joints, bolts & - - 500
washer,
etc)
TOTAL - - 5,000

Chapter 6 EXPECTED OUTCOMES

● The proposed project “Mini Portable Crane” represents the principle of Pascal’s Law and
its application of hydraulics.
● The project which we have studied upon and built it and the time we spent on it broadened
our knowledge about the principle of hydraulics and its advantages and disadvantages.
● In the field of physics, this project will give a small contribution to the lifting techniques
by using hydraulics appliances.
● The project can be used in industrial activities and in the household activities too.
● The project can be used for lifting, loading and unloading the stuff in the industries and
houses.
● The aim of the proposal for a hydraulic system is to propose a system capable of providing
synchronous lift of heavy loads.

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 ● Using less effort from the human hand, the force is multiplied by the system itself and the
lifting is done.
● This project is used for the lifting of up to the weight limit of 50kg as it can also be used
in the household activities as mentioned before.

Chapter-7 WORKS ACCOMPLISHED

Literature review on the project.

• The theoretical framework of the project.
• Design and necessary calculations.
• Market survey and Material selection for the project.
• Submission of the mid-term project report.

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 Chapter 6 REFERENCES

[1] "Hydraulic Jack," Wikipedia, [Online].

https://en.wikipedia.org/wiki/Jack_(device)#Hydraulic_jack
[2] M. Rouse, "Techtarget," Whatis.com, [Online].
http://whatis.techtarget.com/definition/hydraulics
[3] "Hydraulic Lifts: Pros and Cons," PFLOW INDUSTRIES, [Online].
https://www.pflow.com/hydraulic-lifts-101-pros-cons/
[4] M. Tadesse and T. Meshesha, "Design and Development of Portable Crane in Production
Workshop," American Journal of Mechanical Engineering, vol. 5, no. 2017, pp. 41-50.
[5] "Pascal's Law," Wikipedia, [Online].
https://en.m.wikipedia.org/wiki/Pascal%27s_law
[6] "Pascal's Principle and Hydraulics," NASA, [Online].
https://www.grc.nasa.gov/www/k-
12/WindTunnel/Activities/Pascals_principle.html?fbclid=IwAR10OFgSTz6yTf9_fJXaEP0r
A0
RDkm2l2jddNS7j5L1LhqnBSi5kPhAQc6U#:~:text=Pascal's%20law%20states%20that%20
whe
n,other%20point%20in%20the%20container.&text=Applied%20to%20a%20more%20comp
lex,
allows%20forces%20to%20be%20multiplied.

24