International Journal of Research in Engineering and Science (IJRES)
ISSN (Online): 2320-9364, ISSN (Print): 2320-9356
www.ijres.org Volume 12 Issue 10 ǁ October 2024 ǁ PP. 75-86
Design and production of a derrick crane for materials
handling
*1 W.A.Akpan , 2 E.O.Wilson 3 AE Oboh 4 II Nyaudo
1
Department of Mechanical Engineering, School of Engineering and EngineeringyTechnology,
Federal University of Technology, Ikot Abasi, Nigeria.
2
Department of Mechanical Engineering, School of Engineering, Akwa Ibom Stat Polytechnic, Ikot
Osurua, Nigeria.
3
Department of Mechanical Engineering, Faculty of Enineering, University of Uyo, Nigeria
4
Department of Petroleum and Gas Engineering, School of Engineering and Engineering Technology,
Federal University of Technology, Ikot Abasi, Nigeria
*Corresponding author:
[email protected] and
[email protected] (+234824297786)
Abstract
The design and production of a derrick crane for materials in for engineering workshop was motivated by the
need to ease material handling for an engineering workshop.Previous designs were reviewed and this unique
design was produced.The derrick crane is hydraulicaaly operated manually. All calculations for done and the
strength of the materials selected determined accordingly. The derrick designed and produced is capable of
carry a maximum load of 10,000N. It has mechanical advantage of 0.5 and velocity ratio of 0.55. It has an
efficiency of 91% and has special features incorporating castor wheels for easy movement and manouvarability
around the engineering workshop. Future design should be anchored on using Artificial intelligence to drive the
machine and its load functions in a typical engineering workshop.
Keywords: crane, derrick, , engineering, load, materials handling, workshop
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Date of Submission: 07-10-2024 Date of acceptance: 19-10-2024
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I. Introduction
A crane is a machine that is capable of raising and lowering heavy loads and moving them vertically or
horizontally. Cranes are different from hoist, because hoist can only lift objects but cannot move them sideways
[1](Jennings, 1998). They are also different from conveyors that lift bulky materials such as grains and coal in a
continuous process. The name crane is obtained from the fact that these machines have a shape with a great
semblance to the long neck of the bird that bears the same name. The use of cranes is of great antiquity. But it is
only since the great industrial development of the 19 th century, and the introduction of the motive powers, other
than manual labour, that the crane has acquired the important and indispensable position it now occupies
[2](Ernest, 1995). It is however worthy of note that, in all other places here finished goods are handled, or
manufactured goods or made, cranes of various forms are in universal use.
A derrick crane , which is one form of crane compreise: an upright derrick post having a hollow
interior; a turning ring rotabably supported to rotate around a lower part of the derrick post about a vertical axis,
a derrick boom pivotally supported at the inner proximal end thereof on the turning ring in a manner permitting
up and down derrick movement of the boom, etc. A derrick crane utilizes various kinds of motive powers for its
operation, namely: manual, steam, hydraulic and electric. A hydraulic driven crane for example, in addition to
most of the above listed parts consists of : hydraulic damper, a chain with hook attached, a puller welded to the
upright derrick post and a free rotary tyre.
A derrick has been defined as a tall machine used for moving or lifting heavy loads, especially on a
ship . They also define a derrick as a tall structure over an oil well for holding the drill.
Wage (1993) [3]gives a broader definition of cranes. He sees cranes as machines by means of which
heavy bodies may be lifted, and also displaced horizontally within certain defined limits. According to him, the
name crane alludes to the arm or jib from which the load to be moved is suspended, but is now used in a broader
sense to include the whole mechanism by which a load is raised vertically and moved horizontally. A crane has
also been described as a machine that is capable of raising and lowering loads and moving them horizontally. It
has also been demonstrated by[4] Banga T and Sharma s,c,(2008) that cranes are used for lifting loads-
construction materials, loose materials, packages, containers, finished and semi-finished products in industries
and placing them at desired place. They added that, for this purpose the crane has three motion in general
namely: hoisting, derricking and slewing. A crane however comprises of an upright derrick post having the
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Design and production of a derrick crane for materials handling
interior, a turning rotatably supported to rotate around a lower part of the derrick post about a vertical axis; a
derrick boom privotally supported at the inner proximal and thereof on the turning ring in a manner permitting
up-and –down derricking movement of the boom. Derrick cranes consist of a mast, a bull-wheel on which it
rotates about a vertical axis, and supporting members (guys). These cranes are widely used in construction
projects, industrial and multi-storey building construction, plant erection, loading and unloading of cargoes at
ports, ship building etc. [5] demonstrates that the different types of motive power used to actuate cranes are
manual, steam, hydraulic and electric. These also give a classification of cranes.
The derrick crane can utilize either of the afore-mentioned motive powers, but for the sake of this
project, we shall be concerned with the hydraulic system as the prominent motve power for the operation of the
derrick crane,
Hydraulics is based on a very simple fact of nature-you cannot compress a liquid. You compress a gas ,
but no matter how much pressure you apply onto a liquid, it is not possible to compress it. Now if you put a
liquid in a sealed system and push on it at one end, that pressure is transmitted through the liquid to the other
end of the system.
According to [6] the Greeks were among the first to understand about the use of water to provide lift
and force and the name hydraulic originates from the Latin word for water-Hydra. In the middle ages, Leonado
d vinvi formulated the basic principles of hydraulic called continuity and Galileo experimented with hydraulics.
Today most hydraulic systems utilize oil rather than water but the principles remain the same, you cannot
compress a liquid. Also a force that is applied at one point is transmitted to another point by the incompressible
fluid. Because of its liquid nature, hydraulic systems can transmit force through pipes of any shape and length
such that the force can be applied at one central point and transmitted efficiently to another point or multiple
points far away. This is exemplified by the master cylinder in car brakes, whereby by someone stepping on the
brake pedal, stopping pressure is applied on the brakes on all four wheels. Terminologies related to the hydraulic
propelled derrick crane include-Hydraulic press-this is a device to lift larger load by the application of a
comparatively much smaller force. It is based on Pascal’s law; hydraulic accumulator-this is a device used to
store pressure energy which may be supplied to hydraulic machines such as presses, lifts and cranes; hydraulic
intensifier-this is a device used to incres the intensity of pressure of water by means of energy available from a
large quantity of water at a low pressure; Hydraulic damper- this is a device used for lifting heavy loads by the
application of small force on a plunger, which in turn exerts a pressure to the cylinder that lifts the load.
The hydraulic system is very similar to the air pressure system in which the air on the inside exerts
equal pressure on all parts of the system. And if there is no leakage, the pressure remains constant throughout
the system. The hydraulic jack works on the same principle of incompressibility whereby as the jack is being
compressed. But moves up to occupy another space, thereby pushing up the spindle that is in contact with the
mainframe of the crane[7]
Over the years, humans have used a wide variety of devices to lift objects since ancient times. One of
the earliest versions of the cranes to be developed was the shaduf, first used to move water in Egypt about four
thousand years ago. The Shaduf consist of a long pivoting beam balanced on a vertical support. It is still being
used in rural areas of Egypt and India.As early as the first century, cranes were built that were powered by
human beings or animals operating a thres mill or large wheel. These early cranes consisted of a long wooden
beam, known as boom, connected to a rotating base [8,9]
But an important development in crane design occurred during the middle ages, when a horizontal arm
known as a jib was added to the boom. The jib was attached to the boom in a way which allowed it to pivot
allowing for the increased range of motion. By the sixteenth century, cranes were built with two treadmills, one
on each side of a rotating housing containing the boom. Cranes continued to rely on human or animal power
until the middle of the 19th
Century, when steam engines were developed. By the end of the19th century internal combustion
engines and electric motors were used to power cranes [1].
But sequel to the industrial revolution of the 19th century, cast iron and steel took over from wood as
the major materials for taller building. Also internal combustion engines and electric motors replaced the
prevailing modes of powering cranes. During the 1950’s, the availability of stronger steels, combined with an
increase demand for taller buildings, led to the development of cranes with very long booms attached to small
truck, or too many crawlers with caterpillar threads[9].
Modern cranes usually use internal combustion engines or electric motors and hydraulic systems to
provide a much greater lifting capability than was previously possible, although manual cranes are still utilized
where the provisions of power would be uneconomic.
It is worthy of note that ‘for dockslide jib cranes the use of electric power is making rapid strides. For
overhead travelers in workshops, and for most of the cranes which fall into our second class (of crane types),
electricity as a motive power has already displaced nearly every other method. Cranes driven by shafting or by
mechanical power, have been largely superseded by electric cranes, principally on account of the much greater
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Design and production of a derrick crane for materials handling
economy of transmission, For many years the best workshop travelers were those driven by quick running
ropes; these performed admirable service, but they have given place to more modern electric traveler.
Cranes may be divided into two main classes-rovolving and non-revolving. In the first, the load can be
lifted vertically, and then moved round a central pivot, so as to be deposited at anu conveneient point within the
range. The first class is the ordinary jib crane. In the second class there are in addition to the lifting motion, two
horizontal movements at right angles to one another. A typical example of this is the overhead craneor traveler.
Jib cranes can be subdivided into fixed cranes and portable cranes; in the former, the central post or pivot or post
is firmly fixed in a permanent position, while in the latter, the whole case is mounted on wheels, so that it may
be transported from place to place[5].
There also exist Hand or manual cranes-These are extremely useful where the load is not excessive,
and the quantities to be dealt with are not motive powers. They are also relevant where speed is not of
importance and ost a vital consideration. Steam cranes is extremely useful power for all cranes that ae not
operated from a central power station. The steam crane is of immense advantage since it is toally self-
contained. That is, it can be moved by its own locomotive power, if desired, for long distances without requiring
any complicated means of conveying power to it. It is rapid in work, faily economical and can be adapted to the
most varying circumstances; where however, there are a number of cranes all belonging to the same installation,
these are placed so as to be conveniently worked from a central power station. Where the work is rapid heavy
and continuous, as is the case at large ports, docks and railways or other warehouses, experience has shown that
it is best to produce the power in a generating station and distribut it to the cranes.
Hydraulic crane is rapid in action, very smooth and silent in working, easy to handle and not excessive
in cost or upkeep. These are advantages which have ensured its adoption in every part of the world. Hydraulic
cranes, as earlier noted are just one typr of hydraulic equipment that uses to provide pressure.The hydraulic
crane uses a compressible fluid such as oil, allowing for a great amount of pressure and a quick release when the
equipment is turned of. It is worthy of note that, while a hydraulic crane is commonly thought to be faster and
more positives for materials handling, like the conventional cranes its ability to achieve true balance is limited to
one specific radius. It is also note worthy that down to the closing decades of the 19 th century, hydraulic power
was practicaaly the only system available for making cranes from a power station. Over the years, the
performance, sophistication and opertely pressure of hydraulic cranes have steadily risen causing old models to
become obsolete or at the very least comparably frustrating to use.
Electric cranes as a motive power for cranes is a recent introduction. Transmission of energy by electric
means can be carried out with an efficiency that is unprecedented among the other prevailing models. And, the
electric motor is adaptable to any type of crane. When they are worked from a power station, great advantage is
gained that, the same plant which drives them can be used for many other purposes, such as working machine
tools and supplying current for lighting. For dockside jib crane, the use of electric power is making rapid strikes.
For overhead cranes in workshops, and for most non-revolving cranes, electricity as a motive power has already
displaced most other methods. Cranes that are driven by shafting, or by mechanical power, have been largely
superseded by electric cranes, principally on account of the much greatet economy of transmission. However,
cranes can also be classified into industrial and consruction cranes with particular reference to their names.
Very few machines exist in as wide a variety of designs as cranes. Before cranes are constructed, the
manufacturers consider the sites whre they will be used and the weight they need to lift. In addition cranes are
often modified to suit the needs of the user . For these reasons, it is not much of an exaggeration to say that no
two cranes are exaxtly alike. Cranes for industrial purpose are generally designed to remain permanently in one
location. Contruction cranes on the other hand are divided into mobile and tower cranes. Cranes types can be
detrmined either by hteir degree of mobility or ability to caryy greater loads and reach greater heights with
increased stability [10].
Cranes types according to degree of mobility include derrick crane, tueck-mounted crane, side lift
crane, ough terrain crane, all terrain crane, crawler crane, railroad crane and floatimg crane.While crane types
according to ability to carry greater loads and reach greater heights include but not limited to the following:
tower crane, selierecting crane, telescopic crane, hammer-head crane, level luffing crane, gantry crane, overhead
crane, deck drane, jib crane, etc.
Truck-mounted crane consist of crane mounted on a truck carrier. Such cranes are designed for
travelling on streets and highways, thus eliminating the need for special requirement to transport the crane to
worksite[11]. Great care is usually taken to avoid swinging the load sideways from the direction of travel, as
most of the anti-tipping lies in the strength and stiffness of the chassis suspension. Most cranes of this type also
have moving counterweights for stabilization beyond that of their outriggers.
Sidelift crane is a road going truck or semi-trailer that is able to hoist and transport IOS standard
containers. Lifting of containers is achieved throough the use of parallel crane –like hoists, which can be used to
lift a container from the ground, or from a railway vehicle.
Rough terrain crane is a crane mounted on an under carriage that is designed to pick and carry
operations and for off road and rough terrian applications.Outriggers that extend horizontally and vertically are
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Design and production of a derrick crane for materials handling
used to level and stabilize the cranes and simgle-engine machines where the same engine is usually mounted in
the undercarriage rather than in the upper , like the crawler cranes.
All terrain crane is mobile crane which has the necessary equipment to travel with high speed on public
roads/ highways and on the job siste in rough terrain with all wheel and crab steering.It combines the road
ability of truck-mounted crane and the maneuverability of a rough terrain crane. All terrain cranes od ATs have
2 to 9 axels and are designed for lifting loads up to 1200 metic tones.
Crawler crane is a crane mounted on under-carriage with a set of trucks(also called crawllers) that
provide for the stability and mobility of the crane. Crawler cranes range in loifting capacity from 40 US tones to
3500 US tones. The main advantage of the crawlwe cranes is that they can move around on site and then
perform each lift with very little set-up, since the crane is stable on its tracts with no outtiggers. In addition a
crawler crane is capable of travelling with a load. But the main disadvantage of the crawler crane is that they are
very heavy and cannot be moved easily from onr job site to the next without significsnt expense. Tyipcally a
large crawler must be disassembled and moves by trucks, rail cars or ships to be transported to it next location.
Railroad crane is a crane witth flanged wheels used by railroads. The simplest form is just a crane
mounted on a railroad car or on a flat car. More complex devices in the crane are purpose built,
Floating crane is the type used mainly in bridge building and port construction, but are also used for
occasional loading and unloading of especially heavy oe awkward loads on or off ships. Some floating cranes
are mounted on a pontoon , others are specialized crane barges with a lifting capacity exceeding 10,000 tones
and have been used to transport entire bridge sections. Floating cranes have been used to salvage sunken ships.
Derrick crane comprise an upright derrick post having a hollow interior , a turing ring rotatably
supported to rotate around the upper part of the derrick about a vertical axix. It could be powered by either
manual , steam, hydraulic or electric means. The derrick cranes are sometimes mounted on rail wagoms for
quik transpotation and for woring near rail-lines and are known as whirler cranes. These cranes are available up
to capacities of 49 tones with 25 meters boom length and 15 meters work radius.
The derrick cranes can be used as tower cranes for purposes of eretion of high industrial and residential
buildings of heights 100 meter . They are also designed to work as port tower cranes –for use in ports for
container and general cargo handling, as shipyard cranes –for use in ports for container and general cargo
handling, as shipyard cranes for use in ship building and ship repairing works with longer capacities and larger
working raddi[4].
This research work is focused on designing and production of a derrick crane with special features like
castor wheels for use in an engineering workshop.
II. Materials and Methods
2.1 Desing Criteria
It is required to design and produce a 1000 kg derrick crane for Engineering workshop with unique features of
manoevarability with castor wheels.
2.2 Theory of operation
The machines works by the application of the principle of moment by multiplication of the effort applied at the
handle of the jack which pushes hydraulic fluid in an enclosed cylinder to do work. The fluid in the cylinder
follows Pascal’s principle of transmissibility; which transmits the multiplied force to lift the load to the expected
height.
2.3 Design Analysis
The operation of the derrick crane is based on the the operation princilple of the lever of the third class. The
free body diagram of this machine is shown in Figure 1.
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Design and production of a derrick crane for materials handling
Figure 1 Simple moment of the derrick crane
Based on the principle of moment and taking the moment about the point F, Equation 1 results.
We have,
W1 xL2 F2v xL1 Equation 1
where F is the Fulcrum RF is the reaction at the fulcrum, F2 v is the applied force
Therefore the Mechanical Advantage (MA) is given in Equation 2 :
Load W1
MA= MA Equation 2
Effort F2v
Similarly the velocity ratio (V.R) in Equation 3 :
x
V .R Equation 3
y
where x is the distance moved by the effort and y is the distance moved by the load at the same time
The efficiency is given in Equation 4:
M .A
V .R Equation 4
W1 is the load (N), L1 , L2 are distance of the effort and disatance of the load from the fulcrum.
For an hydraulic system which will be used as the motive force, Pascal’s principle of hydrostatics is applied.
Fundamentally given in Equation 5,
F1 W
Equation 5
A2 A1
where F1 is the force applied on the plunger, A1 , A2 are the cross sectional area od the plunger and ram
respectively. P1 , P2 are the pressure intensities of the plunger and ram respectively.
Thus the Mechanical advantage of the system is presented in :
A1
M .A Equation 6
A2
The velocity ratio is the equivalent to the effort moved by the effort(hand moment) divided by the distance
moved by the load.
For a simple jack this shown in Figure 2.
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Design and production of a derrick crane for materials handling
Figure 2: Effort load relationship of simple jack
F1 is the applied load, L1, , L2 are the distances between fulcrum and effort and fulcrum and load at the same
time, x is the vertical distance moved by load and expressed as x in Equation7:
2 L1
x Equation 7
360
And y is the vertical distance, E the effort given in Equation 8 as:
F1 L
E , Equation 8
L2
F is the fulcrum and is the inclination of the handle (applied force)
F2 is the theoretical force on the ram, which is equal to the effort.
It can further be expressed in Equation 9; M.A in Equation 10,
F1 A1
F2 W Equation 9
A2
LA
M . A 1 1 , from Equation 8 Equation 10
L2 A2
Further relationship shown in Equation 11
F1 A1 x
Equation 11
F2 A2 y
Theoritically, the relationship between F2 v and the weight W from Figure 3 is presented:
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Design and production of a derrick crane for materials handling
Figure 3: The relationship between F2 v and the weight W
The retionship between these forces and the inclination is shown is shown in Equation 12
F2v
sin 2 Equation 12
F2
where 2 is the angle at whichF2 is inclined, and F2 is the required fprce to lift load and F1 is the vertical
component of F2 . If we define Q, Z as thr actual vertical distance moved by the load W and the force F2 .
Figure 3 the relationship applied force and weight is shown in Equation 13
Load W W
M .A Equation 13
Effort F2 sin 2 F2v
And its velocity ratio in Equation 14; and efficiency in Equation 15 :
Z
V .R and the efficiency is: Equation 14
Q
WQ Equation 15
F2v Z In analyzing the stress and bending moment for a simply supported beam, Equations 16 and 17
given in apply.
Fx W Equation 16
where W is the weight and Fx is the shear force,
The bending moment at any section of the beam x is:
M x Wx Equation 17
For a rectangular section the moment of inertia is given in Equation 18:
bd 3
I Equation 18
12
And the section modulus in Equation 19:
bd 2
Z Equation 19
12
For an I section, the shear stress and maximum shear stress are given in Equation 20.
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Design and production of a derrick crane for materials handling
(D2 d 2 ) b d 2
Fx B ( y2 )
Fx A y 8 2 4
[12] Equation 20
Ib Ib
The maximum shear occurs at the neutral axis and given in Equation 21,
(D2 d 2 ) b d 2
Fx B ( )
max 8 2 4 Equation 21
Ib
Since it is assumed that bending moment is taken by the flanges only, the flange area and depth of section, Z is
given in Equation 22
37t 4
Z 12.3t 3 Equation 22
3t
For the design of the Fulcrum pin(s) Equations 23 and 24 apply.
R p dLPb Equation 23
where d is the diameter, l is the length and Pb safe bearing pressure of thr pin(s).
Also since the pin is in double shear, the load on the fulcrum of the pin is given as:
2 d 2
RF Equation 24
4
where is the shear stress induced in thgiven as:r fulcrum pin. The maximum bending moment is given in
Equation 25 :
5WL1
M Equation 25
24
The section modulus of the pin is presented in Equation 26:
( d 3 )
Z Equation 26
32
And the induced bending stress is expressed in Equation 27
M
x Equation 27
Z
The factor of safety is given is presented in Equation 28,
TU
FS [13] Equation 28
WS
where TU , is the ultimate tensile strength of the material and WS is the working stress
III. Results and Discussion
3.1 Results
Given :
L1 600mm , L2 1200mm and W1 10,000 N , Therefore from Equation 1,
F2v 20kN
With W1, F2v known, from Equation 2
M.A=0.5
With x= 128mm and y=232mm, from Equation 3
V.R=0.55
From Equation 4 , the the mechanical advantage and velocity ratio known:
91%
With W1 , F2v known, the reaction at the fulcrum
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Design and production of a derrick crane for materials handling
RF 10kN
For the hydraulic jack
Given :
A1 2026,83mm2 , W1 =10000N,
P1 P2 4.93 / mm2
The theorictical force acting on the ram
F2 10000 N
A2 176.72mm2 ,
L1 , L2 known as 6000mm and 1200mm respectively from Equation 13 , mechanical advantage (M.A) of the
jack =5.7
For the same hydraulic jack, with W1 , F2v given as 10000N and 20000N, the
M.A= 0.5
And from Equation 14, the velocity ratio with x=128mm and y=232mm ( xZ , yQ)
V.R=0.55
From Equation 15 with M.A and V.R known
91%
For the horizontal beam
Appying Equation 16,
Fx 10000 N and M x 6000 Nm
From Equation
With b=102mm, d=51 mm, from Equation 19
Z 265.302mm3
Thus from Equation 21
max 2.884 N / mm2
For the I section beam
Given the moment of area of an I beam,
3
I= 6354,82x 10 mm4 , from Equation
max 255.28N / mm2 and from Equationn 22
Z 1,537.5mm3
For the Design of the fulcrum pins and holes:
From Equation 24,
48.73N / mm2
From Equation 25
M 364.58x103 Nmm
From Equation 26
Z 146.6mm3 and from Equation 27
b 2.487kN
From Equation 28, the factor of safety for the given material was computed.
Fs 2
Figure 4 shows the isometric projection of the derrick crane designed and produced.
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Design and production of a derrick crane for materials handling
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Design and production of a derrick crane for materials handling
Figure 4:Isometic projection of the derrick crane with part list
3.2 Discussion
The derrick designed and produced is capable of carry a maximum load of 10,000N. It has mechanical
advantage of 0.5 and velocity ration of 0.55.It has an efficiency of 91% and has special features incorporating
castor wheels for easy movement and manouvarability around the engineering workshop.
IV. Conclusion
The derrick crane with a maximum load carrying capacity of 10,000N was successfully done.The
mechanical advantage and velocity ratio of the derrick crane was 0.5 and 0.55 respectively. The overall
effieciency of the machine was 91% .Future work on using artificial intelligence to drive the machine is a good
direction for reseachers.
References
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Design and production of a derrick crane for materials handling
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