DESIGN OF MECHANICAL GRAB FOR

LIFTING PLATES

Final Year Project Report

Group: 52XX Batch: 20XX-20YY

Safiullah Channa ME-XXABC0

Student name ME-XXDEF10103
Muhammad Azeem Jaffer ME-XXGHI

Internal Advisor: Dr. ABC DEF

Assistant Professor
Department of Mechanical Engineering

Reference#: XX/2014

DEPARTMENT OF MECHANICAL
ENGINEERING
 CERTIFICATE

It is to certify that the following students have completed their project “Design of
Mechanical Grab for Lifting Plates” satisfactorily.

Group: 52 Batch: 2010-2011

Name Seat No.
Safiullah Channa ME-XXABC0
Student name ME-XXDEF10103
Muhammad Azeem Jaffer ME-XXGHI

Internal Advisor
Prof. Muhammad Aklaque
Professor
Department of Mechanical Engineering
NED University of Engineering. &
Tech.

Projects’ Coordinator
Mr. NVD RHM Ahmed
Department of Mechanical Engineering
NED University of Engineering. &
Tech.
 DEPARTMENT OF MECHANICAL
ENGINEERING

NED UNIVERSITY OF ENGINEERING AND

TECHNOLOGY
 ACKNOWLEDGEMENTS
The project “Design of a Mechanical Grab for lifting Plates and Sheets” is at this
completion stage due to Allah’s generous blessings on us, cooperation of the
dedicated Advisor Prof. Muhammad Akhlaque. and at last group members’ dedication
and hard work.
Apart from the efforts of us, the success of this project depends largely on the
encouragement and guidelines of many others. We take this opportunity to express our
gratitude to the people who have been instrumental in the successful completion of
this project.
We would like to show our greatest appreciation too. We are highly grateful for his
tremendous support and help. We feel motivated and encouraged every time we
attended the project meeting. Without his encouragement and guidance this project
could not be completed.
.

I
 ABSTRACT

This report will provide valuable information to a mechanical engineer to build up an

engineering approach in designing a purposeful motorized grab. Through reading of
this report, an individual can know how to precede a project of designing the grab and
which parameters should be of prime focus in research and development phase
These motorized mechanical grabs can be classified into different types. Motors with
electromagnetic brakes are used. This is an important safety feature that prevents the
unit from accidentally opening under load.

To improve the efficiency, safety and quality of material handling functions,

Mechanical Grabs can be used in the heavy industry where material handling is quite
frequent as it not only ensures safety but also allows consumer to save time and costs.
The Automated Telescopic action in the mechanical grab not only provides control to
the user but also provides ease for lifting sheets of variable sizes resulting in
optimized work flows.

II
 TABLE OF CONTENTS

1. Mechanical Grabs............................................................................................1
1.1 Introduction................................................................................................1
1.2 Importance..................................................................................................1
1.2.1 Types of Mechanical Grabs....................................................................2
1.2.2 Arrangement of Mechanical Grab..........................................................3

2. Overhead crane................................................................................................5
2.1 Introduction................................................................................................5
2.1.1 Overhead Crane......................................................................................5
2.1.2 Advantages.............................................................................................5
2.1.3 Standards................................................................................................6
2.1.4 Safety Aspects........................................................................................7
2.1.5 Labeling of Crane:..................................................................................7
2.1.6 Safety Analysis:......................................................................................8
2.1.7 Performance:..........................................................................................8
2.1.8 Structural:...............................................................................................8
2.1.9 Mechanical:............................................................................................9
2.1.10 Electrical:..........................................................................................11
2.1.11 Testing:.............................................................................................14
2.1.12 Proof load test:.................................................................................15
2.1.13 Rated load test:.................................................................................15
2.1.14 Operational test:...............................................................................16
2.1.15 Test Reports:.....................................................................................17
2.1.16 Inspection:........................................................................................17
2.1.17 Daily Inspection:..............................................................................17
2.1.18 Monthly Inspection:.........................................................................18
2.1.19 Annual Inspection:...........................................................................18
2.1.20 Inspection Report:............................................................................20
2.1.21 Maintenance:....................................................................................20
2.1.22 Maintenance Procedures:.................................................................20
2.1.23 Adjustments:....................................................................................21

III
 2.1.24 Operations:.......................................................................................22
2.1.25 Special Criteria:................................................................................25

3. Hoists...............................................................................................................27
3.1 Types of Hoists.........................................................................................28
3.1.1 Wire Rope Hoist or Chain Hoist:.........................................................28
3.1.2 Construction Hoist:..............................................................................29
3.1.3 Mine Hoist:...........................................................................................30

4. Hoist Standards..............................................................................................31
4.1 Introduction:.............................................................................................31
4.2 Safety Aspects:.........................................................................................31
4.2.1 Labeling/Tagging of Hoists:.................................................................31
4.2.2 Test Reports and Periodic Recertification Tags:..................................32
4.2.3 Safety Analysis and Documentation for Hoists used for Critical Lifts:
32
4.2.4 Performance:........................................................................................32
4.2.5 Structural:.............................................................................................33
4.2.6 Mechanical:..........................................................................................33
4.2.7 Electrical:.............................................................................................35
4.2.8 Testing:.................................................................................................38
4.2.9 Proof Load Test:...................................................................................38
4.2.10 Rated Load Test:...............................................................................39
4.2.11 Operational Test:..............................................................................39
4.2.12 Inspection:........................................................................................40
4.2.13 Inspection Reports:...........................................................................42
4.2.14 Maintenance:....................................................................................42
4.2.15 Maintenance Procedures:.................................................................43
4.2.16 Adjustment:......................................................................................43
4.2.17 Repairs and Replacements:..............................................................44
4.2.18 OPERATIONS:................................................................................44
4.2.19 Special Criteria:................................................................................47

5. Design of Mechanical Grab...........................................................................48

5.1 Design:.....................................................................................................48
5.2 Methodology:...........................................................................................50
IV
 5.3 Operation of Mechanical Grab:................................................................51
5.4 Components of Mechanical Grab:............................................................53
5.4.1 Housing................................................................................................54
5.4.2 Outer Beam..........................................................................................55
5.4.3 INNER BEAM.....................................................................................57
5.4.4 Side claw left........................................................................................59
5.4.5 Side claw Right....................................................................................61
5.4.6 Side Assembly......................................................................................62
5.4.7 Sliding Beam Assembly.......................................................................64
5.4.8 Rack & Pinion Design Calculations:....................................................67
5.4.9 Other Drawings:...................................................................................71

Conclusion
References

V
 LIST OF FIGURES

Figure 1: Manual Mechanical grabs.........................................................................2

Figure 2: Automatic Mechanical Grabs....................................................................3
Figure 3: Overhead Cranes used in industry.............................................................4
Figure 4: Overhead Crane with hoist........................................................................6
Figure 5: Chain Hoist Forces..................................................................................28
Figure 6: Mine Hoist................................................................................................30
Figure 7: Grab Side dimensions..............................................................................48
Figure 8: Grab Front dimensions............................................................................49
Figure 9: 3D Model.................................................................................................50
Figure 10: Inner and outer beam rack pinion arrangement..................................51
Figure 11: Sliding Beam Mechanism.....................................................................52
Figure 12: Extension of grab along its length.......................................................52
Figure 13: Main Drawing......................................................................................53
Figure 14: Housing................................................................................................54
Figure 15: Outer Beam..........................................................................................56
Figure 16: Inner Beam...........................................................................................58
Figure 17: Side Claw left.......................................................................................59
Figure 18: Side Claw Right...................................................................................61
Figure 19: Side Assembly.......................................................................................62
Figure 20: Side Wall..............................................................................................63
Figure 21: Extension of Grab along its width.......................................................64
Figure 22: Un extended Mechanical Grab............................................................64
Figure 23: Sliding Beam Assembly........................................................................65
Figure 24: Sliding Beam Assembly (Hidden lines)................................................66
Figure 25: Reference Chart [1].............................................................................68
Figure 26: Reference Chart [2].............................................................................69
Figure 27: Locking Handle....................................................................................71
Figure 28: Motor....................................................................................................72

i
 CHAPTER #1

1. Mechanical Grabs

1.1 Introduction

This report will provide valuable information to a mechanical engineer to build up an

engineering approach in designing a purposeful motorized grab. Through reading of
this report, an individual can know how to precede a project of designing the grab and
which parameters should be of prime focus in research and development phase.

In our industries there is always a need of an efficient system of handling raw

material. In this regard the first step is to implement a fast and efficient grabbing
system which can only be done by a overhead crane which should be productive,
systematized and cost effective. Mechanical grab refers to overhead crane specially
designed to collect heavy duty raw material such as (plates, bullets and round bars
etc).

These motorized mechanical grabs can be classified into different types. Motors with
electromagnetic brakes are used. This is an important safety feature that prevents the
unit from accidentally opening under load. To improve the efficiency, safety and
quality of your material handling functions. We have done all the design, and analysis
calculation.

1.2 Importance
Mechanical grab for lifting sheets are used in applications where large quantities of
sheets are handled and transported. The processing speed and occupational safety
increase to a maximum because direct contact with the sheet is eliminated. Stack of
sheets consist of stacked and bound sheets. Requirement for transport with a sheet
stack grab is the ability to grab below the packages. If this is given, you can also
transport loosely bound packages. Here, hold-down devices which prevent slippage of
the sheets are used.
Other advantages are as follows:
The use of load suspension equipment is essential at places where large
quantities of loads are handled in quick time.
Load suspension equipment developed as HSSE Standards, ensure maximum
occupational safety
When handling such loads. Workflows can be optimized, which means
considerable savings in more ways than one.
1.2.1 Types of Mechanical Grabs
Mechanical grabs can be mainly divided in two:
Manual
Automatic
There are many different types of manual mechanical grabs shown in the figure
below. These are Mechanical grab is without any electrical and hydraulic components,
usually made of ropes and connecting rod driving force, which is the most common
used mechanical double rope grab, mechanical four rope grab and single rope grab.
Grab bucket can be made into different shapes according to the demands, such as
clamshell type, orange peels type, etc.

Figure 1: Manual
Mechanical
grabs

There are also several types of automated mechanical grab having different
applications as shown in the figure below:
 Figure 1: Automatic Mechanical Grabs

1.2.2 Arrangement of Mechanical Grab

Hoist Overhead Crane is a regular crane widely used at outdoor and warehouses to
load, unload or grab materials The Grab crane is widely used in power plants, yard,
workshop, bulk terminals, etc. The handling and transportation, the cranes are heavy
duty work system, all agencies operating in the driver room, into the direction of the
cab platform: side entry, side entry and top entry, nominal weight, including weight
grab, grab, parallel and vertical direction to open the main beam in two forms
Figure 2: Overhead Cranes used in industry
 CHAPTER # 2

2. Overhead crane

2.1 Introduction
In this section we would be looking at the overhead cranes, there types uses and
advantages.

2.1.1 Overhead Crane

An overhead crane, commonly called a bridge crane, is a type of crane found in
industrial environments. An overhead crane consists of parallel runways with a
traveling bridge spanning the gap. A hoist, the lifting component of a crane, travels
along the bridge. If the bridge is rigidly supported on two or more legs running on a
fixed rail at ground level, the crane is called a gantry crane.

2.1.2 Advantages

Overhead cranes are commonly used in the refinement of steel and other metals such
as copper and aluminum. At every step of the manufacturing process, until it leaves a
factory as a finished product, metal is handled by an overhead crane. Raw materials
are poured into a furnace by crane, hot metal is then rolled to specific thickness
and tempered or annealed, and then stored by an overhead crane for cooling, the
finished coils are lifted and loaded onto trucks and trains by overhead crane, and
the fabricator or stamper uses an overhead crane to handle the steel in his factory.
The automobile industry uses overhead cranes to handle raw materials.
Smaller workstation cranes, such as jib cranes or gantry cranes, handle lighter loads in
a work area, such as CNC mill or saw.

Almost all paper mills use bridge cranes for regular maintenance needing removal of
heavy press rolls and other equipment. The bridge cranes are used in the initial
construction of paper machines because they make it easier to install the heavy cast
iron paper drying drums and other massive equipment, some weighing as much as 70
tons.

In many instances the cost of a bridge crane can be largely offset with savings from
not renting mobile cranes in the construction of a facility that uses a lot of heavy
process equipment.
 Figure 3: Overhead Crane with hoist

2.1.3 Standards
ASME B30.2: "Overhead and Gantry Cranes (Top Running Bridge, Single or
Multiple Girder, Top Running Trolley Hoist)"

ASME B30.17: "Overhead and Gantry Cranes (Top Running Bridge, Single Girder,
Underhung Hoist)"

ASME B30.11: "Monorails and Underhung Cranes"

BS 466: "Specification for Power driven overhead travelling cranes, semi-goliath and
goliath cranes for general use" (1984)
ISO 4301-5: "Cranes; classification; part 5: overhead travelling and portal bridge
cranes" (1991)

ISO 8686-5: "Cranes; design principles for loads and load combinations; part 5:
overhead travelling and portal bridge cranes" (1992)

Indian Standard - 807

Indian Standard - 3177

Indian Standard -4137

Safety standards for the design, test, inspection, maintenance, operation, and
personnel certification/recertification for overhead and gantry cranes, including
underhung monorail, and jib cranes are mentioned below [2].

2.1.4 Safety Aspects

Generally, high quality off-the-shelf, Original Equipment Manufacturer (OEM) type
equipment is acceptable for critical and noncritical lifts if it is designed, maintained,
operated, etc., according to this standard [2].

2.1.5 Labeling of Crane:

• The rated load of all cranes shall be plainly marked on each side of the crane.
If the crane has more than one hoisting unit, each hoist load block shall be marked
with its rated load. This marking shall be clearly legible from the ground floor (OSHA
requirement for all overhead cranes).
• Cranes that have the specified design features, maintenance/inspection, and
test intervals to lift critical loads shall be marked conspicuously so that the operator
and assurance personnel can distinguish that the crane is qualified for critical lifts.
• A standard system of labeling shall be established and used throughout the
installation.
• A standard tag-out system shall be established and used throughout the
installation to indicate equipment that is not to be used due to inspection
discrepancies, ongoing maintenance operations, etc.

2.1.6 Safety Analysis:

A hazard analysis shall be performed on all cranes used for critical lifts. The analysis
shall, as a minimum, determine potential sources of danger, identify most probable
failure modes, and recommend resolutions for those conditions found in the hardware-
facility-environment-human relationship that could cause loss of life, personal injury,
or loss of crane, facility, or load. The analysis also shall include crane description,
reference documentation, severity assessment, and assessment of specified passive
and structural components between the hook and the holding brakes. Hazards that are
identified shall be tracked (recorded and current status maintained) until final closure
is verified. A system of risk acceptance is required for hazards that cannot be
eliminated. The hazard analysis shall be done as part of the initial crane certification
process, included in the crane documentation, and updated as required to reflect any
changes in operation and/or crane configuration.

2.1.7 Performance:
Operational life, crane service classification, load capability, and the desired control
characteristics with which the crane handles the load shall be addressed for all
designs. The expected operational life shall be specified or detailed for system
components. Crane service classification requirements shall be based on the worst
expected duty the unit will encounter. Each load-bearing component shall be specified
or detailed to lift the maximum imposed loads resulting from zero to rated hook load
with appropriate safety factors. Operational requirements shall be considered in the
design phase to ensure load and function are adequately defined and critical crane
design features are incorporated on the delivered units.

2.1.8 Structural:
Structural design shall be in accordance with industry standards for
material selection, welding, allowable stresses, design limitations, framing, rails,
wheels, and other structural elements. Refer to ANSI and CMAA standards for
specific design details.

2.1.9 Mechanical:
• The use of high quality, off-the-shelf, OEM type equipment is acceptable for
critical and noncritical lift applications if it meets all user requirements and the
requirements of this document. This high quality commercial equipment employs a
modular type construction of the hoist unit with standard frame sizes and
interchangeable gear boxes, drums, motors, brakes, and controls to achieve a wide
range of capacities, lifts, operating speeds and controls. These interchangeable parts
are standardized for each manufacturer’s product line and the hoists are built to order.
• The mechanical design requirements for crane components are as follows:
1. They shall meet all applicable requirements of OSHA, ANSI, and CMAA.
2. For critical lift application, speed reduction from the motor to the drum on the
hoist should be achieved by enclosure in a gear case. If open gears are required, they
shall be guarded with a provision for lubrication and inspection. Gearing shall be
designed and manufactured to comply with the latest American Gear Manufacturers
Association (AGMA) gears standards.

3. Hooks shall meet the manufacturer’s recommendations, and shall not be

overloaded. Swiveling hooks should rotate 360 degrees on antifriction bearings with
means for lubrication. If grease is a contamination concern, drip funnels (cups) or
non-lubricated bearings should be provided. Latch-equipped hooks shall be used
unless the application makes the use of a latch impractical or unnecessary. When
required, a latch or using shall be provided to bridge the throat opening of the hook to
retain slings, chains, or other similar parts under slack conditions.

4. Each hoisting unit shall be provided with at least two means of braking: a
holding brake and a control brake. The torque ratings ,physical characteristics, and
capabilities of the brakes shall be in accordance with CMAA specifications.
5. For cranes used for critical lifts, two means of braking shall be provided, each
capable of bringing a rated load to zero speed and holding it (with and without
power). If the control brake and holding brake are designed to operate as a system and
cannot independently stop and hold a rated load, then another means of braking is
required for cranes used for critical lifts (e.g emergency brake).

6. Worm gears shall not be used as a braking means unless the lead angle is
sufficient to prevent back driving. The braking properties of a worm gear tend to
degrade with use; the design engineer shall consider this when purchasing new
equipment or in existing installations where the hoist is subject to heavy use.

7. In the procurement of new lifting equipment, the use of cast iron components
in the hoist load path shall be approved, as a minimum, by the installation NASA
Safety Director. The material properties of cast iron allow catastrophic failure and
should not be considered as reliable as steel or cast steel. The engineer shall consider
this when selecting equipment and avoid the use of load bearing cast iron materials
where possible.

8. Safe and adequate access to crane components to inspect, service, repair, or

replace equipment shall be provided for during design. The design shall provide for
visual and physical accessibility.

9. Pneumatic cranes shall have the capability to lock out the supplyair pressure to
prevent unauthorized use.

10. Based on the sensitivity of the loads to be lifted, cranes shall have appropriate
speed modes that provide for safe, smooth starting and stopping to preclude excessive
“G” forces from being applied to the load.

11. All wire rope hoists shall have not less than two wraps of hoisting rope on the
drum when the hook is in its extreme low position. Drum grooves, when provided,
shall be as recommended by CMAA. The rope ends shall be anchored securely by a
clamp or a swaged terminal in a keyhole slot, provided a keeper is used to prohibit the
swage from moving out of the narrow slot. Other methods recommended by the hoist
or wire rope manufacturer are acceptable if the rope termination anchor together with
two wraps of rope on the drum will give an anchor system equal to or greater than the
breaking strength of the wire rope.

12. Manually operated (non powered) hoist cranes that are off-the-shelf OEM
type are acceptable for critical and noncritical lift applications. They shall comply
with applicable ANSI requirements. These hoists need only be equipped with at least
one brake as described in industry standards and no limit switches, if proper over-
travel restraint is provided.

13. Air operated chain hoists can be equipped with over-travel protection devices
instead of the hoist travel limit switches.

14. The final upper limit switch (limit control value) shall exhaust air from the
crane hoist, set the brakes, and require reset at the upper limit switch (limit control
valve) level.

15. A minimum clearance of 3 inches overhead and 2 inches laterally shall be

provided and maintained between the crane and all obstructions.

2.1.10 Electrical:
1. Wiring and safety devices shall be in accordance with National Fire Protection
Association (NFPA) National Electrical Code. Conduit and wiring shall be such that
on-site work is minimized. Hard wire conductors such as festooned cables or
articulated cable carriers, instead of power or feed rails, shall be considered to provide
power and control to overhead cranes handling explosives or solid propellants or to
cranes with solid state controls.

2. Electrical enclosures shall provide protection for the contained equipment

against environmental conditions according to the class rating established by National
Electrical Manufacturers Association(NEMA).
3. Though not a requirement, besides electrical power overload protection
required by the National Electrical Code, under-voltage, and phase reversal should be
considered.

4. Control stations shall operate on 150 volts DC, 120 volts AC, or less Positive
detent pushbuttons or a control lever shall be used for speed control. Controls shall
return to the off position when the operator relieves pressure. A red, emergency stop
pushbutton shall be provided to operate the mainline contactor and/or the main circuit
breaker. A positive lockout to the controls shall be provided to ensure the safety of
maintenance personnel.

5. All cab-operated cranes with step type control shall be equipped with lever
controls. The levers shall be of the continuous effect type and provided with a dead
man feature that will not unduly tire the operator during lengthy operations.

6. The electrical system shall be designed fail-safe to ensure that a failure of any
component will not cause the crane to operate in a speed range faster than
commanded. A failure that causes a speed different from that selected is acceptable
provided no hazards are introduced. Failure modes that cause the bridge, trolley, or
hoist to slow down or come to a safe stop are acceptable; those that could cause a hard
stop, unplanned directional shifts, and/or loss of control are unacceptable [2].

7. Provisions for grounding the hook are required for handling explosives, solid
propellants, flammables, or any other load that requires a non electrical or static-free
environment.

8. For cranes used for critical lifts, an assessment shall be performed to

determine the operational needs for remote emergency stops independent from the
operator controlled emergency stop. Not all cranes used for critical lifts require a
remote emergency stop. Remote emergency stops are required for cranes used for
critical lifts where the crane operator’s view is restricted or obstructed. When
provided, this independent remote emergency stop should be located such that the
independent remote emergency stop operator(s) can clearly see the critical lift area(s).
The remote emergency stop circuit shall be separate from and take precedence over
the operator control circuit. The control, when activated, shall cause all drives to stop
and the brakes to set. Hand-held remote emergency stop pendants should be
standardized and should include power and circuit continuity indication. For those
cranes required to make critical lifts and have not been modified to provide a remote
emergency stop, handling procedures shall be developed and implemented to
minimize the risk.

9. For cranes used for critical lifts, dual upper limit switches are required. For
electric cranes, the limit switches shall meet the following requirements:

• Initial upper limit switch electrical contacts shall be a set of normally closed
contacts in the “raise” contactor circuit such that movement in the raise direction shall
be precluded after the limit switch is encountered. Movement in the “lower” direction
will not be inhibited.
• Final upper limit switch electrical contacts shall be a set of normally closed
electrical contacts wired into the mainline circuit, hoist power circuit, main contactor
control circuit, or hoist power contactor control circuit such that all crane motion or
all hoist motion shall be precluded after the limit switch is encountered. These
normally closed contacts may be located in the low voltage control circuitry.
• After a final upper limit switch has been activated, movement of the load will
require action (resetting) at the final upper limit switch level. An inspection shall be
made to determine the cause of failure of the initial upper limit switch. Stopping crane
motion by the above design configuration may result in a hazardous suspended load
condition. The crane design should include a means of detecting limit switch failure
and allow for safe inspection and repair. For example, a system may be equipped with
two different colored an enunciators lights, one for each limit switch. A reset button
may be included so that when a final upper limit switch is tripped, the load can be
lowered immediately. The reset button should be secured to prevent unauthorized use.

• The initial upper limit switch shall be adjusted sufficiently low to preclude
inadvertent actuation of the final upper limit switch if the hoist actuates the initial
upper limit switch at full speed with no load. Similarly, the final upper limit switch
shall be adjusted sufficiently low to ensure that the hoist will not two-block (or
otherwise damage wire rope) if the hoist actuates the final upper limit switch at full
speed with no load. Both limits shall be tested from slow speed to full speed to verify
correct operation. It should be noted that this requirement effectively lowers the
usable hook height of the hoist. The limit switch arrangement shall be considered
during new equipment design.

10. For cranes used for critical lifts, lower limit switches to prevent reverse
winding of the wire rope shall be provided.

11. Electrical cranes shall have the capability to be locked out at the main breaker
to prevent unauthorized use.

12. Cranes shall be designed fail-safe in the event of a power outage.

2.1.11Testing:
Three types of tests are required for cranes: proof load tests, rated load
tests, and operational tests. The proof load tests and operational tests shall be
performed prior to first use for new cranes, or for existing cranes that have had
modifications or alterations performed to components in the load path. This applies
only to those components directly involved with the lifting or holding capability of a
crane that has been repaired or altered. Repairs or alterations to non-lifting, secondary
lifting, or holding components such as suspension assemblies, electrical system, crane
cab, etc., do not require a load test, although a functional check should be performed
to determine if the repairs or alternations are acceptable. The rated load and
operational tests shall be performed at least every 4 years. Cranes used frequently for
critical lifts shall be load tested annually. Cranes used infrequently for critical lifts
shall be load tested before the critical lift if it has been more than a year since the last
test. If a crane is upgraded (increased lifting capacity), a proof load test and an
operational test shall be performed based on the upgraded rating. All load and
operational tests shall be performed by qualified personnel according to written
(specific or general) technical operating procedures approved by NASA and/or
contractor safety representatives. An inspection of the crane and lifting components
shall be performed after each load test and prior to the crane being released for service
to ensure there is no damage. This inspection may include Nondestructive Evaluation
(NDE) of components that are suspected to be cracked or otherwise affected by the
test. The rated load test requirement may be fulfilled by a concurrently performed
proof load test.

2.1.12 Proof load test:

Before first use and after installation, all new, extensively repaired, extensively
modified, or altered cranes shall undergo a proof load test with a dummy load as close
as possible to, but not exceeding 1.25 times the rated capacity of the crane. A proof
load test also should be performed when there is a question in design or previous
testing. The load shall be lifted slowly and in an area where minimal damage will
occur if the crane fails. The load rating of the crane shall be clearly marked to be
legible from the operator’s or user’s position and shall not be more than the proof test
weight divided by 1.25.

2.1.13 Rated load test:

Each crane shall be tested at least once every 4 years with a dummy load equal to the
crane’s rated capacity. Cranes used frequently for critical lifts shall be load tested at
least once per year. Cranes used infrequently for critical lifts shall be load tested
before the critical lift if it has been more than a year since the last test. The acceptable
tolerance for rated load test accuracy is +5/-0 percent unless otherwise specified by
design.

2.1.14 Operational test:

Load hoisting, lowering at various speeds (maximum safe movement up and down as
determined by the installation NASA Safety directorate and the responsible
engineering and operations/maintenance organizations), and braking/holding
mechanisms. Holding brakes shall be tested to verify stopping capabilities and
demonstrate the ability to hold a rated load.
Trolley and bridge travel (maximum safe movement in all directions with varying
speeds as determined by the installation NASA Safety directorate and the responsible
engineering and operations/maintenance organizations).

All limit switches, locking devices, emergency stop switches, and other safety
devices, excluding thermal overload and circuit breakers. The limit switch, emergency
stop, and locking device tests except for the final upper limit switch shall be
performed with no load on the hook at full speed. The final upper limit switch can be
tested by manually tripping the switch and verifying that all hoist motion is precluded.

Cranes used for critical lifts are required to be equipped with at least two means of
braking (hoist), each capable of bringing a rated load to zero speed and holding it. The
operational test must demonstrate each brake’s ability to stop and hold a rated load.
This can be done in one of the following ways:

• Each brake’s ability to hold shall be statically tested (under no load) with 150
percent of the rated load hoisting torque at the point of brake application.

• Alternately, each brake shall be tested for its ability to stop a rated load
moving at full speed in the down direction. (CAUTION: It must be possible to
quickly reenergize the out-of-circuit brake or provide other safety measures to
perform this test safely.)

2.1.15 Test Reports:

After each test, designated personnel shall prepare written, dated,
and signed test reports including procedure reference. Inadequacies shall be
documented and, if determined to be a hazard, corrected prior to further use. These
reports shall be kept on file by the owner organization for a minimum of two test
cycles and shall be made readily available. Following the rated load test, cranes shall
be given a permanently affixed tag identifying the equipment and stating the next
required rated load test date or certification expiration date.
2.1.16 Inspection:
1. Daily and periodic safety inspections shall be performed on all cranes and
crane accessories. Inadequacies discovered during an inspection shall be documented
and, if determined to be a hazard, corrected prior to further use. Inspections shall be
made by qualified designated personnel according to approved technical operating
procedures.
2. All new, extensively repaired, or modified cranes shall be given a daily and a
periodic inspection prior to first use. For component repair on cranes, only the
inspections that apply to the repaired portion need to be performed prior to first use
unless a periodic inspection interval expires during the downtime.

3. Cranes in regular service must be carried out regularly.

2.1.17 Daily Inspection:

These inspections shall be performed by the certified operator prior to first use each
day the crane is used, and shall include the following:

• Check functional operating and control mechanisms for mal adjustments that
could interfere with normal operations.

• Without disassembling, visually inspect lines, tanks, valves, drain pumps ,gear
casings, and other components of fluid systems for deterioration and leaks. This
applies to components that can be seen from the ground level or for which there is
safe access via crane inspection walkways.

• Without disassembling, visually inspect all functional operating and control

mechanisms for excessive wear and contamination by excessive lubricants or foreign
matter.

• Visually inspect hooks for cracks and deformities.

• Visually (without climbing up to bridge) inspect rope reeving for proper travel
and drum lay, and inspect wire rope for obvious kinks, deformation, wire clips, and/or
damage.

2.1.18 Monthly Inspection:

At least once per month:

1. Inspect for wear, twist, distortion, or stretch of hoist chains.

2. Perform a thorough inspection of all ropes paying particular attention to the

signs of deterioration and damage.

3. Inspect for visible deformation or cracks in hooks

2.1.19 Annual Inspection:

At least once per year, inspect for:

1. Deformed, cracked, or corroded members and welds and loose bolts or rivets
in crane structure and runway. Various methods of nondestructive examination such as
ultra sonics , x-ray, magnetic particle, dye penetrant, etc., shall be used as needed [2].

2. Cracked or worn sheaves and drums.

3. Wear or cracks in pins, bearings, shafts, gears, followers, and locking and
clamping devices. NDE techniques should be used if cracks are suspected.

4. Wear in brake and clutch system parts, linings, pawls, and ratchets that are
readily accessible without major disassembly beyond an acceptable limit. Major
teardown to inspect such parts should be based on a frequency consistent with
gearbox lubrication analysis and other manufacturers’ recommended maintenance
programs for these components.
5. Inadequacies in load and other indicators over full range.

6. Wear in chain drive sprockets and stretch in the chain beyond anacceptable
limit.

7. Gasoline, diesel, electric, or other power plants for proper performance or

noncompliance with applicable safety requirements.

8. Evidence of a malfunction in travel, steering, braking, and locking devices.

9. Evidence of a malfunction in any safety device.

10. Pitting or other signs of deterioration in electrical apparatus.

11. Special attention shall be given to feed rails.

12. Evidence of overheating.

2.1.20 Inspection Report:

After each formal periodic inspection, qualified, authorized
personnel shall prepare written, dated, and signed inspection reports. These reports
shall include procedure reference and adequacy of the crane/crane components.
Inadequacies shall be documented and, if determined to be a hazard, corrected prior to
further use. These reports shall be filed and be made readily available by the
organizational element responsible for crane inspection [2].

2.1.21 Maintenance:
A preventive maintenance program shall be established based on manufacturers’
recommendations and/or experience gained from use of the equipment. The program
shall include procedures and a scheduling system for normal periodic maintenance
items, adjustments, replacements, and repairs. The program also shall ensure that
records are kept and unsafe test and inspection discrepancies are documented and
corrected [2].

2.1.22 Maintenance Procedures:

Before maintenance, adjustments, repairs, and replacements are initiated,
the following safety precautions shall be taken:

1. Move crane to an area where maintenance will not interfere with other
operations.

2. Turn off all controls, move main or emergency switch to OPEN, and lock and
tag switch in OPEN position unless it is necessary to have power on toper form the
maintenance task.

3. If other cranes are operating on the same runway as the crane being repaired,
ensure that proximity limit switches are operating on all cranes or that an observer is
stationed to prevent interference with other cranes.

4. Cranes shall not be operated until all safety devices have been activated and
tested/adjusted if involved in the maintenance action.

2.1.23 Adjustments:
: Based upon the manufacturer’s documentation and/or experience, adjustments shall
be made to ensure that all crane components function properly ,paying particular
attention to:
1. Brakes. (Appropriate precautions should be taken by inspectors, repair
personnel, and others who may be potentially exposed to airborne dust fibers from
any asbestos friction materials present in crane braking mechanisms.)
2. Control system.

3. Limit switches.
• The hoist initial upper limit switch shall be verified by running the empty
hook at full speed into the limit switch. It is recommended that the switch be verified
at slow speed prior to adjustment.

• For cranes used for critical lifts, the final upper limit switch shall be
independently verified and adjusted as described above at installation and after
modifications that could affect switch operation. The switch can be tested periodically
by manually tripping it and verifying that all hoist motion is precluded.
4. Power plants.

5. Critical operating mechanisms and safety devices.

2.1.24 Operations:
:
The following practices shall be observed for crane operations:

1. General operating procedures describing crane operation, emergency steps,

communication requirements, and special requirements including checklists and
inspection requirements shall be prepared, approved, and followed for each crane.
There must be a formal system for review, approval, and update to maintain valid
operating procedures. Emergency procedures shall be developed for contingency
actions such as power loss, brake failure, or other emergencies.

2. Operations shall be analyzed for hazards. The analysis shall consider the
environment in which the operation occurs, hazards associated with crane
maintenance, and, in general, a systems safety analysis of the equipment, facility,
load, and interfaces as a whole in support of the lifting operation.

3. Methods and procedures shall be developed for lowering a load in the event
of crane failure or other contingencies. These should be demonstrated and verified if
practical.

4. A crane shall not be loaded beyond its rated load (capacity) except for
required testing.

5. Cranes may be used to load test items such as slings, platforms, or lifting
fixtures if specifically identified to do so based on a specified percentage of rated load
and a safety analysis approved by the installation NASA Safety directorate and the
responsible engineering and operations/maintenance organizations. This is to ensure
that the crane is not damaged due to sudden unloading should the test article fail.

6. Cranes shall not be used for side pulls unless specifically designed to doso.

7. There shall be a system for documenting crane problems/discrepancies .Prior

to an operation, the operator shall review any previously noted
problems/discrepancies to determine possible impact on planned activity.

8. The operator shall ensure that the crane is within inspection and testing
intervals by examination of the periodic recertification tags and/or documentation.

9. Before each lift or series of lifts, the operator shall perform a preoperational
check to demonstrate operational readiness. If controls do not operate properly, the
operator is responsible for notifying the supervisor. Repairs and adjustments shall be
made before operations begin.

10. The operator shall establish safety zones before initiating operations. Safety
zones should have appropriate barriers (rope, cones, etc.) established prior to lift.
11. Before each lift or series of lifts, the operator shall functionally test proper
operation of the upper limit switch with no load on the hook. Upper limit switches
shall not be used as operating controls.

12. Before starting to hoist, the following conditions shall be noted: the hoist rope
shall not be kinked, multiple part ropes shall not be twisted around each other, and the
hook shall be centered over the load in such a manner as to prevent swinging or side
pulls. When raising loads that approach the rated capacity of the crane, the operator
shall know the weight of the working load. The operator shall test the holding brakes
each time a load approaching the rated load is handled. The brakes shall be tested by
raising the load minimally above the surface and holding the load with the brake. The
load should be held long enough to allow any dynamics to dampen out.

13. If radio communications are to be used, crane operators and/or lift supervisors
shall test the communication system prior to the operation. Operation shall stop
immediately upon communication loss, and shall not continue until communication is
restored.

14. If hand signals are required, only standard signals shall be used. Hand signals
shall be posted in a conspicuous location.

15. Crane crew emergency egress routes should be verified to be free of

obstructions prior to hazardous operations. The availability of crane crew protective
equipment should be verified prior to hazardous operations.

16. If there is a slack rope condition, it shall be determined that the rope is
properly seated on the drum and in the sheaves before starting the hoist.

17. During hoisting, care shall be taken that there is no sudden acceleration or
deceleration of the moving load and that the load does not contact any obstructions.

18. Loads shall be secured, balanced, and controlled with proper slings. The use
of tag lines to keep the load stabilized shall be required whenever load swinging is
anticipated to be a viable hazard. Tag line personnel shall take care not to impart
undesirable motion to the load.
19. Person(s) shall not ride the hook or load at anytime. For personnel lifting
requirements.

20. Personnel shall not be located under suspended or moving loads unless the
operation adheres to the OSHA-approved NASA Alternate Standard for Suspended
Load Operations.

21. The load shall not be lowered below the point where less than two full wraps
of rope remain on the hoist drum.

22. A responsible person shall be in charge of the operation and shall instruct all
personnel involved in the proper positioning, rigging, and moving to be done.

23. An operator shall be at the crane controls at all times while a load is
suspended (OSHA requirement). Due to the length of some NASA operations, an
operator change may be required while a load is suspended. This shall be
accomplished via a procedure designed for the specific crane and operation approved
by the installation NASAS safety directorate, ensuring that the crane controls are
manned at all times.

24. Hands shall be free from encumbrances while personnel are using crane
ladders. Articles that are too large to be carried in pockets or belts shall be lifted and
lowered by hand line.

25. Necessary clothing and personal belongings in crane cab shall be stored so as
not to interfere with access or operations. Tools, oil can, waste, extra fuses and other
necessary articles shall be stored properly, and shall not be permitted to lie loose in
the cab or on the crane. Operators shall be familiar with the operation and care of the
fire extinguisher provided.

26. Crane crew discipline shall be maintained at all times during a crane
operation. There shall be no eating, drinking, or rowdiness during crane operation.
27. Outdoor hoisting operations should not commence if winds are above20 knots
steady state or if gusts exceed 35 knots.

28. A carbon dioxide, dry chemical, or equivalent fire extinguisher shall be kept
in the cab or in the immediately available vicinity of the crane.

2.1.25 Special Criteria:

Special precautions shall be taken while handling explosives or Electro Explosive
Devices (EEDs). Safety support shall be available. Barricades and warning signs shall
be erected to control access. Voltage checks on crane hooks that will handle
explosives or EEDs shall be performed to verify that the measured energy level does
not exceed 20 decibels below the maximum safe no-fire energy level in the bridge
wire of the associated EED. (Example: For a NASA Standard Initiator with a
maximum safe no-fire energy level of 1
Watt , the measured energy level shall not exceed 10 milli watts, which corresponds to
100 milli volts measured across a 1 ohm resistor.) The crane hook shall be connected
to facility ground before connecting to explosives or EEDs. Electrical grounding of
the hook and load shall be accomplished prior to lifting operations while handling
explosives, EEDs, or electrically sensitive devices/payloads. The grounding shall be
measured/verified to be within specification by inspection personnel and recorded
prior to the lift. If a ground connection must be disconnected to facilitate operations,
an alternate ground should be connected prior to disconnecting the existing ground.
The final attachment/detachment must be at least 10 feet from exposed propellant
grain, explosives, or EEDs. The use of radio transmissions near explosives shall be
evaluated for danger potential prior to the operation. Policy shall be developed and
enforced for crane operation during electrical storms. Operations are generally
permitted without restriction within enclosed metal or framed buildings that are
properly grounded. Restrictions are necessary for outside operations or for those that
cannot tolerate power failure/lo

CHAPTER #3
3. Hoists

As the name would suggest, hoists are devices used to lift or lower a load by using a
rope or chain wrapped around a drum or lift-wheel. They can be powered by
electricity, air pressure or by manual means. The component to which the load is
actually attached to is called the lifting hook.

A basic hoist can be defined by two characteristics; the lifting medium it uses and its
source of power. Regular hoists can use either wire rope that can be wrapped around a
drum or something cylindrical, or a load-chain that is raised by a pulley and a profile
to engage the chain in order to lift loads. The power supplied for hoists to lift weights
can come from hydraulics, electrical or air driven motors. Despite the fact that hoists
have been around since the 1800s, electrical hoists only came about in the early
1900s.

Hoists come as integral-package units or can be customizable. Integral-package units

are cost-effective and can only be used for moderate applications. Customizable units
allow for more access on the application of the hoist as a user can decide on which of
the different parts he wants to use. However, these hoists are more expensive as
compared to integral-hoists though they can be easily repaired and are more durable.
The type of hoist a person selects depends on the application of the hoist.

Electronic hoists have an additional feature called the hoist controller that can have
various features depending on the preset specifications. Some examples of such
features can be for the hoist to automatically lift a load when a container is full or
acceleration and deceleration of the hoist’s speed when picking up or putting down a
load. They also supply the electrical energy needed for the hoist to function.

As compared to the various types of hoists, electrical hoists are the most economical
as they are more cost effective and easier to repair. As compared to the manual hoist
that would require extensive manpower to run it, electrical hoists save cost on man
power and are more efficient. Hydraulic or pneumatic hoists have their own
advantages as well but may have a tendency of needing repairs more often as
compared to the electrical hoist.

3.1 Types of Hoists

3.1.1 Wire Rope Hoist or Chain Hoist:

More commonly used hoist in today's worldwide market is an electrically powered

hoist. These are either the chain type or the wire rope type.

Nowadays many hoists are package hoists, built as one unit in a single housing,
generally designed for ten-year life, but the life calculation is based on an industry
standard when calculating actual life.

Common small portable hoists are of two main types, the chain hoist or chain
blockand the wire rope or cable type. Chain hoists may have a lever to actuate the
hoist or have a loop of operating chain that one pulls through the block (known
traditionally as a chain fall) which then activates the block to take up the main lifting
chain.

For a given rated load wire rope is lighter in weight per unit length but overall length
is limited by the drum diameter that the cable must be wound onto. The lift chain of a
chain hoist is far larger than the liftwheel over which chain may function. Therefore, a
high-performance chain hoist may be of significantly smaller physical size than a wire
rope hoist rated at the same working load.

Both systems fail over time through fatigue fractures if

operated repeatedly at loads more than a small
percentage of their tensile breaking strength. Hoists
are often designed with internal clutches to
limit operating loads below this threshold. Within
such limits wire rope rusts from the inside outward
while chain links are markedly reduced in cross section
through wear on the inner surfaces. Regular
lubrication of both tensile systems is recommended
to reduce frequency of replacement. High speed
lifting, greater than about 60 feet per minute
(18.3 m/min), requires wire rope wound on a drum,
because chain over a pocket wheel generates fatigue-inducing resonance for long lifts.
 Fig 2: Construction Hoist

The unloaded wire rope of small hand-powered hoists often exhibits a snarled "set",
making the use of a chain hoist in this application less frustrating, but heavier. In
addition, if the wire in a wire hoist fails, it can whip and cause injury, while a chain
will simply break.

"Chain hoist" also describes a hoist using a differential system, in which a compound
pulley with two different radii and teeth engage an endless chain, allowing the exerted
force to be multiplied according to the ratio of the radii.

3.1.2 Construction Hoist:

Also known as a Man-Lift, Buck hoist, temporary elevator, builder hoist, passenger
hoist or construction elevator, this type of hoist is commonly used on large scale
construction projects, such as high-rise buildings or major hospitals. There are many
other uses for the construction elevator. Many other industries use the buck hoist

for full-time operations, the purpose being to carry personnel, materials, and
equipment quickly between the ground and higher floors, or between floors in the
middle of a structure. There are three types: Utility to move material, personnel to
move personnel, and dual-rated, which can do both.

The construction hoist is made up of either one or two cars (cages) which travel
vertically along stacked mast tower sections. The mast sections are attached to the
structure or building every 25 feet (7.62 m) for added stability. For precisely
controlled travel along the mast sections, modern construction hoists use a motorized
rack-and-pinion system that climbs the mast sections at various speeds.

While hoists have been predominantly produced in Europe and the United States,
China is emerging as a manufacturer of hoists to be used in Asia.

3.1.3 Mine Hoist:

This is a type of HOIST which is used in underground mining. This was previously
used to lift up the things from underground with the help of human and animal to lift
the things up.

Different types of mining hoists are available in market with a lot of specification and
improvements.
Figure 4: Mine Hoist
 CHAPTER #4

4. Hoist Standards

4.1 Introduction:

This chapter establishes safety standards for the design, inspection, test, maintenance,
and Operation of hoists. These standards apply to electric, air-powered, and manual
hoists, including those used to raise/lower empty personnel work platforms, surfaces,
or stations.

4.2 Safety Aspects:

Generally, off-the-shelf, OEM type equipment is acceptable for critical and noncritical
lifts if it is designed, maintained, operated, etc., according to this standard.

4.2.1 Labeling/Tagging of Hoists:

(1) The hoist’s rated capacity shall be marked on it or its load block. This marking
shall be clearly legible from the ground floor.

(2) Hoists that have the specified design features, maintenance/inspection, and test
intervals to lift critical loads shall be marked conspicuously so that the operator and
assurance personnel can distinguish that the hoist is qualified for critical lifts.

(3) A standard system of labeling shall be established and used throughout the
installation.

(4) A standard tag-out system shall be established and used throughout the installation
to indicate equipment that is not to be used due to inspection discrepancies, ongoing
maintenance operations, etc.
4.2.2 Test Reports and Periodic Recertification Tags:
After each test, designated personnel shall prepare written, dated, and signed test
reports, including procedure reference. Inadequacies shall be documented and, if
determined to be a hazard, corrected prior to further use. These reports shall be filed
and shall be made readily available by the organization responsible for testing the
hoist. Following the rated load test, all hoists shall be given a permanently affixed tag
identifying the equipment and stating the next required rated load test date or
certification expiration date.

4.2.3 Safety Analysis and Documentation for Hoists used for

Critical Lifts:

A hazard analysis shall be performed on all hoists used for critical lifts. The analysis
shall, as a minimum, determine potential sources of danger, identify most probable
failure modes, and recommend resolutions for those conditions found in the hardware-
facility-environment human relationship that could cause loss of life, personal injury,
or loss of crane, facility, or load. The analysis also shall include hoist description,
reference documentation, severity assessment, and assessment of certain passive and
structural components between the hook and the holding brakes. Hazards that are
identified shall be tracked (recorded and current status maintained) until final closure
is verified. A system of risk acceptance is required for hazards that cannot be
eliminated. The hazard analysis shall be done as part of the initial certification
process, included in the hoist documentation, and updated as required to reflect any
changes in operation and/or configuration.

4.2.4 Performance:

Operational life, duty cycle, load capability, and the desired control characteristics
with which the hoist handles the load shall be addressed for all designs. The expected
operational life shall be specified or detailed for system components. Duty cycle
requirements shall be based on the worst expected duty the unit will encounter. Each
load-bearing component shall be specified or detailed to lift the maximum imposed
loads resulting from zero to rated hook load with appropriate safety factors.
Operational requirements shall be considered in the design phase to ensure load and
function are adequately defined and critical hoist design features are incorporated on
the delivered units. Environmental conditions must also be considered.

4.2.5 Structural:

Structural design shall be in accordance with industry standards for material selection,
welding, allowable stresses, design limitations, framing, wheels, and other structural
elements. Refer to CMAA standards for specific design details.

4.2.6 Mechanical:

The use of high quality, off-the-shelf, OEM type equipment is acceptable for critical
and noncritical lift applications if it meets all user requirements and the requirements
of this document. This high quality commercial equipment employs a modular type
construction of the hoist unit with standard frame sizes and interchangeable gear
boxes, drums, motors, brakes, and controls to achieve a wide range of capacities, lifts,
operating speeds, reeving arrangements, and controls. These interchangeable parts are
standardized for each manufacturer’s product line and the hoists are built to order. The
mechanical design requirements for hoist components are as follows:

1. They meet all applicable requirements of OSHA, ANSI, and CMAA.

2. Electric and air operated hoists should be provided with at least two means of
braking: a holding brake and a control brake. The torque rating, physical
characteristics, and capabilities shall be in accordance with CMAA specifications.

3. Powered (electric and air) hoists used for critical lifts shall have two means of
braking, each capable of bringing a rated load to zero speed and holding it (with and
without power). If the control brake and holding brake are designed to operate as a
system and cannot independently stop and hold a rated load, then another means of
braking is required (e.g., emergency brake). The brakes shall be designed so that they
can be tested.

4. For critical lift application, speed reduction from the motor to the drum on the
hoist should be achieved by enclosure in a gear case. If open gears are required, they
shall be guarded with a provision for lubrication and inspection.

5. All wire rope hoists shall have not less than two wraps of hoisting rope on the
drum when the hook is in its extreme low position. Drum grooves, when provided,
shall be as recommended by CMAA. The rope ends shall be anchored securely by a
clamp or a swaged terminal in a keyhole slot, provided a keeper is used to prohibit the
swage from moving out of the narrow slot. Other methods recommended by the hoist
or wire rope manufacturer are acceptable if the rope termination anchor together with
two wraps of rope on the drum will give an anchor system equal to or greater than the
breaking strength of the wire rope.

6. Safe and adequate access to hoist components to inspect, service, repair, or

replace equipment shall be provided for during design. The design shall provide for
visual and physical accessibility.

7. Manually operated (non powered), off-the-shelf OEM type hoists are

acceptable for critical and noncritical lift applications. They shall comply with
applicable ANSI requirements. These hoists shall have at least one brake as described
by industry standards. No limit switches are required if proper over-travel restraint is
provided.

8. Air operated chain hoists can be equipped with over-travel protection devices
instead of the hoist travel limit switches.

9. Initial and final upper limit switches (limit control valves) shall be provided
and tested for air-operated hoists . The final upper limit switch (limit control valve)
shall exhaust air from the hoist, set the brakes, and require reset at the upper limit
switch (limit control valve) level.
10. Worm gears shall not be used as a braking means unless the lead angle is
sufficient to prevent back driving. The braking properties of a worm gear tend to
degrade with use; the design engineer shall consider this when purchasing new
equipment or in existing installations where the hoist is subject to heavy use.

11. In the procurement of new lifting equipment, the use of cast iron components
in the hoist load path shall be approved, as a minimum, by the installation NASA
Safety Director. The material properties of cast iron allow catastrophic failure and
should not be considered as reliable as steel or cast steel. The engineer shall consider
this when selecting equipment and avoid the use of load bearing cast iron materials
where possible.

12. Gearing shall be designed and manufactured to comply with the latest AGMA
gear standards.

13. Hooks shall meet the manufacturer’s recommendations, and shall not be
overloaded. Swiveling hooks should rotate 360 degrees on antifriction bearings with
means for lubrication. If grease is a contamination concern, drip funnels (cups) or non
lubricated bearings should be provided. Latch equipped hooks shall be used unless the
application makes the use of a latch impractical or unnecessary. When required, a
latch or using shall be provided to bridge the throat opening of the hook to retain
slings, chains, or other similar parts under slack conditions.

4.2.7 Electrical:
Electrical design requirements are as follows:
1. Wiring and safety devices shall be in accordance with the NFPA National
Electrical Code.

2. Electrical enclosures shall provide protection for the contained equipment

against environmental conditions.

3. Though not a requirement, besides overload protection required by the

National Electrical Code, under voltage and phase reversal should be considered.
4. For powered hoists used for critical lifts, an assessment shall be performed to
determine the operational needs for remote emergency stops independent from the
operator controlled emergency stop. Not all hoists used for critical lifts require a
remote emergency stop. Remote emergency stops are required for hoists used for
critical lifts where the operator’s view is restricted/obstructed. When provided, this
independent remote emergency stop should be located such that the independent
remote emergency stop operator(s) can clearly see the critical lift area(s). The remote
emergency stop circuit shall be separate from and take precedence over the operator
control circuit. The control, when activated, shall cause all drives to stop and the
brakes to set. Hand-held remote emergency stop pendants should be standardized and
should include power and circuit continuity indication.

For those hoists required to make critical lifts and have not been modified to provide a
remote emergency stop, handling procedures shall be developed and implemented to
minimize the risk.

5. Electrical control stations shall operate on 150 volts DC, 120 volts AC, or less.
Positive detent pushbuttons or a control lever shall be used for speed control. Controls
shall return to the off position when the operator relieves pressure. A red, emergency
stop push button shall be provided to operate the mainline contactor, main circuit
breaker, or pneumatic source. A dump valve is acceptable for the emergency stop for a
pneumatic hoist.

6. The electrical system shall be designed fail-safe to ensure that a failure of any
component will not cause the hoist to operate in a speed range faster than
commanded. A failure that causes a speed different from that selected is acceptable
provided no hazards are introduced. Failure modes that cause the hoist to slow down
or come to a safe stop are acceptable; those that could cause a hard stop, unplanned
directional shifts, and/or loss of control are unacceptable.

7. For hoists used for critical lifts (except manual), dual upper limit switches are
required. For electric hoists, the limit switches shall meet the following requirements:
• Initial upper limit switch electrical contacts shall be a set of normally closed
contacts in the “raise” contactor circuit such that movement in the raise direction shall
be precluded after the limit switch is encountered. Movement in the “lower” direction
will not be inhibited.

• Final upper limit switch electrical contacts shall be a set of normally closed
electrical contacts wired into the mainline circuit, hoist power circuit, main contactor
control circuit, or hoist power contactor control circuit such that all hoist motion shall
be precluded after the limit switch is encountered. These normally closed contacts
may be located in the low voltage circuitry.

• After a final upper limit switch has been activated, movement of the load will
require action (resetting) at the final upper limit switch level. An inspection shall be
made to determine the cause of failure of the initial upper limit switch. Stopping hoist
motion by the above design configuration may result in a hazardous suspended load
condition. The hoist design should include a means of detecting limit switch failure
and allow for safe inspection and repair. For example, a system may be equipped with
two different colored a enunciator lights, one for each limit switch. A reset button may
be included so that when a final upper limit switch is tripped, the load can be lowered
immediately. The reset button should be secured to prevent unauthorized use.

• The initial upper limit switch shall be adjusted sufficiently low to preclude
inadvertent actuation of the final upper limit switch if the hoist actuates the initial
switch at full speed with no load. Similarly, the final upper limit shall be adjusted
sufficiently low to ensure that the hoist will not two-block (or otherwise damage wire
rope) if the hoist actuates the final switch at full speed with no load. Both limits shall
be tested from slow speed to full speed to verify correct operation. It should be noted
that this requirement effectively lowers the usable hook height of the hoist. The limit
switch arrangement needs to be considered during new equipment design.

4.2.8 Testing:

Three types of tests are required on hoists: proof load tests, rated load tests, and
operational tests. The proof load tests and operational tests shall be performed prior to
first use for new, extensively repaired, or altered hoists. The rated load and
operational tests shall be performed at least every 4 years. For hoists used for critical
lifts, these tests shall be based on frequency of usage. Hoists used frequently for
critical lifts shall be load tested annually. Hoists used infrequently for critical lifts
shall be load tested before each critical lift if it has been more than a year since the
last test. If a hoist is upgraded, a proof load test and an operational test shall be
performed based on the upgraded rating. All load and operational tests shall be
performed by qualified personnel according to written (specific or general) technical
operating procedures approved by NASA and/or contractor Safety representatives. An
inspection shall be performed after each load test and prior to the hoist being released
for service to ensure there is no damage. If cracks or structural damage is suspected,
suitable NDE techniques shall be used to determine the condition.

4.2.9 Proof Load Test:

Before first use and after installation, all new, extensively repaired, modified, or
altered hoists shall undergo a proof load test with a dummy load as close as possible
to, but not exceeding 125 percent of the rated load. The hoist rating will not be more
than 80 percent of the proof load test weight. For platform hoists, test the hoist at 125
percent of rated capacity prior to hookup to the platform. With the platform attached,
verify that the actual lift does not exceed the rated capacity of the hoist. The rated load
of a hoist shall be clearly legible from the operator’s or user’s position. Platform hoist
systems shall be clearly marked with the maximum load to be lifted by the system.

4.2.10 Rated Load Test:

All hoists, except platform hoists shall be tested at least once every 4 years
with a dummy load equal to hoist’s rated capacity. For hoists used for critical lifts,
these tests shall be based on frequency of usage. Hoists used infrequently for critical
lifts shall be load tested before each critical lift if it has been over a year since the last
test. Hoists used frequently for critical lifts shall be load tested at least once per year.
The acceptable tolerance for rated load test accuracy is + 5/-0 percent unless
otherwise specified by design. The rated load test can be fulfilled by a concurrently
performed proof load test. Platform hoists do not require rated load tests.
4.2.11Operational Test:
Together with proof load and rated load tests, the following shall be
performed with a dummy rated load unless otherwise specified (platform hoists shall
be operationally tested every 4 years using the attached platform only):

1. Perform all hoist functions in an unloaded condition.

2. Test operation of brakes and limit, locking, and safety devices.

3. Determine trip setting of limit switches and limiting devices by tests under no
load conditions. Conduct tests first by hand, if practical, and then under the slowest
speed obtainable. Test with increasing speeds up to the maximum speed. Locate
actuating mechanisms so that they will trip the switches or limiting devices in time to
stop motion without damaging the hoist.

4. After testing in the unloaded state, apply the test load to the hoist to check the
proper load control. Test load hoisting, lowering at various speeds (maximum safe
movement up and down as determined by the installation NASA Safety directorate
and the responsible engineering and operations/maintenance organizations), and
braking/holding mechanisms (holding brakes shall be tested to verify stopping
capabilities and demonstrate the ability to hold a rated load). The load should be held
long enough to allow any dynamics to dampen out.

5. Powered hoists used for critical lifts are required to be equipped with at least
two means of braking, each capable of bringing a rated load to zero speed and holding
it. The operational test must demonstrate each brake’s ability to stop and hold a rated
load. This can be done in one of the following ways:

6. Each brake’s ability to hold shall be statically tested (under no load) with 150
percent of the rated load hoisting torque at the point of brake application.

7. Alternately, each brake shall be tested for its ability to stop a rated load
moving at full speed in the down direction. (CAUTION: It must be possible to
quickly reenergize the out of circuit brake or provide other safety measures to perform
this test safely.)

8. Test Reports and Periodic Recertification Tags. After each test, designated
personnel shall prepare written, dated, and signed test reports, including procedure
reference. Inadequacies shall be documented and, if determined to be a hazard,
corrected prior to further use. These reports shall be filed and shall be made readily
available by the organization responsible for testing the hoist. Following the rated
load test, all hoists shall be given a permanently affixed tag identifying the equipment
and stating the next required rated load test date or certification expiration date.

4.2.12 Inspection:

1. Daily and periodic safety inspections shall be performed on all hoists in

regular service.
2. Prior to first use, all new or altered hoists shall be inspected to the
requirements of both daily and periodic inspections. Inspections shall be performed by
qualified personnel according to approved technical operating procedures. In
adequacies discovered during an inspection shall be documented and, if determined to
be a hazard, corrected prior to further use.

3. Daily Inspections. These inspections shall be performed each day the hoist is
used and shall include the following:

• Inspect braking mechanisms for evidence of slippage under load.

• Inspect load chain for wear, twists, damage links, or foreign matter.
• Visually inspect hooks for deformation, chemical damage, or cracks.
• Inspect load bearing components for damage.

4. Formal Periodic Inspections. These inspections shall be performed at varying

intervals, depending on activity, severity of service, environment and criticality.
• Annual Inspections. At least once per year:
• Check for loose bolts and rivets and cracked or worn drums and sheaves.
Various methods of NDE such as ultra-sonic x-ray, magnetic particle, dye penetrant,
etc., shall be used as needed.
• Check for worn, corroded, cracked, or distorted parts such a spins, bearings,
shafts, gears, rollers, and locking and clamping devices. NDE techniques shall be used
if cracks are suspected.
• Inspect motor brake and load break for excessive wear.
• Inspect electrical apparatus for pitting or other signs of deterioration. Visually
inspect for signs of overheating.
• Inspect hook-retaining nuts or collars, pins, welds, or rivets used to secure
retaining members for deformations, cracks, or excessive corrosion. NDE techniques
shall be used if cracks are suspected.
• Ensure that supporting structure is not deformed or cracked.
• Check that warning labels are legible.
• Monthly Inspections. At least once per month:
• Inspect wire rope monthly (except those on platform systems that shall be
inspected at least twice a year), paying particular attention to the following signs of
deterioration and damage:

1. Twelve randomly distributed broken wires in one or four broken wires in one
strand in one lay.

2. Individual wires with 1/3 wear of original outside diameter.

3. Kinking, crushing, bird caging, or any other damage resulting in distortion.

4. Evidence of heat damage.

5. End connectors that are cracked, deformed, or with evidence of rope pullout.

6. Corrosion (internal or external) that results in reduction of rope diameter, or at

end connectors.
4.2.13 Inspection Reports:
After each formal periodic inspection, qualified, authorized personnel shall prepare
written, dated, and signed inspection reports. These reports shall include procedure
reference and adequacy of the hoist/hoist components. Inadequacies shall be
documented and, if determined to be a hazard, corrected prior to further use. These
reports shall be filed and be made readily available by the organizational element
responsible for hoist inspection.

4.2.14 Maintenance:
A preventive maintenance program shall be established based on manufacturer’s
recommendations and/or experience gained from use of the equipment. The program
shall include procedures and a scheduling system for normal periodic maintenance
items, adjustments, replacements, and repairs. The program shall also ensure that
records are kept and unsafe test and inspection discrepancies are documented and
corrected.

4.2.15 Maintenance Procedures:

Before maintenance, adjustments, repairs, and replacements are initiated the following
safety precautions shall be taken:

1. Move hoist to designated maintenance area.

2. Turn off all controls and main energy feed system and lockout unless task
requires them to be on.

3. If power has to be on, “Warning,” “Out-of-Order,” or a like sign shall be

placed in a conspicuous location or an operator shall remain at the pendant.

4. Hoists shall not be operated until all safety devices have been activated and
tested/adjusted if involved in the maintenance action.
4.2.16 Adjustment:
Based upon the manufacturer’s documentation and/or experience, adjustments shall
be made to ensure that all hoist components function properly, paying particular
attention to:
1. Brakes. (Appropriate precautions should be taken by inspectors, repair
personnel, and others who may be potentially exposed to airborne dust fibers from
any asbestos friction materials present in braking mechanisms.)
2. Control system.
3. Limit switches:

• The hoist initial upper limit switch shall be verified by running the empty
hook at full speed into the limit switch. It is recommended that the switch be verified
at slow speed prior to adjustment.

• For hoists used for critical lifts, the final upper limit switch shall be
independently verified and adjusted as described above at installation and after
modifications that could affect switch operation. The switch can be tested periodically
by manually tripping it and verifying that all hoist motion is precluded.

4.2.17 Repairs and Replacements:

Repairs or replacements shall be provided for safe operation. Special
attention shall be given to:

1. Worn or damaged braking components such as friction discs, ratchets, pawls,

and pawl springs.
2. Load-supporting components that are cracked, bent, or worn.
3. Missing or illegible warning labels.
4. For repair/replacement requirements for hoist hooks with deformation or
cracks, see Chapter 5. If repaired, hoist hooks shall be proof load tested using the
associated hoist proof load value.
5. The need to replace wire rope shall be determined by a certified or otherwise
qualified person based on an evaluation of inspection results.
6. Replacement rope or chain shall be of the same size, grade, and construction
as original furnished by hoist manufacturer. When replaced, disassemble and inspect
mating parts for wear, replace mating parts if necessary, and perform a proof load test
using the associated hoist proof load value.

4.2.18 OPERATIONS:

1. Only certified and trained operators shall be authorized to use/operate lifting

devices, including hoist operations, except for platform operators where procedural
controls can be provided in a technical operating procedure.

2. The following practices shall be observed during all hoist operations:

• When an “Out-of-Order” sign has been placed on the starting controls, the
hoist operator shall not power the unit or start operations until required repairs,
inspections, and retests have been made.

• Before starting a hoist, the operator shall be certain that all personnel are clear
of the area. Operators shall not engage in practices that will divert their attention
while operating a hoist.

• The operator shall test all controls before beginning an operation. If the
controls do not operate properly, adjustments or repairs shall be made before
operations begin.

• Hoists shall not be loaded beyond rated load except during authorized tests.
Platform systems shall not be loaded beyond maximum load as designated on the
platform hoist system.
• Hoists shall not be used for handling personnel unless specifically designed
for such purpose

• Personnel shall not be located under suspended or moving loads unless the
operation adheres to the OSHA-approved NASA Alternate Standard for Suspended
Load Operations.

• An operator shall be at the hoist controls at all times while a load is suspended.
Due to the length of some NASA operations, an operator change may be required
while a load is suspended. This shall be accomplished via a procedure designed for
the specific hoist and operation approved by the installation NASA Safety directorate,
ensuring that the hoist controls are manned at all times.

• Before each lift or series of lifts, the operator shall functionally test proper
operation of the upper limit switch with no load on the hook. Upper limit switches
shall not be used as operating controls.

• Hoists may be used to load test items such as slings, platforms, or lifting
fixtures if specifically identified to do so based on a specified percentage of rated load
and a safety analysis approved by the installation NASA Safety directorate and the
responsible engineering and operations/maintenance organizations. This is to ensure
that the crane is not damaged due to sudden unloading should the test article fail.

• Installed or fixed air or electric powered hoists, excluding platform systems,

shall be operated by designated personnel only.

• The operator shall ensure that the hoist is within inspection and periodic
certification intervals by examination of its tag(s) and/or appropriate documentation.

• Outdoor hoisting operations should not commence if winds are above 20knots
steady state.
• Hoists shall not be used for side pulls unless specifically designed to doso.

• If radio communications are to be used, operators and/or lift supervisors shall

test the communication system prior to the operation. Operation shall stop
immediately upon communication loss, and shall not continue until communication is
restored.

• If hand signals are required, only standard signals shall be used. Hand signals
shall be posted in a conspicuous location.

• When raising loads that approach the rated capacity of the hoist, the operator
shall know the weight of the working load. The operator shall test the holding brakes
each time a load approaching the rated load is handled. The brakes shall be tested by
raising the load minimally above the surface and holding the load with the brake. The
load should be held long enough to allow any dynamics to dampen out.

4.2.19 Special Criteria:

Special precautions shall be taken while handling explosives or Electro Explosive

Devices (EEDs). Safety support shall be available. Barricades and warning signs shall
be erected to control access. Voltage checks on hoist hooks that will handle explosives
or EEDs shall be performed to verify that the measured energy level does not exceed
20 decibels below the maximum safe no-fire energy level in the bridge wire of the
associated EED. (Example: For a NASA Standard Initiator with a maximum safe no-
fire energy level of 1 watt, the measured energy level shall not exceed 10 milli watts,
which corresponds to 100 millivolts measured across a 1 ohm resistor.) The hoist
hook shall be connected to facility ground before connecting to explosives or EEDs.
Electrical grounding of the hook and load shall be accomplished prior to lifting
operations while handling explosives, EEDs, or electrically sensitive
devices/payloads. The grounding shall be measured/verified to be within specification
by inspection personnel and recorded prior to the lift. If a ground connection must be
disconnected to facilitate operations, an alternate ground should be connected prior to
disconnecting the existing ground. The final attachment/detachment must be at least
10 feet from exposed propellant grain, explosives, or EEDs. The use of radio
transmissions near explosives shall be evaluated for danger potential prior to the
operation.

Policy shall be developed and enforced for hoist operation during electrical storms.
Operations are generally permitted without restriction within enclosed metal or
framed buildings that are properly grounded. Restrictions are necessary for outside
operations or for those that cannot tolerate power failure/loss.

CHAPTER #5
5. Design of Mechanical Grab

5.1 Design:
Design is based on the following dimensions:

Figure 5: Grab Side dimensions

Figure 6: Grab Front dimensions
5.2 Methodology:

3D model of mechanical grab was made on PRO Engineer Wildfire 4.0. Our design
consists of motorized rack and pinion resulting in telescopic action of sidewall
allowing mechanical grab to carry and lift sheets of different widths. The manual side
claw arrangement allows sheet of different lengths to be lifted as shown in the figure
below:

Figure 7: 3D Model

Calculations were performed for the system to evaluate structural stresses, rack
pinion design and motor torque was calculated for evaluation.

Major components of automated mechanical grab are as follows:

1. Housing
2. Outer beam
3. Inner beam
4. Side claw left
5. Side claw right
 6. Side Assembly
7. Sliding Beam Assembly.

5.3 Operation of Mechanical Grab:

The mechanical grab consisting of parts mentioned earlier has a motorized rack and
pinion arrangement which allows the sliding beam assembly to perform telescopic
action as a consequence sheets of variable width can be lifted via mechanical grab.

PINION
RACK

Figure 8: Inner and outer beam rack pinion arrangement

The sliding beam assembly operated by motor pulley mechanism diving element is
the timing belt. The driven pulleys then transmit torque to the gears which further
drives the pinion. There is an idling gear to drive the pinion of the inner beam as a
consequence opposite direction of rotation is achieved resulting in the telescopic
action of grab as Shown in the figure below:
 Figure 9: Sliding Beam Mechanism

The manual extension of the mechanical grab allow it to carry sheets of variable
length. The mechanism designed is quite simple with side claws having holes on
interval and a locking handle is available to lock the claw at a particular length.
Extension of the grab along its length is shown in the figure below:

Figure 10: Extension of grab along its length

5.4 Components of Mechanical Grab:
Detailed design is shown in the figure below:

Figure 11: Main Drawing

Each Component in detail is discussed below:

5.4.1 Housing
Detailed design is shown in the figure below:
Figure 12: Housing
 Detailed design is shown in the figure below:
Specifications are as follows:
 Length: 1160 mm Thickness: 10 mm
 Height: 540 mm Material Code: HR-275

5.4.2 Outer Beam

Design Calculations for calculating factor of safety for outer beam against maximum
payload condition (@ cantilevered beam) is shown below:

Main Beam Calculation For Crane Design

Beam Cross Section

Beam Details Value Units NOTATIONS

Height 270 mm
σ = maximum stress (Pa (N/m2), N/mm2, psi)
Width 80 mm M= Maximum Moment
y = Perpendicular distance from to neutral axis
Thickness 10 mm
X (m, mm, in)
q = uniform load per length unit (N/m, N/mm,
Area ` 6600 mm2
lb/in)
Moment of Inertia (I) (1/12xbxh^3) 52882620 mm4
F= Maximum Load
Y 89.51 mm L = length of beam (m, mm, in)
Length (L) 1050 mm
Load (F) 49050
Max Moment (M) 51502500
Max Stress (σ =MY/I) 87.18 Mpa
Material Description (HR-275 )
Yield Strength 275 Mpa
F.O.S 3.2
 Note : F.O.S greater than 3, Design is safe.
Reference : Machinery's Handbook(12th Edition), Chapter#4: Strength of Materials

Detailed drawing is shown in the figure below:

 Figure 13: Outer Beam

5.4.3 INNER BEAM

Design Calculations for calculating factor of safety for inner beam against maximum
payload condition (@cantilevered beam) is shown below:

Beam Cross Section

Beam Details Value Units NOTATIONS

Height 220 mm
σ = maximum stress (Pa (N/m2), N/mm2, psi)
Width 50 mm M= Maximum Moment
y = Perpendicular distance from to neutral axis X (m,
Thickness 20 mm
mm, in)
Area ` 9200 mm q = uniform load per length unit (N/m, N/mm, lb/in)
Moment of Inertia (I)
39348640 mm4
(1/12xbxh^3) F= Maximum Load
Y 65.40 mm L = length of beam (m, mm, in)
Wheel Base (L) 1050 mm
Load (F) 49050
Max Moment (M) 51502500
Max Stress (σ =MY/I) 85.60 MPa
Material Description (HR-275 )
Yield Strength 275 MPa
F.O.S 3.2

Note: F.O.S greater than 3, Design is safe.

Reference : Machinery's Handbook(12th Edition), Chapter#4: Strength of Materials

Detailed drawing is shown in the figure below:

Figure 14: Inner Beam

5.4.4 Side claw left
Detailed drawing of side claw (left side) is shown below:
 Figure 15: Side Claw left

Stress calculations for side claw are mentioned below:

Axial Stress Calculation for members

Member Cross Section

Beam Details Value Units NOTATIONS

Height 70 mm
σ = maximum stress (Pa (N/m2), N/mm2, psi)
Width 50 mm
Thickness 8 mm

Area ` 1664 mm2

Moment of Inertia (I) (1/12xbxh^3) 979086.592 mm4

F= Maximum Load
Y 24.26 mm
L 875 mm
Load (F) 24525
Max Moment (M) 21459375
Max Stress (σ =F/A) 14.74 Mpa
Material Description (HR-275 )
Yield Strength 275 Mpa
F.O.S 18.7

Note : F.O.S greater than 3, Design is safe.

Reference : Machinery's Handbook(12th Edition), Chapter#4: Strength of Materials

Holes for the locking handle are provided to vary side claws length according to sheet
length which is to be lifted.
5.4.5 Side claw Right
Detailed drawing of side claw (right side) is shown below:

Figure 16: Side Claw Right

5.4.6 Side Assembly
Side Assembly drawing is shown in the figure below which consists of three main
parts side wall, side claw left and side claw right.
Figure 17: Side Assembly
Detailed drawing of side wall is shown in the figure:
Figure 18: Side Wall
The purpose of side assembly is to simulate sliding beam action of rack and pinion.
This allows the mechanical grab to hold sheets of variable width. Both open and
closed positions are shown in the figures below:
Figure 19: Extension of Grab along its width

Figure 20: Un extended Mechanical Grab

5.4.7 Sliding Beam Assembly
The most pivotal component of the mechanical grab system is the sliding beam
assembly as shown in the figure below:

Figure 21: Sliding Beam Assembly

The motorized system consists of belt and pulley arrangement driving which drives
the pinions as a result rack mounted on outer and inner beam moves in the opposite
direction resulting in the extension of the grab.
Figure shown below clearly depicts the operation of the grab:

Figure 22: Sliding Beam Assembly (Hidden lines)

 5.4.8 Rack & Pinion Design Calculations:
Design Calculations for rack and pinion are mentioned below:

Rack & Pinion Calculations

Value Unit
Data s s
Mass to be
Moved(m) 1161 kg
Speed(v) 0.5 m/s
Acceleration
Time(tb) 3 s
Acceleration Due m/s
to Gravity(g) 9.8 2
Load Factor(ka) 1.5
Coefficient of
Friction 0.1
Life-Time Factor 1.05
Safety Coefficient 1.2
Linear Load
Distribution
Factor(LKHB) 1.5

Value Unit
Calculations s s
Accelaration m/s
(a=v/tb) 0.17 2
Feed Force (Fu
=( m·g·μ+m·a)/100
0) 1.33 KN
Fu(.par)=Fu(Tab)/K
A · SB · fn · LKHb 2.29 KN

Result
Fu(.par)>Fu Fulfilled
Reference tables used for calculations are mentioned below:

Figure 23: Reference Chart [1]

 Figure 24: Reference Chart [2]

Calculation for the no. of teeth of rack and pinion is given below:
Rack Pinion Tooth Profile
To estimate rack and pinion gear tooth strength
Production gears must be designed using Lewis Form Factor or FEA
Pinion tooth geometry is assumed the same as for the rack!

Inputs
Pitch, P(mm) 6.284
Pressure angle, alpha (degrees, rad) 14 0.244
Safety factor, sf 2
Number of teeth on pinion, N 25
Tooth material CR-45
Allowable bending stress, sb (psi) 40000
Tooth width, wr (in) 1.000
Tooth geometry
Circular pitch (in) 0.499935177
Tooth height (root to tip), hr (in) 0.386
Addendum, ar (in) 0.159
Dedendum, br (in) 0.192961171
Clearance, cr (in) 0.034
Tooth thickness, tr (in) 0.250
Tooth thickness at root, trr (in) 0.360
Shear area, Area (in^2) 0.250
Distance pitch line to root, hl (in) 0.227

Reference formulae for rack pinion are listed below:

Motor Torque Calculation is shown below:

Torque Calculation for Rack & Pinion Drive

Data Value Unit Formulation

Feed Force(F) 2290 N

Diameter (D) 5.00E-02 m
Gear Ratio(i) 1
Efficiency (n) 0.85

67.3529
Torque (TL) 4 N-m

134.705
Total Torque Requirement 9 N-m
3.18268 Rp
Rpm(N=V/πD) 6 m

5.4.9 Other Drawings:

1. Handle:
 Figure 25: Locking Handle

2. Electric Motor:
Mechanical Grab has a cylindrical short circuit motor with an incorporated
electromagnetic brake. The motor and brake have been designed for
continuous service with high duty factors and cycles. The brakes are
electromagnetic disc, with asbestos free flat-faced linings. Thy offer great
reliability and automatic braking in the event of power failure. The friction
linings are long lasting ad the brake is easy to regulate.
Figure 26: Motor

CONCLUSION
Mechanical Grab is an essential requirement of industries which require frequent
transportation of work pieces from one location to another. With this system installed
safety, optimized work flow resulting in cost and time saving is achieved.

Design of a Mechanical Grab for lifting Sheets and Plates was indeed a great learning
experience for us as this project allowed us to study various norm of the industry
along with safety and HSSE requirement of the industry, this project developed a
creative conceptualization of various other design requirements. We are very thankful
to our advisor who helped us in every aspect of the design and developed phase.
Our Design was developed on Pro Engineer 4.0 Software with hand written design
calculations depicting various inputs and outputs achieved. The Grab designed is
capable of lifting 10 ton Payload having a Motorized rack and pinion arrangement to
provide telescopic action of the sliding beam allowing it to carry sheets of variable.
It also consists of a manual claw system allowing the grab to lift sheets of variable
length, as a consequence of intelligent designing grab is capable of carrying sheets of
variable sizes.

REFERENCES
[1] Manufacturers Hoist Institute. www.mhi.com/hoist

[2] NASA-STD-8719.9 Safety Standard for lifting Devices and

Equipment.

[3] http://www.wisegeek.com/what-is-the-difference-between-a-
hoist-and-a-crane.htm

[4] HTTP://WWW.ENGINEERINGCIVIL.COM/VARIOUS-TYPES-
OF-CRANES.HTML

[5] Machinery's Handbook (12th Edition), Chapter#4: Strength of

Materials

[6] ATLANTA ZD Rack and Pinion Drive – Calculation and Selection