Design and finite element analysis of 100 ton double girder overhead crane

Abstract

Cranes are one of the most common transportation mechanisms in industry. It is used in many fields e.g. workshops, warehouses, powerplant stations, installation lines, shipyards and so on. Improvements on crane's potential capabilities have been increased within computer aided design. It is also witnessed that development in material sciences increased load capacity and decreased total weight, production costs. The crane type studied in this paper; overhead bridge crane is working mostly at inner ambients and predominantly repetitive works. The design of the crane starts with defining all classes related with load severity, load recurrence, lifetime group. The listed classifications and size of desired crane are evaluated by the customer and submitted to the producer to be designed. Designer is responsible to provide crane design valid according to internationally approved standards such as BS, EN, ISO, CMAA. However, the final product is always determined by the help of Finite Element Method. Earthquake-Resistant crane with 100ton capacity works in powerplant station as installation crane is aimed to design in this study. The design calculations are based on mostly BS and ISO Standards. The coefficient factors according to these standards are defined so calculations multiplied with expected loads. There are several different coefficients for each load scenario that creates stress on crane girder. The other main factor in this study is investigation of seismic conditions. Istanbul, Turkey is selected as crane location and since it is high hazardous earthquake location, seismic effects must be considered before designing a crane to avoid human death. Hence, seismic conditions due to possible earthquakes in the design location are studied. Possible earthquake datas are collected and implemented on crane load scenarios. Finally, all calculations of load scenarios above mentioned gathered in final equations and dimensions of crane is defined. At the last chapter, determined dimensions of the crane by mathematical calculations are practised in CAD with SolidWorks software. The design is transferred to Hypermesh software and meshes are generated to perform FEM. Thus, the design gets ready when it fulfills most dangerous possible load scenarios and fatigue test. The optimized results gathered by both mathematical equations and FEM are shown in the last chapter.