BASIC CRANE STATICS QUESTIONAIRE

An overhead crane is shown in the Figure 1 in the following page. The basic crane
specification is as follows.

Span: 5m
SWL: 2000kg
Hoist Mass: 200kg
Girder Section: UC 254x254x73kg
Hoist type: Monorail trolley hoist with 4 wheels

The end carriage wheel of the crane sits on top runway rail. Material and section
property of girder is provided in Table 1.

Assuming when an ideal lifting operation is done in an ideal environment, and girder Commented [A1]:
length=span, Ideal lift in ideal environment means no other load other than
SWL, hoist and dead load. Bending only in x-direction
(vertical).

It should be OK if experienced crane design engineer include

other factors as listed in Q2. Habit do comes automatically.

Q1. Calculate the maximum girder bending stress (in MPa)

Commented [A2]:
Candidates are not expected to have the solution formula
memorized in their head.

SWL, m1= 2000 kg Do allow candidates to browse the internet for the relevant
formula. We can expect any mech/ civil eng graduate to
Hoist Mass, m2= 200 kg know what and how to find the formula in the internet.

Girder Unit Mass, = 73kg/m (The following only for candidates working in other
industries for quite sometimes! NOT for fresh graduate and
crane design engineer!)
Span=Length, L= 5m If candidates still cry for help, do provide them with the
formula sheet. This should be able to remind them of a
Gravitational Acceleration, g= 9.81m/s2 forgotten knowledge. They are however expected to select
the formula themselves.
Hx= D/2= 0.1271m
Ix= 0.0001141m4

Overhead crane can be considered a simply supported model. Commented [A3]:

This is the most basic understanding in field of statics for
every mech/ struc engineer. It is OK if they never state it as
long as they end up with the same simply supported formula.
Since this is an ideal lift in ideal environment,
 L2
Dead Load Moment, M d
8
2238Nm

Live Load Moment, M l

m1 m2 gL
4
26980Nm

Total Bending Stress,

M d M l H x
Ix
32.55MPa

Q2. In a real world, list down other possible factor(s) affecting the total girder stress
when compared to result in Q1. Also, briefly describe the factor(s) and how they
affect the outcome?

a) Impact Load- Due to jerk and sling slackness, Increase x-drection bending stress
b) Inertial Load- Due to long and cross travel of crane, y-direction bending stress
c) Skew Load- Due to end carriage skew, y-direction bending stress
d) Local Stress- Hoist wheel causing local bending of girder flange
e) Wind Load- If installed outdoor, y-direction bending stress Commented [A4]:
1.For candidates w/o experience in crane design before, they
should be able to come out with like external factor,
inertia, momentum or similar physics term.
Q3. Calculate the maximum girder deflection (in mm). 2.For candidates claimed to be material handling/ operation
engineer, they should be able to come out with terms like
side load, swing, impact, slack or similar.
3.For engineers claimed to come from crane design industry,
they are expected to provide at least three correct answers.
SWL, m1= 2000 kg
Hoist Mass, m2= 200 kg
Girder Unit Mass, = 73kg/m
Span=Length, L= 5m
Gravitational Acceleration, g= 9.81m/s2
Hx= D/2= 0.1271m
Ix= 0.0001141m4

5 gL4 Commented [A5]:

Deflection due to Dead Load, d Candidates might only provide live load deflection,
384 EI x especially if they are experienced in crane design industry.
0.2467 mm If so, remind them of dead load and see how they react.

Deflection due to Live Load, l

m1 m2 gL3
48EI x
2.380 mm

Total Deflection d l 2.627 mm

Q4. In a real world deflection test, do you expect the result to vary a lot from the
deflection calculated in Q4. Why?

The result from a real world deflection test should exhibit no significant
difference, if not very slightly less deflection, from the calculated value. Commented [A6]:
A tie breaking bonus.

During a deflection test, the suspended load is required to be static to allow for
a steady reading of deflection. Thus, no other external load listed in Q2 is Commented [A7]:
imposed on the crane. If the candidates answer is that real world deflection is
expected to be greater than calculated value, try reminding
them of this statement.

It is a natural habit for engineers to expect for the worse.

Also, deflection in real world test is taken as the difference between elevation of However, a good engineer should be able to get it right with
girder before and after hooking up SWL. This only measure the deflection due to this reminder.
live load as the crane is already deflected under the dead weight before hooking
up SWL. Thus, a real world deflection test might records a slightly lower
deflection due to dead load deflection omission.

The additional local deflection at hoist wheel due to local bending of flange
should not be noticeable as a result. Commented [A8]:
A tie breaking bonus.