Development and field performance evaluation of a novel forestry crane: an integrated FEA, prototyping, and statistical analysis approach

This study presents the design and prototype development of a functionally enhanced log crane. A 3D model of the prototype was created and analyzed using commercial finite element software. Following necessary design optimizations, a hydraulically driven prototype was manufactured using Strenx 700MC, a new-generation material. The crane features a 10.6-meter-long loading boom with a slewing column capable of moving an additional 2 meters along the carrier vehicle chassis, an innovation in this segment. To counteract the moments generated by the extended loading length and ensure stability under diverse terrain conditions, rotating outriggers were incorporated. The loader reaches a maximum height of 4 meters and a width of 2.5 meters. The loading capacity was further enhanced by redesigning the conventional diametrical loading area into an elliptical-like shape. Comprehensive load tests conducted both indoors and in forest environments confirmed the crane’s performance, with the Turkish Chamber of Mechanical Engineers validating its lifting capacity of up to 3 tonnes (29.43 kN). Field analyses assessed dimensional integrity and loading times, and the results were statistically evaluated using Two-Way ANOVA and Spearman correlation analyses. Log diameter was identified as the dominant factor governing loading efficiency (p < 0.05), while truck type had no significant effect. Spearman correlation confirmed a strong positive relationship between log length and loading time (rs = 0.94 for ST; rs = 0.83 for LT), demonstrating consistent and predictable operational performance across the tested conditions.