Workshop Crane Construction

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Workshop Crane Construction

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  • #760085
    Pero
    Participant
      @pero

      Potentially a cross-topic query/discussion!

      For some time, as I get older and weaker, I have been looking at options for a small workshop crane for lifting chucks and machining accessories onto my lathe and mill without finding anything commercial that fits the bill. To explain a little of why I am doing this, the weight of the heaviest chuck on my lathe is around 40 kg. I can almost lift it but placing it on the lathe and fitting it is way beyond me. Other lathe accessories and accessories for the mill likewise. The idea is to be able to lift the object, extend it over the lathe bed/mill table and lower it gently onto the surface without causing damage to either. It will be fitted to a mobile trolley to service 3 or 4 machines. It will be stable in its most likely used format but extendable supports may be fitted if required.

      I have now moved on to designing/planning for a self-build and have come up with three construction alternatives for a small scale crane with a safe lifting capacity of 100 kg.

      In each case the requirement is for a lifting and extending jib plus a winch.

      Option 1 is for an all-hydraulic system however the cost of hydraulic winches is very high and those I did find were all high speed so not satisfactory. A small electric winch will therefore be used in all cases. The hydraulic actuators for the jib functions were reasonable but also require a hydraulic pump and reservoir, valve system and lots of high pressure hoses and hydraulic fluid. Altogether not exactly encouraging/desirable.

      Option 2 would be an electric winch and two self-contained electric-hydraulic actuators. These are self-contained units with each having a small electrically driven pump powering a hydraulically driven piston (actuator). No need for a separate pump and reservoir, valve manifold or hoses.

      Option 3 is the electric winch coupled with two electric linear actuators, i.e. no hydraulics involved.

      The cost for the components for each system would be roughly comparable. I think the precision of control would be greatest with the electric linear actuators but have no experience with these so would welcome any thoughts or comments.

      I know this topic has come up a number of times but don’t remember anyone planning to go to quite these extremes before so all thoughts and comments on the project would be welcomed.

      I have previously considered an overhead system but as the lathe and mill are at right angles have abandoned this option.

      Thanks for reading.

      Pero

       

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      #760133
      Stuart Smith 5
      Participant
        @stuartsmith5

        You don’t say what your budget is, but a used mobility scooter hoist for a car may be ok.

        There are various designs but one with 2 linear actuators would give up and down and rotary motion.
        Some have a built in winch.

        They have a handset to control the movement. Lifting capacity varies but you can get ones with over 100kg capacity. Obviously depends on how it is mounted. I am thinking of doing the same as you.

        Stuart

        #760139
        Bazyle
        Participant
          @bazyle

          Another possibility is an hydraulic lift table. Put chuck on shelf on little wheeled carriage, roll onto table , lift to lathe bed, lower flap between table and bed to roll off chuck. Arrange that wheeled carriage to be at correct height to screw onto nose.
          If there is room in your shed for a bigger hydraulic table that could also have a small crane arm added with the table providing the vertical movement. A sub table might be made using roller drawer slides to move things off storage onto table then onto mill.

          Also instead of hydraulics and electric winches some smaller movements can be achieved with screwed rod turned by a battery drill, or perhaps permanently connect a old mains drill as there are plenty around now we have all gone battery.

          #760140
          Clive Foster
          Participant
            @clivefoster55965

            Pero

            I agree with Stuart that a mobility scooter hoist could work well for this job. Something I’ve looked into up to the obtain parts and back of envelope design stage.

            My Plan A is to bolt a mobility scooter loading crane of the type intended to be fixed into an hatchback or estate car to a good quality rolling service cart.

            The service cart I have is the 6 drawer version found under Snap-On / Bluepoint brands. It is reassuringly sturdy. I imagine other breeds could be up to the task but Snap-On have a well deserved reputation for making strong stuff. (My big Snap-On rolling mechanics toolbox has load ratings per drawer approaching that of a whole similar sized one from some other suppliers.) Many years ago I bought a similar service cart from a budget supplier, Northern Tools perhaps, that is surprisingly rigid when bolted up but unlikely to be up to handling the offset stresses of a crane.

            I spent maybe £300 – £350 for the Snap-On cart and crane via FaceBook Marketplace and E-Bay.

            Preliminary plan is to fix a short length of scaffold pole to one corner of the cart as a base for the crane pivot device on the existing mounts. Alternative is to mount the crane on a long shaft dropping down into the scaffold pole. At this stage I’m unsure about doing permanent integration, which would be neater, as welded on brackets would be needed.

            These cranes have an inherently limited lift range. Probably not an issue if shifting from storage shelf to machine. Even less so if you store the chucks and other things on the cart. If you choose to do on cart storage probably better to have a cart with the deep top compartment and sliding lid rather than the shallow compartment and hinge up lid that mine has. A strong ratchet strap seems good way to get more, adjustable, lift range.

            Disadvantage of the mobility scooter lift is that it needs some sort of 12 volt power supply. Car battery would be ideal and help balance things but seems expensive given the limited use. I have an old but still good one on the bench for various jobs so no issue for me.

            In the beginning I was going to engineer my own version using a feed screw driven by my 18volt Makita battery drill to drive the lift. Then the penny dropped that I was basically re-inventing the wheel. I imagine an inexpensive hydraulic cylinder and hand pump would work if you chose to engineer your own. Something like the ram and pump used in body repair kits from the likes of Machine Mart for £120 (ish) :-

            https://www.machinemart.co.uk/p/clarke-cs10prh-10-tonne-pump-ram-and-hose/

            perhaps but these seem vastly over powered for this job.

            Clive

            #760145
            Nicholas Farr
            Participant
              @nicholasfarr14254

              Hi, this is what I did in my garage, but it was in the plan during the building of my garage, and all the material was free. It has had 300kg on it, without any issues.

              Test Lift

              Regards Nick.

              #760193
              V8Eng
              Participant
                @v8eng

                I find a folding engine crane works for me but appreciate space and manoeuvrability etc can be an issue with one of those for many places.

                #760206
                larry phelan 1
                Participant
                  @larryphelan1

                  What,s wrong with a simple lifting platform using a trailer hand winch ?

                  I built one some years ago [not my plan, just a copy ] and it does everything I require.

                  Simple and cheap to make and serves as a “place to put things out of my hand ”

                  It can be brought right up to the lathe bed or mill table height and if your chucks are arranged to sit on “mother blocks “, they will end up at the correct height every time.

                  Heavy mill vise ?, no problem ! Broken foot ?  No way !

                  BTW, I think it was Dave Fenner who made the one I copied

                  Just a thought !

                  #760234
                  Nick Wheeler
                  Participant
                    @nickwheeler

                    As above, Pero’s low weight requirements are easily covered with a basic, cheap, hand-operated winch with a safety brake. Something like THIS . While not necessarily intended for lifting, I’ve seen them used that way as they crank in both directions and the weight rating is five times the requirement.

                    Using hydraulics or electrics, let alone a combination of both seems like a huge complication(and expense) for such a simple task.

                    #760239
                    Clive Foster
                    Participant
                      @clivefoster55965
                      On larry phelan 1 Said:

                      What,s wrong with a simple lifting platform using a trailer hand winch ?

                      Nothing at all. Purely a horses for courses question.

                      Lift table is great for sliding transfers from bench or shelf to machine but not so good for anything involving up’n over or pick up from the floor which generally leaves you with some hand effort.

                      Crane is better for direct pick up and anything involving swing over. But a simp-le mobile crane has issues with the legs getting in the way.

                      Considered a lift table to make life easier with the vices, rotary tables and dividing head that i use with my Bridgeport. Eventually decided the cost and space it would take up wasn’t justifiable for something that couldn’t help with the big chucks, and sometimes big jobs, for my large P&W Model B lathe.

                      Given a clean sheet of paper the best option for me would be a roll cart with integrated crane holding all my heavy items. I have too much heavy gear to get away with a single compartment on top without making the thing impractically big. So I need to figure a way to give the crane access to two lower layers of drawer style compartment without then thing overbalancing or breaking the drawer slides. Using an off teh shelf cart like the Snap-On / Bluepoint ones means that only some of teh behave gear can go on the cart. The rest will have to be picked off shelves.

                      Clive

                       

                      #760263
                      Nigel Graham 2
                      Participant
                        @nigelgraham2

                        Once you start considering trolleys, mobile cranes and the like you need consider:

                        1) Is there room to manoeuvre the thing safely to use it, and to park it out of the way?

                        2) Will it move the object to the intended location? I.e. will it let you lift and control the load?

                        3) Is the heaviest object – e.g. a large lathe chuck or a rotary-table,  so heavy you really need motors or hydraulic drives? Will a chain-block or block-and-tackle be as effective?

                        4) If it suits the lathe does it also suit the milling-machine or an assembly-bench, or for ancillary tasks like holding the outer ends of long workpieces on a sawing-machine or bench-drill? Even if the main axes of the machines are at angles to each other?

                        .

                        Answers;

                        1) A straight lift-table won’t so you need some form of ramp or bridge to move the load on. A garage type engine-hoist won’t – these must be  among the most ungainly, awkward contraptions invented!

                        2) Such as the lathe spindle and the milling-machine table and any other point in the workshop.

                        3) How often do you need lift an entire machine-tool? If you need move it, there are usually simpler and safer ways. If you can lift the object by hand but it is of borderline mass, you don’t need a JCB to lift it. For heavy machine-tool fittings a 3 or 4 : 1 mechanical advantage for the lift should be ample as long as you can also move and control the load.

                        (Bear in mind simple block-and-tackle needs some form of ratchet-clamp or belaying-pin so you can lock the load, as it does not have any intrinsic holdfast arrangement.)

                        4) Really expands on Q2.

                        .

                        I equipped my workshop – which is admittedly cramped – with a simple travelling-crane.

                        The crab holds an ordinary chain-block hung on a bar itself intended alternatively as a potential fixed axle for the top sheaves of a multi-fall block-and-tackle. One reason for this option is to avoid chains banging against delicate surfaces like fittings and paintwork on a miniature engine.

                        It reaches most of the workshop area, with a little manipulating of the load occasionally where close to the travel limits or a partial obstruction like the head of the milling-machine.

                        It can place the hefty chucks for the Harrison L5 lathe almost to the mandrel nose.

                        As a “helping-hand” on the band-saw or bench-drill, it is ideal. Indeed, its first ever task was supporting a two-foot square of thick steel plate for drilling (for a special bench-top)!

                        All “hand-raulic” – no over-thinking about motors, bits of studding in drill-chucks or hydraulics. Maintenance is just an occasional spot of oil on the axle journals and horn-plates.

                        No floor area lost to great lumps of trolley.

                        (The long-travel axles run in cast-iron blocks between steel horns, controlled by rubber pads. This modicum of suspension keeps all four wheels in contact with the rails, on what is effectively a six-foot gauge bogie.)

                        #760336
                        Howard Lewis
                        Participant
                          @howardlewis46836

                          Thinking in terms of just a simple block and tackle, a four fold purchase would allow a 100Kg load (A large chuck in my book. I am in my mid 80s and can still just lift a 8″ four jaw into place)  to be lifted with a 25 Kg effort on the rope. A simple pin in a hole would act as a safety lock.

                          Probably less in actual practice, allowing for over engineering and/ or safety factor, more likely to be 10Kg or less effort.

                          Possibly literally less effort and complication than a powered winch with trailing cables.

                          If shop made will not be certified (Will any shop made crane?) but most probably over engineered for the job, and cheaper.

                          Howard

                          #760417
                          Pero
                          Participant
                            @pero

                            Thank you to everyone who has responded. I can see from the responses that I am not the only one who has, or is planning to address the same problem.

                            A few take away points:

                            There is no general answer to the problem. The individual solution will depend on the construction and layout of the workshop, placement of machines and location where chucks and other accessories to be lifted are located.

                            The design of my workshop does not provide for the use of block and tackle solutions, or other single lift solutions, as I not only need left and right movement, as could be provided with the addition of an overhead rail, but backward and forward movement as well for positioning.

                            I do have a heavy duty garage crane which is good for heavy lifts (up to 2 tons) but is too unwieldy to be used in the workshop. Based on this, for my needs I require much less lifting capacity and a greater range of movement. Basing the crane on a mobile bench which could be moved to service different machines would appear to be the first step.

                            Having storage on and under the bench would mitigate for the room it would take up when the crane is not being used. I plan on designing it so the boom folds down completely and is out of the way when not in use.

                            I have abandoned the idea of hydraulics mainly due to to the fact that they tend to be a little jumpy in operation – sensitive enough for most purposes but not quite as delicate as an electrically driven screw (linear actuator) and potentially very messy if there is a high pressure spill.

                            I have looked at mobility scooter lifts. A couple of which looked potentially useful but very expensive new and seemingly not existing on the local secondhand market. Where do they all go?

                            So it looks like DIY with linear actuators, either home made (I have lots of spare electric drills) or commercial units and a small low speed electric winch.

                            As for cost I am uncertain but it does mean the difference between being able to use a couple of very large (and expensive) machines or just leaving them to sulk in a corner. Incidentally the cost of moving them out of the workshop and onto a flat bed truck would greatly exceed the cost of any form of crane construction and the possibility of a sale would not be good.

                            So thanks again for the comments. They have helped firm up my thoughts and hopefully helped a few others along the journey.

                            Pero

                            #760440
                            Les Riley
                            Participant
                              @lesriley75593

                              I had a similar problem so I designed a pillar crane that uses a Clark 500kg pulley block.

                              It runs on 40mm square box section and has a length of scaffold pole for the upright. The diagonal tie is 10mm threaded rod. The scaffold pole sits in a taper roller bearing on the floor and has a plain sealed ball bearing at the top.

                              I now have two of these units, one for the mill and one for the lathe. Their swings overlap so I can do transfers as well.

                              0118608830fe4803bbc5b9468cfe001942c3ae5068

                              #760450
                              ChrisLH
                              Participant
                                @chrislh

                                Another potential source of electric actuators is the ones used in adjustable beds.

                                #760479
                                Bazyle
                                Participant
                                  @bazyle

                                  I like the idea from Les if the roof or wall is strong enough to take the side thrust which rules out a fair few sheds.
                                  Can anyone give advice on length/weight capacity for that kind of beam.

                                  #760498
                                  Stuart Smith 5
                                  Participant
                                    @stuartsmith5

                                    Pero

                                     

                                    I bought a used mobility scooter hoist via ebay. I think I paid £165 for one about 5 years ago.

                                    Stuart

                                    #760534
                                    Clive Foster
                                    Participant
                                      @clivefoster55965

                                      Pero

                                      I’d like to know where all those mobility scooter hoists go too.

                                      Especially as a goodly fraction aren’t used for more than the dispiriting few years between when granny/grandad becomes frail enough to need one so they can get around and when they become too frail to drive it.

                                      Mine was around £70 and about 25 miles away off Facebook but it took maybe a year or more to surface. Regularly saw a few on E-Bay but generally the price was higher than I wanted to pay and/or the distance to great.

                                      I’d caution about using a mobile bench as a base. Having experienced several mobile benches, albeit not in my workshop, they don’t seem work out that well. No immediately obvious reasons but generally just not good to use. Mobile storage drawers work better and also keep stuff clean.

                                      When I kitted out my workshop approaching 20 years ago I used cut down three or four drawer filing cabinets to provide storage space under the benches. two full depth drawers and one cut down to half depth came out at a suitable height. As the common British filing cabinet drawer has half height sides I made lift out trays to increase capacity. Two trays per drawer, a single tray is just too hard to handle. Paper by the yard is heavy so filing cabinet drawers and runners are well up to the load of chucks, vices dividing heads, rotary table et al.

                                      As a result of this discussion I think that when I finally make my crane device I will use ex filing cabinet drawers and runners, cutting the drawers down if needful. Whether best approach will be to fit a three drawer cabinet with castors and slot in extra drawer and runner units where needed or devise my own frame being an open question. The hoist will go on one corner with one pivot of the electric ram being on a pull out pin so the hoist collapses. However I have 12″ chucks, 10″ and 12″ rotary tables, 6 inch vices and a large dividing head to deal with so need more mass handling capability than most folk. Plenty of mass in the drawers makes tipping unlikely!

                                      If you are going to make your own crane the bent jib and electric actuator design typical of scooter hoists is effective and compact. The main drawback is not being able to get single lift floor to bench or machine capability. So provision must be made for an intermediate rest stop and variable length connection between jib and load. In this application a sufficiently minor inconvenience to be tolerated. The alternative of a fixed jib and winch gets cumbersome.

                                      You could build your own actuator with a nut and threaded rod to be driven by a battery drill. As i originally planned to do. These days I’m doubtful as to whether the costs savings compared to buying a nice Far Easter import actuator is really worth the effort. Power tool battery adapters for most major brands can be gotten quite cheaply, along with DC to DC converters if its needful to drop 18 volts down to 12 volts, so your power tool battery can be used to drive the actuator. Hence little worry of the battery being flat when you go to use the device and no need for a power supply and trailing cable for reliable, plug in to the mains, power.

                                      Clive

                                      #760549
                                      Pero
                                      Participant
                                        @pero

                                        Thanks for the further comments. I had looked at an overhead system but found it impossible to obtain the flexibility I require. It would suit some tasks but not all. In regard to load, I am not sure what the safe load would be but as we are only looking at lifting chucks and accessories and not machines it should be fairly easy to come up with a system similar to that used by Les and with a good safety factor built in. Unfortunately I don’t do the calculations and just over-engineer the heck out of anything I build.

                                        It may be a local (Western Australian) thing but scooter hoists just don’t seem to come up in the second hand market. Perhaps the inheritors have their own uses for such things.

                                        The far eastern actuators which I have been looking at come in a wide variety of sizes and powers and look promising – but beware of the shipping costs. The same model with free shipping will likely have the same total cost as one with the shipping added separately – and shipping heavy items from China is no longer as cheap as it once was.  12 Volt units are readily available and as I have a number of 12 Volt packs sitting idle I could run the whole system cord free which would be a bonus. However the thing I am unsure of is how much power from these units I need – they are rated in Newtons and I have no idea how to translate that to something I would be familiar with (e.g. comparison to a hydraulic actuator). Based on normal practice I will probably end up with something way over powered and pay the cost penalty.

                                        My description of the base as a mobile bench was a little vague and I note Clive’s words of caution. I am planning for a fully filled in base unit with either drawers or cabinets, or possibly both, with a heavy duty 40 mm solid wood top that can be used as a general purpose bench when not in use as a crane. I will either go for a purpose build or modify one of the commercially available units with additional weight in the base and one end strengthened to take the crane column as well as mounting the electrics – battery sockets and switch controls.

                                        Thanks for the input it has been very helpful in clarifying my thinking. All I need to do now is clear enough room in the workshop to make a start!

                                        Pero

                                        #760654
                                        Martin Connelly
                                        Participant
                                          @martinconnelly55370

                                          Have you seen the 250kg lever hoists available from Sealey or Yale? They give good control of a load and do not require external power being hand operated.

                                          Martin C

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