毕业设计（论文）

英文翻译

年级、 专业: 2007 级机械设计制造及其自动化

姓 名: 郭 华 江

学 号: 312007080301509
 指 导 教 师: 秦 小 屿

Journal of Terramechanics

Volume 48, Issue 2, April 2011, Pages 157-168

The design process of a self-propelled floor crane

Daryoush Safarzadeh， Shamsuddin Sulaiman，Faieza Abdul Aziz， Desa Bin Ahmad，and Gholam

Hossein Majzoobi

Abstract
In order to prevent the hazards associated with the crane application in workshops and
factories, a self-propelled hydraulic floor crane with wire remote control was
designed. The main focus was directed on remote control of the craneoperations such
as rotation of booms, rear and forward movements, changing travel speed, steering,
braking and hook rotation. This configuration prevents the hazards and damages
which may be created due to the proximity of operator to crane and provides the
feasibility of utilizing the crane in crowded manufacturing areas, fields and hazardous
environments. Research into the stability of crane on a slope route was also performed
to obtain the equations of stability in static and dynamic conditions and recognition of
the ways to enhance the stability. To validate the research work, a scale-model
prototype was built to test the manner of controlling the crane operations from afar.
Research highlights
► We design a crane with wire remote control to decrease hazards and to improve
performance. ► It can be used in hazardous environments and fields. ► Remote
loading and unloading of payload are feasible by use of an articulated hook. ► We
suggest appropriate approaches to convey huge loads and to suppress payload sway.
Keywords: Crane Hazards; Hydraulic; Remote control; Self-propelled
1. Introduction
Cranes are devices utilized for loading, unloading and transmitting the loads. They are
profitable devices but hazardous in nature. We knew the crane activities responsible
for 4% of the reported accidents and according to OSHA regulations, about 15.2% of
crane events are occurred in manufacturing
environments. Many researches have been performed regarding the causes of injuries
and death from cranes 。Crane accidents have been grouped in the following
categories according to NIOSH (National Institute of Occupational Safety and Health)
report, including: swinging loads, overturning of cranes, falling loads, crushing
between moving parts of cranes, falls of people from cranes, power line contact,
overloading, contact the hook assembly with boom tip, obstruction of vision,
assembly and disassembly of boom. Crane hazards are normally related to design and
crane use. From a safety point of view, one of the most important issues in design of a
crane is determination of stability. Stability of ranes has been studied by some
researchers。 Weak segments, stress, strain, displacement, critical points and strength
of parts under definite loads are determined by computer aided finite element
analyses. Strength of the components versus the applied loads is determined based on
FOS (factor of safety). For a safe performance, FOS is typically considered more than
1. Hydraulic floor crane is a kind of crane which has been used in workshops and
factories from olden times. Basically, it is composed of a base, a column, a boom and
a hydraulic cylinder for hoisting the boom. Nowadays, its application has been limited
because of innumerable defects. The major research contribution of this paper is the
use of CAD to design and develop a wire remote control hydraulic floor crane for the
aims of decreasing the hazards, improving the performance and efficiency compared
to the existing types and application in various locations such as hazardous
environments and fields. Hence the main focus was directed on hazards reduction.
Furthermore, the design has been also accomplished based on the required functions
to perform the corresponding operations and employing peculiarities of the existing
types considering their defects including hand-operated actuation, lacking of motor
supplies, low safety, slow response and low speed。
2. Design process
The proposed solution to control the sway is to install a platform for placing the
payload during displacement 。Another benefit of this measure is to reduce
overturning of the crane due to the pendulum motion of payload during
displacement. Overturning issue can also be controlled by increasing the stability of
crane through the appropriate static and dynamic analyses and fortification of the

components as well as the correct selection of the crane dimensions. The other
approach to decrease the hazards is to control the crane performance from a
distance by utilizing a wire remote control system. This system prevents the hazards
which are created by the fall of payload and objects on the operator or the fall of
operator off the crane. Increasing visibility is another approach to reduce hazards
and to increase safety. According to OSHA regulations, safe use of a crane is
compromised when the vision of an operator is blocked and employees cannot see
what the others are doing. The crane size alone limits the operator’s range of
vision and creates blind spots. The crane boom may obstruct the operator’s range
of vision. Often a load is lifted several stories high and the crane operator must
rely upon others to ensure safe movement of the load being handled. The accidents
due to the visibility problems are also occurred by other transporting devices such
as lift trucks. Collins et al. found that visibility problems account for more than 80%
of forklift truck related accident such as striking pedestrians or other vehicles,
falling-off a ramp or loading dock and turning over by hitting obstacles.
The visibility can be increased in two ways:
(a) Movement of the operator slightly far from the crane increases his visibility to
control the crane operations from every side. That is a significant issue especially
in busy locations or when the crane is carrying a huge load which limits the
operator visibility.
(b) Installing the wired or wireless camera in various spots of the crane helps the
operator to control the entire crane operations in out of reach and hidden areas from
afar (
The entire crane systems are covered by a body to protect the moving parts and to
prevent event to people. To enhance flexibility and maneuverability of the crane, a
compacted size and a three-piece boom were proposed. A combination of an
inverter and a DC electromotor with 4 kW power was utilized to control the rear
and forward movement and changing speed of the crane from remote distance.
However, in this system by varying the speed of rotation, torque will be maintained
constant. Thus a mechanical system consists of several pulleys and belts were
designed to reduce the initial speed and to raise the torque
Therefore, changing speed by inverter will be accomplished in a limited range to
give a travel speed between 0 and 2.88 km/h. The normal speed of travel is 2 km/h
so that the operator can walk along with the crane The maximum speed is
2.88 km/h. For the speeds more than 2 km/h in traveling, the operator can sit on the
body. The main part of the hydraulic system is directional control valve assembly
consists of several four-way valves with three positions ，These valves are solenoid
operated so that the port opening can be achieved by a current flow through the
coils. A magnetic field provides electromotive force to move the especially shaped
valve spool. This motion is opposed by a centering spring. The ports are represented
by pump , the return tank, the actuator inlet chamber A and the actuator outlet
chamber B ，Solenoid valves should be used in open-center system that in neutral,
oil flows through the control valve and back to the reservoir.
3. Field application
Development of the crane for application on fields and rough lands may satisfy
some of the field requirements such as loading, unloading and displacement of the
field implements and boxes of the crops and fertilizer. The conditions of the crane
operation on fields differ from the smooth lands. These differences are related to the
required power, traction force, wheel slip, rolling resistance, wind effect and
stability of the crane which is exposed to the perpetual variations due to the
irregularities of the ground and may eventually result in overturning of the crane.
Hence, to adapt the crane for field application, some modifications in the wheel
 size and power would be required. For a driving wheel moving on the soil ，the soil
reaction G is resolved into horizontal and vertical components. The horizontal
component is assumed to act at a distance (r) below the wheel center and is divided
into two forces, a gross traction force Ft and a rolling resistance force Rr.

4. Manufacturing process
To ensure of the crane function, in addition to an initial scale-model, a small
model of AC crane at a scale of 1:2.5 was also manufactured and the operations
such as forward and rear movements, changing speed, rotation of booms, steering
and hook rotation from remote distance were tested. Compared to the designed
model, in this process some modifications were applied to drive system and location
of solenoid valves due to the limitations at the provision of parts or lack of adequate
space. The platform and body were not installed so that the internal sections of the
crane to be in full view To control the hook operation, a wireless camera (model
803 color CMOS) with a receiver (A/V fine tuning type) was connected to the
boom. The details were observed on a laptop. The entire crane operations could be
controlled properly from remote distance via a control box which was located at the
operator’s hands.

5. Stability analyses
The most important process in design of a crane is stability considerations to satisfy
the safety issues. This process includes the proper selection of dimensions, weight
and shape in addition to analyze the status of the lateral and longitudinal stability of
the crane. Stability analyses and determination of the rated capacity have been
achieved in accordance with ISO 4305 standard 1991.

6. Conclusions
This paper presents different aspects to design of a crane with the aim to decrease
the hazards associated with the crane application in manufacturing and crowded
environments. The design process was essentially focused on remote control of the
crane operations. This permits the operator to control the crane functions from a
definite distance to prevent presumptive damages by reason of falling the payload,
power line contact, falls of operator, overturning, crushing the parts and collision
which may be created by swinging of payload during operation. Furthermore, other
recommendations have been also presented to reduce the hazards during the crane
performance. For instance, installation of a platform to place the payload during
transmission to stop the sway, utilization of camera to avoid collision where the
visibility is limited and augmentation of the stability through the selection of
appropriate dimensions, materials, load distribution and factor of safety. Results of the
stability analyses denote the possible ways to improve the stability condition of the
crane. Other considerations were also achieved to improve the crane performance,
including selection of a three-piece boom and a compacted size to enhance flexibility
and maneuverability. Performance rapidity could be also raised through the use of two
discrete electro motors for hydraulic and drive systems. The design is promising for
the future development in crane industry and control systems for robotic
applications.
地面力学周刊
48 期，第二版，2011 年 4 月出版，第 157-168 页
自动地板起重机的设计过程
Daryoush Safarzadeh， Shamsuddin Sulaiman，Faieza Abdul
Aziz， Desa Bin Ahmad，and Gholam Hossein Majzoobi
摘要
为了防止吊车在车间和工厂的应用危险，一种自动远程控制液压地板起重机被
设计而出。其主要焦点在远程控制起重机，像旋转吊杆，前进和后退运动。改变
行走速度、转向、制动和吊钩的旋转。这种装置可以防止因起重机操作人员靠近
起重机而带来的危险，同时提供了起重机在拥挤的危险环境制造领域的可行性。
研究起重机在斜坡稳定性也能去获得从静态和动态稳定性的方程，并且可以识
别加强其稳定性。为了验证此项研究内容，制造一个原型样机去测试从远程控制
的起重机。
研究思想
我们设计了一个起重机用电线远程控制去减少危害和改善绩效。它可以用在危险
的环境和领域里。远程加载和卸载通过使用一种挂钩来铰接是可行的。我们用适
当的途径来传递巨大的高负载并且可以一直有效载荷的摇摆。
关键词：起重机危害；液压；远程控制；自动推进
1. 引言
起重机式一种用来装卸并传递载荷的设备。他们是有用的设备但在本质上很危险
我们知道起重机事故在报告中约有 4%，并且根据职业安全与卫生条例，约有
15.2%的起重机事故发生在生产制造领域。很多研究表明起重机经常导致人的的
受伤和死亡。起重机安全事故已经归组入美国国家职业安全与卫生院的类别，包
括，摆动负载，起重机的颠覆，载荷下落，起重机活动件的破坏。人从起重机上
坠落，电线接触，过载，挂杆顶部的挂钩连接，阻碍视线，起重机吊杆装配和
拆卸，起重机的相关危害通常参照美国国家安全手册来设计起重机，其中最重
要的一个问题是设计一个起重机的稳定性，起重机已经被一些学者所研究，弱
区段、应力、应变、位移、临界点和在一定载荷强度下的零件负荷是由计算机辅助
进行有限元分析。部件的强度是考虑安全因素的基础上由外载荷决定的。为了安
全性能，安全因素通常应该超过 1。液压地板起重机是一种在以前已经应用于车
间和工厂的起重机。基本上，它是由一个基座，一个圆柱，一个吊杆和一个液压
缸起重吊杆。如今，因为它有很多缺陷已经很少应用，而此文的主要的研究贡献
在于运用计算机辅助设计去设计发明一个远程控制的液压地板起重机目的是为
了 减少危害，相比在典型的各样危险环境下提高性能和效率。因此主要焦点在
危险的减少，此外，设计也已经完成在要求的功能去履行相应的操作基础之上
采用独特的安装方式去解决包含起吊操作、电力不足、低安全性能、反应迟缓和
低速度等缺陷。

2.设计过程
推荐的控制摇摆的解决方法是在移动时安装一个安放有效负载的平台。这个措施
的另一个好处就是减少移动过程中起重机由于有效负载的摇摆运动而产生的翻
转可能。翻转事件也可以通过增加起重机的稳定性来控制。这些可以通过合理的
静态和动态分析，成分的加强以及正确的选择起重机的维度实现。另一个减少危
险的方法是利用有线的远程控制系统远距离控制起重机。这个系统可以防止由有
线负载和操作员身上物体的掉落或者操作员掉下起重机产生的危险。增加能见度
是另一个减少危险增加安全的方法。根据 OSHA 规则，起重机的安全使用会在操
作员的视线被阻挡和被雇佣人不能看见其他人在做什么的时候得不到保障。只是
起重机的大小就能限制操作员的视线范围，制造盲区。起重机的吊杆可能会遮挡
操作员的视线范围。经常是负载物升到几层楼高，起重机操作员必须依靠其他人
来保证被操作的装载物的安全运动。靠其他诸如起重机的传输装置也会由于能见
度问题出现事故。Collins 发现能见度问题证明 80%以上的叉式升降装卸车事故
与其相关，如疾步的行人或其他车辆，掉下斜坡或装载码头，以及被撞击障碍
物打翻。
能见度可以通过两种方式增加：
(a)操作员一点点远离起重机的运动会增加他从各方面控制起重机操作的能见度 。
那是一个有意义的事件，特别是在繁忙的地方或者是在起重机正在搬运一批限
制操作员能见度的大货物的时候。
(b)在起重机的不同区域安装有线的和无线的照相机有助于操作员从远处在不能
及和隐藏的区域内控制整个起重机的运作。整个起重机系统被主体覆盖以保护运
动零件，并防止对人的伤害。为了加强起重机的灵活性和机动性，推荐了紧致的
尺寸和三片吊杆。反相器和四千瓦力的 DC 电动机相结合，用于控制前后运动和
起重机远距离改变速度。然而，通过区分旋转速度，在这个系统中，将维持扭矩
持续。那么机械系统由几个滑轮组成，并且传动带被设计来减少原始速度，增加
扭矩。
因此，采用变频调速就可以限制运动速度在 0 和 2.88km/h 之间。正常的运动速
度是 2km/h，因此，操作人员可以跟着起重机的最大速度 2.88km/h 移动。移动速
度超过了 2km/h 时，操作人员可以坐在机体上。主要的液压系统部件定向控制阀
是由四通阀在三个位置组成。这些阀门是螺旋管阀门因此端口的开启可以通过一
个线圈电流流过来完成，磁场可以提供电动力去驱动特殊形状的阀门。这个运动
是由置于中心的弹簧反向运动所成。在端口中用泵返回水池，执行机构进口室 A
和出口室 B 在同一室。电磁阀在自然环境下可以运用在开放的中心系统下，油
液流经控制阀回到油缸内。
3.田间应用
应用于田间和粗糙路面的起重机的发展会满足一些田间诸如田间工具和庄稼和
肥料盒子的装载，卸载和移动要求。起重机在田间里的工作条件与在光滑路面上
的工作条件不同。这些不同与所需动力，牵引力，轮滑，抗翻转性，风的影响和
起重机的稳定性相关。这些不同由于地面的不规则而显示了其永恒的多变性并可
能最终导致起重机翻转。因此，为了适应起重机的田间应用，就需要在轮胎大小
和动力上做一些修改。对于在土地上行驶的驱动轮，土地反作用力 G 取决于水平
成分和垂直成分。假定水平成分在轮胎中心下方一段距离(r)处作用并且分成两
种力，一个是总的牵引力 F，另一个是抗翻转力 Rr。
4.制造过程
为了保证起重机的功能和最初的比例模型，也制造了一个 1：2.5 比例的 AC 起
重机小模型。还测试了前后运动，改变速度，吊杆旋转，远距离转向和吊钩旋转
与设计模型相比，由于零件供应限制或缺少足够的空间，在此过程中，在驱动
系统和螺旋管阀的位置上做了许多修改。平台和主体部分未安装以便起重机的内
部结构能够从全局选择。为了控制吊钩的运作，一个带收音机（ A/V 良好收听
型）的无线照相机（型号 803，颜色 CMOS）与吊杆连接。在电脑上可以观察到所
有细节。整个起重机操作能够通过位于操作者的手中的控制盒子从远距离合理控
制。
5.稳定性分析
设计一个吊机的最重要过程是考虑它的稳定性和安全性能。这个过程包含适当的
尺寸选择，重量和形状，以及起重机横向和纵向稳定性的分析。稳定性分析和测
定的额定容量已经与 ISO 4305 标准 1991 年一致。
6.总结
本文呈现了设计一台旨在减少事故的起重机的不同方面。这些事故与起重机在制
造方面以及在拥挤环境下的运用相关。设计过程从根本上聚焦在起重机运作的远
距离控制上。这使得操作者能够从一定距离处控制起重机作用来阻止可以预期的
危害。有效负载下降，电线互接，操作者的摔倒，翻转，压坏零件和碰撞，这些
可能因操作中有效负载的摇摆而产生。而且，在起重机施工中还有其他优点也呈
现出来了以减少危害。例如，在转移过程中，平台的安装来放置有效负载以防止
摇摆，在能见度受限的地方和通过选择合适的维度，材料，装载分布和安全因
素争论稳定性的地方，使用照相机以避免碰撞。稳定性分析的结果表示可能的方
式来提高起重机的稳定条件。也有其他的考虑来改善起重机的表现，包括选择三
片吊杆和紧致的尺寸以加强灵活性和机动性。通过分别为液压系统和驱动系统使
用两个电镀车也能提高运作速度。这种设计对于起重机产业和自动应用的控制系
统的未来发展很有发展前景。