“Design & Performance Analysis of EOT Crane, Modification from DC Electromagnetic to Thruster Brake System”

Abstract: The Electrical Overhead Travelling (EOT) crane is one of the most widely used material handling systems in industrial applications such as steel plants, manufacturing industries, warehouses, and construction sectors. The braking system of an EOT crane plays a vital role in ensuring operational safety, load control, reliability, and smooth functioning. Conventional DC electromagnetic brake systems used in cranes often face problems such as high maintenance, overheating, brake coil failure, and reduced braking efficiency during continuous operation. To overcome these limitations, the present study focuses on the design and performance analysis of an EOT crane by modifying the existing DC electromagnetic brake system into an electro-hydraulic thruster brake system.

The project involves studying the working principles of both braking systems and comparing their performance based on braking torque, response time, reliability, energy consumption, maintenance requirements, and operational safety. The design analysis includes load calculations, braking force estimation, motor compatibility, and stress considerations under different operating conditions. The thruster brake system provides fail-safe operation, faster response, better heat dissipation, and improved braking performance compared to the conventional DC electromagnetic brake.

The modification aims to enhance crane efficiency, reduce downtime, improve safety standards, and minimize maintenance costs. The results obtained from the analysis indicate that the electro-hydraulic thruster brake system offers superior operational performance and reliability for heavy-duty industrial crane applications. Therefore, replacing DC electromagnetic brakes with thruster brakes can significantly improve the overall performance and service life of EOT crane.

Keywords: EOT Crane, DC Electromagnetic Brake, Electro-Hydraulic Thruster Brake, Braking System, Performance Analysis, Material Handling Equipment, Crane Safety, Brake Modification, Industrial Automation, Brake Torque, Fail- Safe Braking, Mechanical Design.