2 Meter-Tall Working Model Crane

During my summer internship at ASTRI (Hong Kong Applied Science and Technology Research Institute) in 2024, I collaborated with 2 other interns to design and build a 2 meter-tall working model crane to demonstrate advanced sensors used for construction site safety.

The challenge was to create a model that replicated real-world crane functionality, with a focus on precise movement and integration with electronic systems. I was excited to take on this complex project because it allowed me to push my technical and design skills to a new level.

Design Overview

The crane was designed to have full 360° rotation, vertical movement of the hook, and trolley translation along the jib. We incorporated stepper motors and an Arduino control system to enable precise mechanical movements so the crane could be operated with a controller.

Using CAD, we created a 3D model of the crane and we performed FEA to make sure the crane is able to withstand operational forces while maintaining stability.

The model was constructed using a combination of aluminum t-slot extrusions, manufactured sheet metal parts, and 3D-printed components to balance strength, weight, and ease of assembly.

Front Jib Design Lead

As the team lead for the front jib design, I was responsible for ensuring that the jib could perform both the vertical and horizontal movements of the hook as well as the crane’s ability to lift and lower the front jib.

My focus for the front jib was for it to be both sturdy and lightweight, incorporating a simple and compact linear motion guide for the smooth translation of the hook trolley.

To protect the motors and ensure safe operation, I integrated limit switches that control the range of the trolley's movement. This design allows for precise, guided motion of the hook trolley while maintaining the overall structural integrity and efficiency of the jib.

Skills Used

  • CAD Modelling

  • FEA

  • Mechanical Design

  • Prototyping

  • Material Sourcing

  • Arduino Programming

  • Team Collaboration

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