Design and Study of Advanced Cranes with Robotic ARM

Design and Study of Advanced Cranes with Robotic ARM

Prasad Nanasaheb Punekar

Student of Mechanical Engineering JSPMs Rajarshi Shahu College of Engineering,

Tathwade, Pune

Anmol Shripad Patil

Student of Mechanical Engineering JSPMs Rajarshi Shahu College of Engineering,

Tathwade, Pune

Swarup Pandurang Patil

Student of Mechanical Engineering JSPMs Rajarshi Shahu College of Engineering,

Tathwade, Pune

Aniket Shridhar Shivane

Student of Mechanical Engineering JSPMs Rajarshi Shahu College of Engineering,

Tathwade, Pune

Dr. Namdev A. Patil (Guide) Assistant Professor

Dept of Mechanical Engineering JSPMs Rajarshi Shahu College of Engineering,

Tathwade, Pune

Abstract Cranes are one of the essential industrial equipment for material handling jobs and manufacturing industries. And Robots are something that can be better than the human arm as they can be utilized 24 hours a day. They also help in increasing productivity by reducing the cycle time and also increasing the quality of the product because of fewer errors and high precision. In this research paper, We publish our work and research on a completely new concept of assembling a robotic arm to an overhead crane. We have carried out detailed research about cranes and robotic arms as well as done the necessary calculation with the help of some research papers and books that are given in references. Along with that, design of the model is also done based on calculations.

Keywords Alliance, Crane, Robotic Arm,

1. INTRODUCTION

   This research paper will present the work done on a completely new and innovative idea of assembling an industrial robotic arm to the overhead crane and make a clear understanding about where and how it could be used in different areas, and we will discuss the design procedure and general calculations of all the parts used in this model, and nowadays some of the companies are also working on this idea.

   Objective

   To create a smart, flexible, and multiple application workspace for a warehouse/workshop using Crane with a Robotic arm.

   Basic Idea : This research which was carried out between the 5th of August to 10th of March 2022, had includes project reviews under experience professors

   Crane : An overhead crane consists of parallel runways with a traveling bridge spanning the gap. Overhung cranes have a huge work envelope and can pretty much reach every corner of a warehouse or assembly line. But, they are not programmable and serve only for a limited purpose of just weight lifting.

   Robotic Arm : A robotic arm is a type of mechanical arm, usually programmable. A robotic arm can serve a lot of applications such as part assembly, lifting jobs with minimal changes in the front-end attachment. But, it is mounted over a rigid surface and so has a very limited work envelope, and usually zero mobility.

   Advanced cranes with robotic arm : Mounting a robotic arm to an overhung crane overcomes both the disadvantage of a limited number of applications (crane) and a limited work envelope (robotic arm). Combining these two enhances the number of applications and increases the level of automation and increases the work envelope. The robotic arm attains enhanced mobility due to the crane and can deliver its variety of functional applications at any desired location on the assembly line/warehouse.

2. METHODOLOGY

This project work which was carried out between the 5th of August to 10th of March 2022, includes project reviews of experienced professors.

We have followed the following steps to carry out the complete work of the project.

1. We started with defining the problem statement followed by analysis.

2. We moved to the design considerations and calculatioN for the model of the crane.

3. Based on calculations and constraints we designed the CAD model of the crane and robotic arm.

4. Each part of the CAD model is then analyzed on ANSYS with extreme load conditions.

5. The CAD model is also simulated on CATIA Kinematics.

6. Lastly based on the result of analysis and simulation the necessary changes were made in design and CAD.

1. MATERIALS, ABBREVIATIONS AND UNITS

   TABLE. 3.1 MATERIALS

   Material	Yield strength (MPa)	Ultimate Strength (MPa)
   Mild steel	350	440
   Rolled steel	310	461
   Stainless Steel	215	505
   Hard Steel	550	450

   TABLE. 3.2 ABBREVIATIONS AND UNITS

   Parameter	Denotation	Unit
   Moment	M	N/mm2 or 2
   Mass	m	kg
   Moment of inertia	I	N/mm4
   Distance from the	Y	m/mm
   Stress		N/mm2 or 2
   Weight	W	N
   Force	P	N
   Length	L	m
   Effective length	Le	m

2. CALCULATIONS

   Fig. 4.1 (3D view of parts for which the calculations are performed.)

   max = 310 (yield strength for hot rolled steel) M = (max * I) / y

   = (310 * 1.28 * 108) / 105

   = 3.78 * 108 N.mm

   M = 3.78 * 105 N.m

   Maximum Moment when load at center

   Fig. 4.1.2 – FBD for Grider ( for Robotic Crane)

   M = W * L/2

   W = (3.78 * 105) / 17.5 W = 21600 N

   W = mg

   21600 = m * 9.8 m = 2204.0816 kg

   Girder undergoes shear (Maximum force is achieved when load is applied at center)

   Fig. 4.1.3 – FBD for Grider ( for Robotic Crane)

   Wmax = 19000 N

   RA = 98000 N = W/2 RB = W\2 =98000 N

   By shear force diagram,

   4.1) Calculations for Girder (for Robotic Crane) :

   Girder undergoes a bending moment. (Always maximum bending moment for a point load is achieved, when the load is applied at center)

   SfAL = 0

   Fig. 4.1.4 – SFD for Grider ( for Robotic Crane)

   Fig. 4.1.1 – I- Section for Grider ( for Robotic Crane)

   Flexural Formula

   (M/I) = (/Y)

   I = (BD3 – bd3) / 12

   I = (210 * 2103 – 126 * 1483) / 12

   I = 1.28 * 108 mm4

   Sf @ A = 98000N SfA = 98000N SfLB =98000N

   Sf @ B = 196000N SfB = -98000N

   SfLC = -98000N SfC = 0N

   5.2) Calculations for Girder (for Conventional Crane)

   Girder undergoes a bending moment. (Always maximum bending moment for a point load is achieved, when the load is applied at center)

   Fig. 4.2.1 – I- Section for Grider ( for Conventional Crane)

   Flexural Formula

   (M/I) = (/Y)

   I = (BD3 – bd3) / 12

   I = ( 440 * 4403 – 264 * 3083)) / 12

   I = 2.4806 * 109 mm4

   max = 310 (yield strength for hot rolled steel) M = (max * I) / y

   M = (310 * ( 440 * 4403 – 264 * 3083)) / 12* 220

   M = 3.4954 * 109 N.mm

   Maximum Moment when load at center

   Fig. 4.2.2 – FBD for Grider (for Conventional Crane)

   M = W * L/2

   W = (3.4954 * 106) / 17.5 W = 199737.1429 N

   W = mg

   199737.1429 = m * 9.8 m = 20381.3411 kg

   1. Calculations for Struture of long travel :

      Structure for long travel, undergoes bending moment. (Always maximum bending moment for a point load is achieved, when the load is applied at center)

      Fig. 4.3.1 – I- Section for Structure of long travel

      Flexural Formula

      (M/I) = (/Y)

      I = (BD3 – bd3) / 12

      I = (390 * 3903 – 234 * 2743) / 12

      I = 1.56274 * 109 mm4

      max = 310 (yield strength for hot rolled steel) M = (max * I) / y

      = (310 * I) / y

      = 310 (390 * 3903 – 234 * 2743) / (12 * 195)

      = 2.42712 * 109 N.mm

      M = 2.42712 * 106 N.m

      Maximum Moment when load at center

      Fig. 4.3.2 – FBD for Structure of long travel

      M = W * L/2

      W = (2.42712 * 106) / 12.5 W = 194169.5565 N

      W = mg m = W / g

      m = 194169.5565 / 9.8

      m = 19813.22005 kg 20000 kg

      4.4 Calculations for Structure of Long travel :

      Structure for long travel in shear (maximum shear force is achieved when the load is applied at the center). We Take the weight at the end so that we get maximum input for long travel (for shear calculations)

      Fig. 4. – FBD for Grider ( for Robotic Crane)

      Wmzx = 196000N

      Shear force will be maximum when the load will act at the center.

      Rp = W/2 = 98000N RQ = W/2 = 98000N

      By shear force diagram,

      SfPL = 0

      Sf @ P = 98000 N SfP = 98000 N SfLR = 98000N

      Sf @ R = -196000N SfR = -98000N

      SfLQ = -98000N Sf @ Q = 98000N SfQ = 0 N

   2. Calculations for Structure of Pillar:

   Fig. 4.4.1 – I- Section for Structure of Pillar

   Pillar undergoes Buckling.

   P = ( 2EI ) / L2 (Le = L)

   1000 * 9.8 = (2 *210 * 103 * ( a4 – (a-16)4 ) ) / (12 * 82 * (103)2 )

   a = 90.52942911 mm

   a 91mm

   Inner Dimension = a-16 = 75mm Outer Dimension = a = 91mm 4.5) Robotic Arm Carrier :

   Robotic Arm carrier is designed through simple stresses and strain calculation.

   Material : AISI Type 304 stainless yield = 215 Pa = 215 Nmm2

   FOS = 2.5

   t (allowed) = yield / FOS = 215 / 2.5 = 86 N/mm2 T = 86 N/mm2

   86 = (20000 * 98) / ((/3) * 32.5 * x)

   x = 66.96 mm (thickness)

   x 70 mm

   T = 86 N/mm2 T = P / A

   T 86 N/mm2

   T = (20000 * 9.8) / (70 * 200)

   T = 14 N/mm2

   Hence, the design is valid. Why 200 mm is taken as x1 :

   • The diameter of circle is 65mm. So we have to put the length of the cross-section greater than 65mm (i.e. 200 mm).

   • For proper force distribution, to the downplate. We have to increase the length of the cross-section (200 mm), proportional to the downplate.

3. DESIGN (CAD MODEL) :

   Fig. 4.2 Design (CAD Model) – Advanced Crane with Robotic Crane

4. ANALYSIS :

   The developed 3D model is imported into ANSYS 2021 R2 software. A Crane is designed on a 20 tonne load. The physical and mechanical properties for the analysis are supplied as per the values in the table . The stress value and total deformation of the crane parts are obtained separately.

   Fig. 6.1 Ansys of long travel

   Fig. 6.2 Ansys of cross travel

   Fig. 6.3 Ansys of arm carrier

   Fig. 6.4 Ansys of wheel carrier

   Fig. 6.5 Ansys of wheel

5. RESULT & DISCUSSION:

The following results are obtained based on the Analysis. For all parts, we do analysis on the extreme load conditions. in that we consider all factors like fixed surface, friction surface, etc.

1. Long Travel has a 0.030 m deflection. In this we had two long travels which will support the load, along with the load carrier, hence force will be distributed in both the travels, hence deflection considered negligible.

2. Cross Travel has a 6.28 mm Deflection. normally industries had this much deflection.

3. The Arm Carrier has a 0.004 mm deflection, Which is negligible.

4. The Wheel Carrier has 0.01 mm deflection.

5. Wheel has a 0.0037 mm deflection, which is also negligible.

Fig. 7.1 Force vs Total Deformation for cross travel

Fig. 8.1 Force vs Stress for cross travel

The following Factor of safety are found based on analysis,

TABLE 8.1 FACTOR OF SAFETY (FOS) OF DIFFERENT COMPONENTS (PARTS)

Part Name	Factor of safety(FOS)
Long Travel	1.5
Cross Travel	2.8
Arm Carrier	2.5
Wheel Carrier	5
Wheel	10.7

8. REFERENCES

[1] Tomas H Orihuela,"Design of Monorail Systems".

[2] A D Anjikar and C Chanda, Design Procedure Of Overhead Monorail For Material Handling System For Food Processing Industry, Int. J. Mech. Eng. & Rob. Res. 2013 ISSN 2278 0149 Vol. 2, No. 4, October 2013.

[3] Nenad ZRNI, Sran BONJAK, and Vlada GAI, Loading Capacities Curves For I-section Runway Beams According To Bottom Flange Bending And Lateral Buckling (the University of Belgrade, Faculty of Mechanical Engineering).

[4] N.S. Trahair, Lateral Buckling of Monorail Beams I-beams, Engineering Structures 30 (2008) 3213 3218.

[5] Rajpandian R, Design and Analysis of Overhead Crane Structural Columns IOSR Journal of Electronics and Communication Engineering (IOSR-JECE) e-ISSN.

[6] Anwar BadawyBadawy Abu-Sena, Mohamed Salah Al-Din Soliman, Omer Nazmi Ali AbdelNabi, Behavior and resistance of beam-column structural elements, Journal of Constructional Steel Research 71 (2012) 171181.

[7] CMAA 74: Crane manufacturers association of America specification 74.

[8] https://www.admet.com/effect-specimen-geometry-tensile- testing-results/

[9] Strength of Materials by Prof. Indrajeet M.Jain

[10] Design Analysis of a Remote Controlled Pick and Place Robotic Vehicle by B.O. Omijeh (International Journal of Engineering Research and Development e-ISSN: 2278-067X, p- ISSN: 2278-800X, www.ijerd.com Volume 10, Issue 5 (May 2014), PP.57-68).

[11] Design of a Robotic Arm for Picking and Placing an Object Controlled Using LabVIEWbyShyam R. Nair (International Journal of Scientific and Research Publications, Volume 2, Issue 5, May 2012).

[12] Design of a Robotic Arm with Gripper & End Effector for Spot Weldingby Puran Singh (Universal Journal of Mechanical Engineering 1(3): 92-97, 2013).