Chandima Perera

Jeremy Brown

Xiangyu Sun

Brianne Luff

In The BeginningIn The Beginning

• Identified Opportunity… – The lifting properties of certain types of

modern cranes pose a safety hazard if guidelines are not adhered to.

Design ConceptDesign Concept

• Solution… – To create a safety system to ensure the safe

operation of today’s modern cranes.

– This system would guarantee that the crane load is in accordance with the load chart.

– This in return will assure that no unnecessary crane accidents arise due to excessive loads.

Crane Load Failsafe SystemCrane Load Failsafe System

What and Who Benefits?

• Ensures safety to operators and people in the crane operating vicinity.

• US studied reported 22 deaths in the US from 1984-94 due to overloading.

• Reduces the risk of collateral damage.• The crane itself.• Assets surrounding the crane’s operational area.

Design SpecificationDesign Specification

• Model crane was built to simulate actual crane operations.

• Weight and boom angle measurements are taken by PIC.

• The PIC calculates the maximum load at the corresponding boom angle. It then controls the hoist and boom angle motors.

Instrumentation ComponentsInstrumentation Components

Two Geared DC Motors PotentiometerLoad Cell (0-10lb)

16F877 PIC Board

Instrumentation Amplifier

Model Crane DesignModel Crane Design

Electrical DesignElectrical Design

Coding FlowchartCoding Flowchart

Model Load ChartModel Load Chart

Demonstration VideoDemonstration Video

Problems EncounteredProblems Encountered

• Instrumentation– Noise from instrumentation– Overshooting in reverse boom direction– Calibration of load cell– Insuring safety protocols during operation

• Mechanical– Clearance issues in brackets and boom– Difficulty machining Plexiglas– Mounting pulleys– Installation of potentiometer

Future Design ConsiderationsFuture Design Considerations

• Load cell or instrumentation amplifier with a more stable signal.

• Emergency system override

• Audio/Visual warning alarms prior to motor shutdown

• Max load display for corresponding boom angle

ConclusionConclusion

• The Crane Failsafe System is a success!

• The team was able to apply our knowledge obtained from this course to create a functioning prototype with added features.

• We believe this System may have industry potential in crane safety.

Any Question?Any Question?