The team is currently constructing a 7-foot-scale apparatus of a Luffing Jib Tower Crane for repeated tip-over testing to determine various safety parameters. The apparatus was first designed and modeled in SolidWorks CAD software to ensure that the design met all functional requirements, adhered to specified tolerances, achieved the desired motion capabilities, and was both feasible and reliable for its intended purpose.
The preliminary work involved designing a crane that could repeatedly tip over to an angle of up to 20 degrees before being caught by a catch mechanism. The design of this catch mechanism underwent multiple iterations to ensure the crane could fall to the specified angle without sustaining significant damage. The crane’s structure was optimized to handle this repeated tipping motion, while also integrating this catch mechanism to safely and securely stop the crane’s movement at the desired angle.
Additionally, the crane was designed with the capability to rotate over 360 degrees, allowing for complete flexibility in movement. An important part of this design process was ensuring that the new crane apparatus could seamlessly integrate with the electronics of existing cranes, specifically using ODrive BLDC motors. This compatibility ensures that the crane can be easily adopted into an existing system without requiring major modifications.
This apparatus has been designed to hoist a payload of up to 5 lbs. To gather valuable data for operational analysis and performance assessment, the scale model of the crane includes a camera angle sensor to track the position of the crane’s load, providing crucial data that helps monitor the load’s movement and the crane’s overall behavior. This data is essential for optimizing crane operations and ensuring precise control and monitoring in real-world applications.
The materials used for this apparatus include steel for the catch mechanism, base, and tower sections, providing durability and strength to handle the mechanical stresses during operation. Aluminum spur gears are employed for the slewing mechanism, while a worm gear is used for the luffing function. These gear choices are integral to the smooth and controlled movement of the crane, with each gear design and ratio carefully selected to meet the functional requirements.
To assess the feasibility and performance of the initial design, the gear ratios and machine deck were first tested on a 3-foot scale model, which was constructed using MDF and 3D-printed components. The purpose of this scale model was to evaluate the effectiveness of the early catch mechanism iterations and determine whether the proposed gear ratios and overall machine design were suitable. The 3-foot model served as a prototype, allowing for testing and refinement before proceeding to the full-scale 7-foot model.
Currently, the team is actively working on the construction of the 7-foot-scale apparatus using various methods to ensure precision and strength. The catch mechanism, base, gears, and tower sections have been cut out of steel using a water jet. Once the components were cut, they were welded together to ensure structural integrity. As the physical structure of the crane is completed, the electronics are being integrated into the system, which will include the installation of the camera angle sensor. The final step will involve testing the fully constructed crane with the integrated electronics and motors to ensure everything operates smoothly, the gear ratios are optimal, and the crane can function as intended without any issues.
