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1. Internship project Amanuel w

2. portable crane Portable crane is a small crane that can be broken down into several parts for case of transportation. It must be assembled and bolted into a place where to be used effectively. They are transportable and require no external power. They can be used where no overhead lift is available and relatively short lift required. It also increase efficiency and productivity while decreasing operator bending and risk of back injury. Types of Portable Crane Thus cranes are broadly categorized into three 1 Overhead crane 2 Fixed cranes 3 Mobile cranes:

3. 1.2 Problem of Statements them and In Asella malt factory there are four working section place. From those i have visited most of there i have observed many drawbacks 1 . In machine tower plant there is necessity of lifting system but there is no lifting system in the machine tower which is the main problem of these plant. The problems are: It is not possible to solve emergency problem immediately It is difficult to take heavy motor at the top of the machine tower Time loss 2 . There is overloading of power because of the company have many expansions project which adds a lot of machines. But ELPA from the beginning still know supply a power rate of 15KV. 3 . The company uses water to transfer or pump over the barley from steeping to germination box which is more water consuming.

4. 1.3 Proposed solution I proposed different solutions to save the downtime occurred, man power, fuel consumption and any other related problems. Such as lifting crane, 1.4 Objectives 1.4.1 General Objectives The general objective of the project is to design moveable lifting crane. 1.4.2 Specific Objectives To design vertical column, boom, cylinder, base plate, hand bar, wheel, hook, chain, and pins. To determine the overall cost of the portable crane. To design the 3D model of all component of machine

5. 1.5 Methodology The methodology incorporated in design and development of portable crane in Assela malt factory is indicated as follows; 1. Primary source Direct observation Interviewing employees of different expert 2.Secondary source Reference Different websites 1.6 Significance my project can lift heavy loads about 3 ton that is beyond the capacity of human being applying only small force in the factory. The costs of the materials are relatively cheap hence it can be used widely and can be made by local materials. Flexibility and movability Capable of reaching everywhere and anywhere. 1.7 Limitation The limitations of my project are; my project can’t lift loads beyond 3 tons. Can’t lift the loads beyond 3 meters. Since it moves manually it requires time. Lack of part manufacturing

6. WORKING PRINCIPLE AND 3D Working Principle Its working principle is that the part to be lifted (the motor, machine components, heavy metal etc.) is suspended on the hook by adjusting the boom by the actuator using the fluid and applying the hand pump by holding down and up so that the piston extends against the load, in turn the load is lifted. The height and the amount of weight to be lifted are adjusted by extending or retracting the boom out of or into upper frame. The loaded lifting machine is moved to the desired place by the simple push of handle. The machine also has a feature of becoming compact for the purpose of using available space, storing and transportation.

7. Parts of portable crane a.Vertical column Vertical column is supporting components. It holds the boom, cylinder, hand bar and attached to the base plate. It maintains the rigidity of the crane. The maximum lifting distance of the crane is depend on the length of this component. It is made of high strength metal. Figure 3. 4 Vertical column b.Boom The boom is modeled as simply supported beam, and it is subjected to a bending stress due to bending moment developed at the fixed end where it is pinned with the vertical column. Boom is the component on which the hook with chain is attached. Also it is connected to the vertical column with actuator to lift up and down the load.

8. c.Cylinder The main function of cylinder is to retain the working fluid and to guide the piston. Hydraulic cylinder usually made of cast steel or cast iron, But for my design purpose i select cast steel because of high heat resistance, easily machine able and low cost. Figure 3. 5 cylinder d.Base plate Base plate /Truck serve as a base for carrying all the weight of the proposed design project. In addition it carries the load by all the components of the crane .It is composed of four bars and each of them is modeled as a beam. Bar 1 and Bar 2 are side bars on which the center connecting bar is supported over. And the other is end bar which is provided at the back end of the two side bars to give extra strength. To know the stress developed in these components first i should know the all loads applied and let’s first calculate all the masses of all the other components.

9. Figure 3. 6 Base plate e.Hook Hook is the component which is fixed with the boom and it is used for hanging the load on the boom which moves up and down in lifting the load. Figure 3. 7 hook

10. COST ANALYSIS, MANUFACTURING AND MATERIAL SELECTION 5.1 COST ANALYSIS For any application there is a limiting cost beyond which the design cannot go. When this ultimate exceed i have to be consider another alternative solution or materials. In cost analysis there are two factors namely; cost of processing the material into finished goods and materials cost. It is likely that the cost of the materials must be low but, the processing may involve costly manufacturing process. Cost analysis means the cost that the project takes or costs to buying the material i used to do this project.

11. N O Material Cost(birr) Quantity Total price 1 Boom 5000 1 5000 2 Vertical column 5500 1 5500 3 Base plate 6400 1 6400 4 Hook 3000 1 3000 5 Pin 1000 8 8000 6 Cylinder 7000 1 7000 7 Piston 2000 1 2000 8 Piston rings 600 1 600 9 Piston barrel 450 1 450 10 Wheel 400 4 1600 Total     18 39550 Table 1 Table of cost of material

12. MANUFACTURING PROCESS components Manufacturing processes Vertical column, boom and hook Milling, hardening, tempering, surface grinding Actuator, Drilling, milling Base plates Milling ,drilling, i lding Pins, bolts and nuts Turning, threading Cylinder, piston and piston rings Drilling and different machining operations

13. A. MATERIAL SELECTION The selection of a material for a machine part or structural member is one of the most important decisions that the designer is called on to make. To prepare any machine part, the type of material should be properly selected, considering design and safety. Selection of material for engineering application is given by following factors. Availability of material, suitability of the material for the required component, cost of the material, strength of the material I have used different types of steels for this design, but most of the materials for this machine use mild steel

14. Component Result Material used Hydraulic inner cylinder diameter 576mm AISI 1045 steel Thickness of cylinder 10 mm Outer diameter of cylinder 596 mm Diameter of piston head 15 mm Cast iron Diameter of piston rod 7 mm Piston length 600 mm Vertical column 1136.7 mm Cast steel Boom, hook 0.036 mm 5 .1 RESULT AND DISCUSSION Table 5. 1 material analysis

15. 5.2 CONCLUSION For many years cranes have been designed for lifting heavy objects with different capacity in different work sites. Portable cranes are one type of cranes designed for lifting objects which are beyond the capacity of human being. As Assela malt factory is one of the companies where in many different lifting operation is practicable. The maximum carrying capacity 3 ton, and maximum lifting height is estimated as greater than 3.14m from the ground run by using hand pump of hydraulic system. The four-month industrial internship program gives me a great knowledge about my working area very well, allows me to upgrade my practical and theoretical knowledge, it improves my inter-personal communication skill among other individual workers and employees, it also increases my self-confidence to take an action and taking responsibility on the task given to me, finally it enables me to be hard worker and a successful engineer for my future life.

16. 5.3 RECOMMENDATION I recommended Asella malt factory the following points. Asella malt factory should; Depend on what i have designed the next internship comer may get a hint to modify or redesign this project. I suggest that the company to manufacture and use this portable crane for its production increments. Communicate with workshop and maintenance office of company to help the students to expand their capacity by designing new machine, modifying the existing machine and also implementing designed machine for the company to reduce the extravagance of costs on maintenance to overcome related problem identified in company. Give workshop course for students to increase effectiveness and advise them during construction. Fulfills the materials required for the construction of machine. Debre Tabor University should ;

17. Thank you!!