Module-III
Qno. 1 Explain the different types of cranes used in mechanical material handling.
Discuss their design, construction, and the role of guards and limit devices in ensuring
safety.
Ans: Cranes are essential lifting devices used in mechanical material handling to transport
heavy loads vertically and horizontally. Based on design and application, the main types of
cranes include:
Type of Crane Common Use Mounting
Overhead (Bridge) Factories, assembly lines Fixed (ceiling/rails)
Gantry Shipyards, outdoor yards Movable (on rails)
Jib Workstations, docks Wall/pillar-mounted
Tower Construction sites Stationary
Mobile (Truck-mounted) Construction, transport Mobile (vehicle base)
Crawler Rough terrains, construction Mobile (tracks)
Design and Construction
Cranes consist of:
• Boom or jib: Load-bearing arm
• Hoist and trolley: For vertical movement and horizontal load travel
• Slew unit: For rotational motion (in tower or jib cranes)
• Support structure: Base or tower
Materials used include structural steel, high-tensile cables, and precision gear assemblies.
Structural integrity and load ratings are essential considerations during design.
Safety Devices
To ensure operational safety, cranes are equipped with:
• Guards: Cover moving parts like gears and belts to prevent accidental contact.
• Limit switches: Prevent over-travel of hoist and trolley.
• Overload sensors: Alert operators or shut down operation if weight limits are
exceeded.
• Emergency brakes: Engage automatically in case of power failure or fault.
Schematic Diagram
Proper training, regular inspection, and adherence to load limits are critical to preventing
accidents.
Qno. 2 Describe the various types of conveyors used in industries. What are their specific
applications and what precautions must be taken during their operation and
maintenance?
Ans:
Conveyors are mechanical systems used for moving materials efficiently across production and
handling units. They are vital in manufacturing, mining, packaging, and warehousing.
Types of Conveyors and Applications
Conveyor Type Application
Belt Conveyor Moving bulk materials like coal, ore, and grains
Roller Conveyor Assembly lines, package handling
Screw Conveyor Powdered and granular materials (cement, flour)
Chain Conveyor Heavy unit loads in automotive and steel industries
Bucket Conveyor Vertical lifting of grains, sand, fertilizers
Pneumatic Conveyor Fine powders and dust (cement, chemicals)
Graph: Conveyor Type vs Load Capacity
Precautions for Safe Operation and Maintenance
1. Guarding: All moving parts (gears, belts, pulleys) should have protective covers.
2. Emergency Stops: Easily accessible stop switches should be installed along the
system.
3. Regular Inspection: Check for wear and tear, misalignment, and belt slippage.
4. Training: Operators must be trained in startup, shutdown, and emergency procedures.
5. Lubrication: Bearings, rollers, and chains require periodic lubrication.
6. Load Limits: Avoid overloading, which can damage motors and belts.
Conclusion
Conveyors improve productivity and reduce manual labor, but unsafe use can lead to accidents.
A combination of correct selection, operator training, and routine maintenance ensures safe and
efficient operation.
Qno. 3 What are the key safety rules and inspection checklist items for hoisting apparatus
and powered industrial trucks? How do these contribute to accident prevention in the
workplace?
Ans: Safety rules and regular inspections are essential for the safe operation of hoisting
apparatus and powered industrial trucks (PITs) such as forklifts, electric trucks, and LPG
trucks. These measures ensure equipment reliability and minimize the risk of mechanical
failure and human error.
Key Safety Rules
1. Only trained and certified operators are allowed to operate hoists and PITs.
2. Loads must not exceed rated capacity to prevent tipping or mechanical failure.
3. Maintain clear visibility; use spotters if the view is obstructed.
4. Use seat belts and personal protective equipment (PPE) at all times.
5. Never lift people using hoisting equipment unless approved platforms are used.
6. Keep hands, feet, and body parts clear of moving components.
7. Engage brakes and power down equipment when not in use.
Inspection Checklist Items
Item Inspection Criteria
Brakes and controls Functional and responsive
Hoist chains, ropes, and hooks No fraying, kinks, or deformation
Warning alarms and lights Operational
Fluid levels (hydraulic, fuel) Within specified range
Tires and wheels Proper inflation and no visible damage
Forks and lift mechanism (PITs) No cracks or bending
Guard devices and limit switches In place and functioning
Contribution to Accident Prevention
Implementing safety rules and inspections helps identify defects early, reducing the risk of
mechanical failure. They also reinforce safe operator behavior, minimizing human errors. As a
result, they significantly reduce injuries, equipment damage, and downtime—ensuring a safer
and more productive work environment.
Qno. 4 Discuss the operating principles and safety requirements for electric, gasoline-
operated, and LPG-powered industrial trucks. How is operator selection, training, and
performance testing conducted?
Ans: Operating Principles
• Electric Trucks: Operated using rechargeable batteries that power electric motors for
movement and lifting. They are clean, quiet, and ideal for indoor use.
• Gasoline-Operated Trucks: Powered by internal combustion engines. These are suitable
for outdoor use due to high emissions and noise.
• LPG-Powered Trucks: Use liquid petroleum gas stored in cylinders. They offer better
emissions control than gasoline and are suitable for both indoor and outdoor
applications with proper ventilation.
Safety Requirements
Truck Type Safety Requirements
Electric Battery maintenance, proper charging area ventilation
Gasoline Fire safety equipment, avoid enclosed spaces
LPG Leak detection, secure cylinder mounting, adequate airflow
Common Safety Rules:
• Never exceed rated load capacity.
• Use seat belts and wear PPE.
• Keep forks low during transit to maintain center of gravity.
• Avoid sudden turns and inclines.
Operator Selection, Training & Testing
1. Selection: Operators must be physically fit, mentally alert, and have good vision and
reflexes.
2. Training includes:
o Understanding truck controls and mechanics
o Load handling techniques
o Hazard recognition
o Emergency procedures
3. Performance Testing:
o Conducted on-site with practical tests
o Includes maneuvering, load lifting, and safety drills
o Evaluation by a certified trainer
Conclusion
Proper training and adherence to safety standards ensure the safe use of electric, gasoline, and
LPG-powered industrial trucks. These measures help prevent accidents, reduce downtime, and
promote efficient material handling in workplaces.
Qno. 5 Explain the structure and working of power elevators including different types of
drives. What emergency procedures should be followed in case of malfunction, and what
specific provisions are made for handicapped users?
Ans: Structure and Working of Power Elevators
Power elevators are vertical transportation systems designed to move people or goods between
floors in a building. The basic components include:
• Cabin: Enclosed platform that carries passengers or cargo.
• Hoistway: Vertical shaft where the elevator moves.
• Guide Rails: Ensure smooth and controlled motion.
• Counterweights: Balance the elevator to reduce motor load.
• Control System: Manages speed, floor selection, and door operations.
• Drive Mechanism: Provides lifting power.
Types of Drives
Drive Type Working Principle
Traction Drive Uses ropes and counterweights; driven by electric motors
Hydraulic Drive Uses hydraulic cylinders to lift the elevator car
Machine-Room-Less (MRL) Compact system with motor in hoistway, energy-efficient
• Traction elevators are used for high-rise buildings.
• Hydraulic elevators are ideal for low-rise structures.
Emergency Procedures
1. Emergency Alarm and Intercom: Allow trapped users to communicate.
2. Automatic Braking System: Engages during power failure.
3. Manual Rescue Operation: Trained staff operate a crank or override system to bring the
elevator to the nearest floor.
4. Power Backup: Elevators must have UPS or generator support for safe evacuation.
Provisions for Handicapped Users
• Braille Buttons and Voice Announcements for the visually impaired.
• Wider Doors and Cabins to accommodate wheelchairs.
• Low-positioned Control Panels for seated access.
• Automatic Leveling to minimize the gap between floor and cabin.
These features ensure safety, accessibility, and efficiency in vertical transportation systems for
all users.
Qno. 6 Differentiate between escalators, moving walks, and man lifts in terms of
construction, types, safety devices, and braking systems. What are the key elements of
their regular inspection and examination?
Ans: Comparison Table
Feature Escalators Moving Walks Man Lifts
Flat or slightly Vertical platform or belt
Construction Inclined, steps-based conveyor
inclined belt with footrests
Pallet type, belt Continuous, vertical,
Types Parallel, crisscross, spiral
type inclined
Safety railings, floor
Safety Step demarcation lights, comb Emergency stop,
switches, emergency
Devices plate switches, skirt brushes speed monitor
shutoff
Braking Friction or disc Safety brakes with
Electromechanical brakes
System brakes locking pins
Diagram: Basic Comparison
[Escalator] ---> Inclined steps | [Moving Walk] ---> Flat surface | [Man Lift] ---> Vertical
platform/belt
Key Inspection and Examination Elements
Component Inspection Criteria
Steps/Pallets Check for cracks, misalignment
Handrails Tension and smooth movement
Brakes Test emergency braking
Drive Chains Lubrication and wear checks
Safety Switches Functionality of emergency stop systems
Lighting & Signage Proper visibility and instructional signs
Graph: Risk of Malfunction vs. Frequency of Use
Conclusion
Each system has unique structural and safety considerations. Regular inspection ensures
components like brakes, steps, and safety switches function correctly—minimizing accidents
and ensuring continuous, safe operation for public and industrial use.
