Progression

The created structures now need to be tested. Therefore the next logical step is to create free body diagrams, showing a wide range of different forces acting on the beam, in order to establish the strength of the structure; and therefore determine what material is needed to create it.

Rendered view of the foot

This is a rendered view of the foot, showing it painted red. The component would be painted to help protect it from corrosion. The majority of the components will be painted for this reason. We will look more into corrosion resistance and life at a later point.

Cut-away view of the foot

This is a cutaway view of the design of the foot, showing the top area, where the leg would fit into and the bottom cylindrical slot the head of the jack would fit into. There is more than one foot, with varying diameters of cylinder, to accomodate various sized jacks

I Beam Trolley

A key component that is critical to the success of the design is the I beam trolley. There are several quality products avilable for a wide variety of prices and with different selling points. The trolleys that would suit our design are shown below:


[£67] 1000 kg Hand Pushed Trolley - Quick Fit

[£90] 2000 kg Hand Pushed Trolley - Quick Fit


[£112] 2000kg Push Type Beam Trolley / Girder Trolley



The quick assembly and/or fitting of any trolley to the structure would be essential in a disaster situation. Combining this with the relatively cheap costs shown above would prove to be a winning formula.

Links:
http://www.mammoth-hire.co.uk/2T-Adjustable-Beam-Trolley-370120/
http://www.sutch.co.uk/English_2008_Page_58.pdf
http://www.angliahandling.co.uk/acatalog/Hand_Pushed_Trolley_-_.html
http://www.liftsafesolutions.co.uk/id72.html
http://www.pacline.com/products/12_overhead_trolleys.php

I-Beam Drawing

The drawing of the I-beam again with dimensions, but without including materials or weights of the beam

Drawing of the leg

This is a technical drawing of the leg of our crane, with key dimensions included. This is only a preliminary drawing however, so details such as materials have been missed out at this point.

Bottle jack dimensions

Unfortunately we did not get a response from a potential supplier for a bottle jack that we had hoped to utilise as a part of the deisgn.
This did propmpt us to consider what other bottle jack to use but we then decided that the design would be far more successful (and cheaper to produce) if we made specific 'shoe' fittings. This will allow any potential users to utilise jacks that they have available; instead of restricting them to one device that we recommend.
The design of the different shoes is key to the success of the overall design so research was conducted to establish a few generic sizes. The results of this research is shown below (and the webpages used are linked at the bottom):

2 ton = 30.1625mm
3 ton = 33.3375mm
5 ton = 34.9250mm
8 ton = 44.4500mm
12 ton = 44.4500mm

From this information is is possible to see that a wide range of 'shoe' is needed; which could be supplied in a generic pack:

Shoe 1 = 30.2mm
Shoe 2 = 33.4mm
Shoe 3 = 35mm
Shoe 4 = 44.5mm

These sizes are all diameters for the shoes. However it has also been proposed that a square shoe be designed; to cater for all jack head types. This will be 150mm x 150mm to cater for most toe/floor jacks.

Conversion chart link:
http://www.engineeringtoolbox.com/inches-mm-conversion-d_751.html

Jack Research links:
http://air-draulics.com/pages/N/botdim.htm
http://www.tootoo.com/d-rp1692028-hydraulic_bottle_jack/
http://www.ttclifting.co.uk/hydraulic/hydraulic_mechenical_jacking_division.html
http://www.allproducts.com/manufacture97/tongrun/product1.html
http://www.allproducts.com/manufacture3/andy/kb-3020.html

Making steel components

• Molten steel is made by melting iron ore and coke (a carbon-rich substance that results when coal is heated in the absence of air) in a furnace, then removing most of the carbon by blasting oxygen into the liquid. The molten steel is then poured into large, thick-walled iron molds, where it cools into ingots.
• In order to form flat products such as plates and sheets, or long products such as bars and rods, ingots are shaped between large rollers under enormous pressure. Hollow tubes, such as those used to form the latticed booms of large cranes, may be made by bending sheets of steel and welding the long sides together. They may also be made by piercing steel rods with a rotating steel cone.
• The cables used to lift weights are made from steel wires. To make wire, steel is first rolled into a long rod. The rod is then drawn through a series of dies which reduce its diameter to the desired size. Several wires are then twisted together to form cable.
  
  

3d Model of I-beam

This is the 3d model we have done in solidworks, showing the i-beam.

I-beam dimensions sketch

This is the end view of the i-beam we intend to use. The dimensions used have been taken from typical dimensions of an i-beam from a supplier.

The I-beam this is based on is designation size 254 x 102 mm.

www.steel-beam.co.uk/universal-steel-beams.php

Solidworks Sketch

This is a solidworks sketch of one of the legs in production. The bottom shoe of each leg is missing; pending response from supplier (jack).

I beam Dimensional analysis

Email to supplier

Bending Diagrams with x2 safety factor (in accordance with BS EN795)

Sheer Stress

Bending Moment

Load Diagram

Dimensions and calculations - I beam

Shear stress

Load Diagram

Bending Moment

Where were some thinking on how we could design the rotating base to of the crane.

At this step we decided to reject the design of the rotating crane due to design was changed and as a group concluded that the rotating crane arm would be costly to produce.

Sliding Device

Where we've decided to use rollers that would slide along the "I" Beam section easily, for easier handle and movement of the object.

Initial Design

Pictures from 17th March meeting

Here are some sketches of deisigns we have decided to take further, from our individual design ideas:

A gib style crane, with approximate dimensions on it.

A more detailed sketch of the crane, with indications of static and moving parts, and dimensions

Afy, Juan, Hector, James

the picture above describes one of my ideas where i thought of using a jack to lift the load also by having a jack on each leg it would allow the main bar to be moved as needed and the whole frame be positioned as needed.





this is simliar to a gantry crane because of the length of the bar i have used an 'I' bar for extra strength and a high second moment of area. the adjustable legs means it can be used on all terrain and rollers will run down the bar to move the load it will be able to lower one side and shift the load.

Available Hoists - Ian Thomas

Here is a link to suitable electric hoists. They are about $200.

http://www.alibaba.com/trade/search/3i1p5tyfchms/500_1000_kg_electric_hoist.html

lifting mechanism

i have been looking into what type of mechanism to use to lift the load. the two most feasible methods would be either a hydraulic jack or a pulley system, both of which will have to be simple to use so that any member of the general public would be able to use it.
A bottle jack can be used however the downfall to this is that the angle that it is used at cannot be more than 5 degrees and on rough terrain this would be hard to keep to, they can however lift upto 12 tons which would be more than enough.
I have found a brilliant system that might work to incorporate what is called a farmers jack onto a tripod design. this works by basically the jack pushing up on itself by this we can attach it to the bar that will be attached to a hook lifting the bar.
I sourced my information on the jacks from (http://www.ttclifting.co.uk/hydraulic/hydraulic_mechenical_jacking_division.html).
Although a jack is probably an efficient method a pulley system would be easier to design and would be easily adjustable. Even though it would need more strength it would also be easily replaceable for parts.

Results of Group Meeting 15/3/10

As a result of the group meeting (1200hrs 15/3/10) the following areas of work were identified:

Material costs to be calculated - Juan and Afy
Existing Crane designs to be uploaded - James
Pully and lifting mechanisms to be investigated (after consultation with Doctor Thomson) - Ian and James
Presentation format and data collection - Hector

All are to produce outline designs for next group meeting (Wed 17/3/10). The most producible design will then be chosen for further production.

What does 1000kg look like? Ian Thomas

In order to clarify what the crane may need to lift (to give a scale to the design) I have done some research on what 1000kgs looks like:

A VW Beetle (new) weighs approx 970Kgs.
An old Mini weighs 670Kgs.
1000Kgs of is approximately 416.66Litres of concrete. This is a the volume of a large family fridge freezer, a large oil drum or the boot room of a medium sized car (Kia Forte for example).

From this research I think we need to base our crane design around a 1m x 1m x 1m cube; with a weight of 1000kgs.

Hydraulic Jacks. Ian Thomas

The following information was found at this web address:

http://www.physlink.com/education/AskExperts/ae526.cfm

Question
How does a hydraulic jack work?
Asked by: Gaurav Kumar

Answer
Hydraulic jacks and many other technological advancements such as automobile brakes and dental chairs work on the basis of Pascal's Principle, named for Blaise Pascal, who lived in the seventeenth century. Basically, the principle states that the pressure in a closed container is the same at all points. Pressure is described mathematically by a Force divided by Area. Therefore if you have two cylinders connected together, a small one and a large one, and apply a small Force to the small cylinder, this would result in a given pressure. By Pascal's Principle, this pressure would be the same in the larger cylinder, but since the larger cylinder has more area, the force emitted by the second cylinder would be greater. This is represented by rearranging the pressure formula P = F/A, to F = PA. The pressure stayed the same in the second cylinder, but Area was increased, resulting in a larger Force. The greater the differences in the areas of the cylinders, the greater the potential force output of the big cylinder. A hydraulic jack is simply two cylinders connected as described above.

Answered by: R C Rosignol, B.S., Physics Teacher, Pace High School, Brownsville, TX


An enclosed fluid under pressure exerts that pressure throughout its volume and against any surface containing it. That's called 'Pascal's Principle', and allows a hydraulic lift to generate large amounts of FORCE from the application of a small FORCE.

Assume a small piston (one square inch area) applies a weight of 1 lbs. to a confined hydraulic fluid. That provides a pressure of 1 lbs. per square inch throughout the fluid. If another larger piston with an area of 10 square inches is in contact with the fluid, that piston will feel a force of 1 lbs/square inch x 10 square inches = 10 lbs.

So we can apply 1 lbs. to the small piston and get 10 lbs. of force to lift a heavy object with the large piston. Is this 'getting something for nothing'? Unfortunately, no. Just as a lever provides more force near the fulcrum in exchange for more distance further away, the hydraulic lift merely converts work (force x distance) at the smaller piston for the SAME work at the larger one. In the example, when the smaller piston moves a distance of 10 inches it displaces 10 cubic inch of fluid. That 10 cubic inch displaced at the 10 square inch piston moves it only 1 inch, so a small force and larger distance has been exchanged for a large force through a smaller distance.

Answered by: Paul Walorski, B.A., Part-time Physics Instructor

Materials

The most important material used to manufacture cranes is steel. Steel is an alloy of iron and a small amount of carbon. For structures that do not require very high strength, a common form of steel known as carbon steel is used. Carbon steel contains less than 2% of elements other than iron and carbon. The most important factor in determining the properties of carbon steel is the amount of carbon present, which ranges from less than 0.015% to more than 0.5%.

And in the other hand for structures that require great strength, particularly in cranes designed to lift very heavy objects, a variety of substances known as high-strength low-alloy (HSLA) steels are used. HSLA steels contain relatively low levels of carbon, typically about 0.05%. They also contain a small amount of one or more other elements that add strength,which include: chromium, nickel, molybdenum, vanadium, titanium, and niobium. Besides being strong, HSLA steels are resistant to atmospheric corrosion and are better suited to welding than carbon steels.

Depending on the exact design of the crane, a wide variety of other materials may be used in manufacturing. Natural or synthetic rubber is used to make tires for mobile cranes.

transportation of the crane

the crane has to be transported across by a standard sized land rover, defender hard top which is more commonly used by emergency services. I researched on a website and discovered these dimensions for the cargo bed(boot) and the box which is located on the roof, from this it it obvious the crane will have to accomodate being disassembled.

Dimensions	m (inches)
Cargo bed length	1.900 (74.8)
Tailgate aperture width	0.864 (34)
Largest box length	1.750 (68.9)
Largest box width	0.755 (29.7)
Largest box height	1.050 (41.3)

Tasks for next group meeting (15/3/10)

The following areas of responsibilty are to be researched by the nominated individual prior to the 2nd meeting:

James Woods
Exisitng Products (and costs).
Design construction and ease of use.

Hector Vela Garza
Enviornmental conditions (of the disaster area that the product is likely to operate within).

Juan Vasquez Amaya
Available materials and properties.

IanThomas
1000kgs - what shape and size can it take
Lifting Jack design

Aftab Thakur
What Transport would carry it.
What size is a 'standard' Land rover. How will this impact the product.

Group Composition

The following Appointments were agreed at a group meeting on 8/3/10:

Project manager - Ian Thomas.
Responsible for Group coordination, Realisation of the task and providing direction when needed. Also responsible for coordinating group meetings and resolving issues regarding the administration of the group.
Finance Officer - Aftab Thakur.
Material Specialist - Juan Vasquez Amaya.
Chief Designer - James Woods.
Stress Analyst - Hector Vela Garza.

All individual appointments (and their responsibilities) will be described in separate blogs; initiated by the designated individual.

Timeline of events

The following timescale is to assist with the smooth running of the tender.

10/3/10
1) Notice of interest lodged.
2) Group appointments to be agreed and described.
3)Initial Group meeting to be complete.
4) Project Manager to create blog regarding Group composition and organisation. All individuals to specify job role and responsibilities within the blog. Any missed areas will be highlighted within the 2nd group meeting.

15/3/10
1) 2nd Group meeting.
2) Initial Research to be complete. (Seperate Blog highlights these initial areas of interest).

22/3/10
1) 3rd Group Meeting.
2) Any specific areas/concerns will be updated at a later date.

29/3/10
1) University leave period (no group meeting but tasks will still be continuously updated on the blog).

19/4/10
1) Group meeting to add finishing touch and complete tender.

23/4/10
1) Tender submitted.

26/4/10
1)Tender presentation submitted.

28/4/10
1) Tender presentation.

is it working?

COntact details

Group M Job Titles:
Project Manager - Ian Thomas. Thomasi@aston.ac.uk
Finance Officer - Afy Thakur. Thakura@aston.ac.uk
Chief Designer - James Woods. WoodsJ@aston.ac.uk
Stress Analyst - Juan Vasquez Amaya. Vasquezja@aston.ac.uk
Materials Specialist - Hector Vela Garza. velagahj@aston.ac.uk