Abstract
<title>Abstract</title> <p>Electric Overhead Traveling (EOT) cranes are widely used in manufacturing, warehousing, steel plants, and material handling industries. The end carriage is a critical structural component that supports the bridge girder and facilitates longitudinal movement of the crane along the runway beams. Even though extensive research has been conducted on crane girders, limited attention has been given to the structural optimization of end carriage assemblies. This study investigates the redesign and optimization of an EOT crane end carriage with the objective of reducing structural height, material consumption, and total cost of project while maintaining acceptable stress and deflection limits. Analytical design calculations were performed according to conventional crane design practices and relevant standards. Finite Element Analysis (FEA) was conducted using ANSYS under static loading conditions corresponding to maximum operational loads. Experimental validation was carried out through load testing and deformation measurements. A modified cross-sectional configuration was proposed and compared with the conventional box-section design. Results demonstrate that the optimized configuration significantly reduces structural height by approximately 300 mm while maintaining deformation within allowable limits. The numerical and experimental results exhibited good agreement, validating the proposed design approach. Due to the reduction in crane height by 300 mm cost of shed construction is reduced up to Rs. 1 Million also improved structural efficiency. This research make available a practical framework for optimizing crane supporting structures for industrial applications.</p>