Design and Fabrication of a Hydraulic Floor Crane

Abstract

Existing hydraulic floor cranes used in engineering workshops are often limited by poor maneuverability, inadequate load stability, inefficient structural configurations, and insufficient verification of critical load-bearing components. These limitations reduce operational flexibility and reliability, necessitating improved portable lifting systems. This study presents the design, fabrication, and performance evaluation of a 1000 kg (9810 N) hydraulic floor crane incorporating a 360° roller mechanism to improve maneuverability and a structurally optimized frame to enhance load-carrying capacity and stability. The boom, vertical column, base frame, pins, welded joints, and overturning stability were analytically designed using established machine design principles, while the hydraulic lifting system was selected based on the required lifting force and boom geometry. A prototype was fabricated from mild steel and experimentally evaluated using calibrated loads ranging from 100 to 1000 kg. Performance was assessed in terms of lifting capacity, cycle time, maximum lifting height, structural behaviour, and operational stability. The crane successfully lifted the rated load without hydraulic leakage, weld failure, permanent deformation, or tipping. It achieved a maximum hook height of 1.78 m under light loading and 1.75 m at the rated load, representing a 1.7% reduction due to elastic deformation while maintaining stable operation throughout the lifting range. The developed crane provides a reliable, economical, and portable material-handling solution with enhanced maneuverability, structural integrity, and operational stability for engineering workshop applications.