1.

OBJECTIVES:
This design project is intended to give a detailed exercise on the use of various stages of the
design process; i.e., problem definition, generation of goals and criteria, proper search, generation of
alternatives, assessment of alternatives, evaluation and decision making, planning, detailed design, anal-
ysis and assessments, testing, engineering drawings and communication of the design. Emphasis will be
focused more on the detailed design phase and the engineering drawing as means for design communi-
cation. Each individual or design team is expected to perform a thorough search, generate imaginative
and creative ideas, evaluate and assess concepts thoroughly using appropriate criteria and various tech-
niques, and then, construct a model prototype (if applicable and required) for the proposed design as
applicable. Simple design calculations and experimental testing are required as applicable to assess the
fabricated model (if a model is fabricated) and will have an important weight in the final assessment and
competition of the model.

The learning outcomes from this project are summarized in the following:
 Demonstrate creative thinking,
 Demonstrate an understanding of modern engineering design methodology through performing
detailed design, performing detailed calculations, life assessment, and proper analysis of a pro-
ject.
 Assess a specific design through simple design calculations,
 Produce appropriate engineering drawings for a design or part of a design,
 Communicate and present the design to others
Credit and assignments of marks are summarized in the project cover sheet.

2. PROBLEM STATEMENT:

It is required to design a motorized jib crane that will be subjected to a static vertical load at the
hook, refer to sketch in Figure-1. The load be allowed to move between points F and H along the main
beam. The main objective is to have a maximum load carrying capacity for a given weight and to mini-
mize cost without exceeding appropriate failure criteria. Additional documents and amendments may be
issued during the course of the project with rules updates, procedures, testing specifications, extra constraints,
and other information or constraints for teams as necessary and/or if prototype is required. These additional
documents carry the full authority of the rules in this document. Additional documents to be released will be
generally based on discussion in the class.

3. DESIGN SPECIFICATIONS:

DIMENSIONS & LOAD CARRYING CAPACITY:

General layout, major dimensions and required load carrying capacity (40,000 �) are shown
on figure-1. Dimensions may vary slightly in your final design but load carrying capacity must be
maintained.
4. DESIGN TASKS & PROJECT DELIVERABLES
(Please note that all tasks have to be submitted in ONE design report by the specified deadline):

The following are the project deliverables required by the submission due date of the project:

0.35 m

?? �

Figure-1 Major dimensions and general layout

I. TASK-I: FULL DESIGN OF BEAM BFGH:

This task is divided into the following subtasks:
 Identify the critical location for the load to be used in the analysis and design of the main beam.
 Provide full external and internal force analysis of the beam and sketch all internal force dia-
grams.
 Pick up the critical section and determine the internal forces at the section.
 Choose an appropriate thin-walled open section for your design. You must compare at least
three possible sections and give a rational for your choice (no detailed calculations).
 After you identify the section to be used:
o If the section is standard, pick up an appropriate dimensions from available sections and
continue the analysis. Iterations may be required if the choice turns out to be in-appro-
priate (most likely will be the case).
o If the section is not standard, specify appropriate proportions to the section, i.e., specify
ratios of the main section dimensions to the thickness. Then, choose an appropriate
thickness and continue the analysis. Iterations may be required if the choice turns out to
be in-appropriate (most likely will be the case).
 Find out the proportions of the sections from codes/standards or by calculations.
 Sketch stress distribution on the section from all internal forces.
 Find the critical point(s) on the section and calculate principal stresses and maximum shear
stresses.
 Discuss the effect of the stress concentration at point-F on the obtained stresses (quantitatively).
  Finalize the design of the section by choosing suitable material, proper factor of safety, and
considering appropriate failure criteria.
 Provide an appropriate engineering drawing for “detail-F” and “detail-G” showing all appro-
priate details. Only detailed sectional engineering drawings are acceptable (no pictorial draw-
ings).

II. TASK-II: COUPLING AND BRAKE MECHANISMS:

Flexible couplings may be generally used to connect the motor shaft to the input shaft of the re-
ducer and a suitable brake mechanism is to be used for the hoisting drum. The hoisting mechanism
should be equipped with appropriate designs features to hold the load in the required position when the
load is suspended and no power is applied to the motor and to safely release and lower or raise the load.
Figure-2 shows a schematic layout of the overall system. In most designs the engagement and the brake
mechanisms are integrated with the hoisting mechanism.

 It is required to do a search for such mechanical mechanisms (namely the coupling and
braking), choose/compose an appropriate system to perform the required actions and provide
appropriate engineering drawings for your design. The coupling should be of flexible type that
may allow slight angular or radial misalignments as shown in figure-2. Only detailed sectional
engineering drawings are acceptable (no pictorial drawings).

Coupling and braking

mechanisms
Motor
Drum-rope
hoisting mecha- Speed re-
nism ducer
Bolts (b)
(a)

Figure-2 (a) Layout of power hoisting mechanism, (b) Coupling

to allow slight radial and angular misalignments

III. TASK-III: GEAR REDUCER DESIGN:

It is required to design a two-step gear reducer (gear box) for the system. To reduce space,
though this will lower efficiency, one of the steps is to be a worm gear integrated inside the reducer,
i.e., not attached to the motor. The following deliverables are expected for the gear reducer:
 Calculate the power required by the motor after assuming a reasonable factor of safety. Pick
up the closest standard motor and provide the specs of the chosen motor.
 Choose a typical shaft in the reducer (only one shaft) and size all sections of the shaft. Spec-
ify details of keyways, fillet radii, splines, bearing seats, etc. Consider fatigue failure and
design for infinite life. This would require going through all the normal steps of: FBD for
the shaft, internal forces, critical sections, fatigue failure considerations, etc. Assume infi-
nite life for the design.
 Provide a proper engineering drawing for a sectional view of the gear reducer showing all de-
tails of: bearing and housing, shafts and all components mounted on the shafts, key-ways, and
 proper layout, etc. Small details, e.g., bearing sousing, fillets and key ways, may be enlarged in
detailed views. Only detailed sectional engineering drawings are acceptable (no pictorial
drawings).

IV. TASK-IV: GEAR REDUCER SUPPORT DESIGN:

Assume that the housing bracket carrying the gear reducer is fixed to the wall by bolts. Choose
an appropriate number of bolts and bolt geometric layout, find the forces on the bolts and design an ap-
propriate size for the bolt.

Make sure to properly cite the standards and codes that you used in all steps, especially tasks-
III and IV.

5. GENERAL NOTES:
 Date for report submission is strict and specified on the heading of the project. A power point
presentation is required with each report. The presentation should be no more than 20 slides.
Please amend the presentation to the end your Word file and submit only one file to Blackboard.
You may amend the presentation as pdf or any other format.
 Use appropriate software to make all the technical drawings. You may use Ideas, AutoCAD,
Pro-Engineering, Solid Works or any other appropriate program. Hand drawings will not be
accepted nor credited. Once again, only detailed sectional engineering drawings are accepta-
ble (no pictorial drawings).
 All drawings should be on A4 sheets (21x29.7 cm) with standard layout. All drawings should
be submitted as integral part of the report. No separate drawings will accepted.
 Choose the appropriate type of drawing, number of drawings, sectional views, detailed views,
etc. that would adequately show your design. Detailed views may be given on separate sheets.
 Materials for all parts to be fabricated must be properly selected.
 Report must be typed and submitted in Soft form (MS-Word file) through the blackboard
turn-it-in link as applicable.
 Make reasonable assumption whenever needed, but make sure that they are necessary, and
make clear note of them in your report.
 Make sure to identify clearly and cite the standards and codes that you’ll use in the project.

Best of luck to all of you!