PHASE 4 - (PART 2)

OVERALL FORCE ANALYSIS

1. CALCULATION OF FORCE ON EACH SIDE

Fc = Force from weight of car

P = Pressure

FL = Force to lift

d = diameter

Wc = Weight due to car

2. CALCULATION OF FORCE TO LIFT

    

Fc = Force from weight of car

P = Pressure

FL = Force to lift

d = diameter

Wc = Weight due to car

A1= Area at P1

A2= Area at P2

3. CALCULATION OF TORQUE TO LIFT

FL = Force to lift

TL = Torque to lift of(power screw)

dm = mean diameter of(power screw)

l = thickness of power screw thread

f =coefficient of friction

wL = angular speed to lift

4. CALCULATION TORQUE OF MOTOR

FT = Force at chain

rm = Radius sprocket at motor

rR = Radius sprocket at driven

D = diameter sprocket

Tm = Torque at motor

TR = Torque at driven sprocket

Vm= Velocity at motor

5. CALCULATION JACK VELOCITY

Apump = area pump

Ajack = area jack

Qpump = flowrate pump

Qjack = flowrate of jack

Vpump = pump velocity

Vjack = jack velocity

WILL BE UPDATED !!

PHASE 4 - FORCE ANALYSIS (PART 1)

DESIGN ANALYSIS

1. To calculate F1,F2 & H2

Estimated weight of car = 5 ton (P allowable)

Safety factor = 2

Maximum weight = 10 ton (2 x 5 ton)

P allowable = 5 ton

d1 = 25mm = 0.025m

h1 = 10cm = 0.1m

2. To calculate Torque,Nm

F2 = 78.4 KN

Power screw:

         Mean diameter, dm  = 10mm and below

         P, Thickness of thread = 1.5mm

         F, coefficient of friction = 0.15

         (Hard steel on cast iron)

Assumptions:

No of teeths, T driven = 28

Diameter driven = 4.74 inch = 0.12m ; r2 = 0.06m

No of teeths, T driver = 14

Diameter driver = 2.49 inch = 0.063m ; r3 = 0.0315m

•             Motor chosen, T = 200 Nm
•             The motor chosen is right

3. To calculate thickness of tank and jack

Chosen material:

Stainless steel type 304

Yield strength, σ = 215 Mpa

Jack outer diameter = 25mm + (11mm x 2)

                                  = 47mm             

Tank outer diameter = 20mm + (9.3mm x 2)

                                 =38.6mm

                    

P = Pressure

σ = Yield Strength

r = radius

t = thickness

MORE CALCULATION SOONER !!

PHASE 3 - SYNTHESIS (PART 1)

COMPONENTS/ PARTS & THEIR TECHNICAL DATA



1. Cylinder (Jack)

    Material = Stainless steel Type 304
    Cylinder size = d, 25mm (DIAMETER)
  

2. Tank (Jack)

     Material = Stainless steel Type 304
     Thickness,t = 11mm
     Outer diameter, d = 47mm
     Inner diameter,d = 25mm


3. Tank (Pump)

    Material = Stainless steel Type 304
    Thickness,t = 9.3mm
    Inner diameter,d = 20mm
    Outer diameter = 38.6mm

4. Threaded Cylinder

    Inner diameter,d = 10mm (Threaded)
    Outer diameter ,d =20mm

5. Power Screw (Pump_Tank)

    Mean Diameter ,dm =0.01m
    Material = Hard steel on cast iron
    Thrust collar friction (Coefficient of friction,fc) =0.15
    Thickness of power screw, l =0.0015m

6. Hydraulic fluid

    Type:
    Lifespan:

7. Sprocket
   
    Driven Teeth ,N1 =28
    Diameter driven sprocket,d = 0.06m
    Driver Teeth ,N1 =14
    Diameter driver sprocket,d = 0.0315m

8. Chain

                                  

side view of chain

top view of chain

    

    Type: 428
    Roller diameter,R = 8.5mm
    Pin diameter = 4.44mm
    Average strength = 1850 Pa    
    Cylinder cc (Max) = 125 cc
    H1 = 10.2mm
    H2 = 11.9mm
    T1 = 1.5mm
    T2 = 1.5mm
    F = 8.55mm
    G = 9.7mm
    W = 7.94 mm
    P,Pitch diameter = 12.7mm



Hydraulic hose
Extension Rod
Tank holder
Spocket shaft
Bolts and nuts
Sprocket driver
Power screw (pump)
Motor
Thrust roller bearing
Thread cylinder (pump)
Remote control switch


WILL BE UPDATED !!







   
   

DP PHASE 2

PHASE 2 - DEFINITION OF PROBLEMS


1.What's the problem and why need to overcome the problem?

Our research survey in this regard that in several automobile garages, revealed the facts that mostly some difficult methods were adopted in lifting the vehicles for reconditioning, repair and maintenance. This fabricated model has mainly concentrated on this difficulty, and hence a suitable device has been designed, such that the vehicle and heavy objects can be lifted from floor land without the application of impact force.

In most of the garages the vehicles are lifted by using screw jack. 

• This needs high man power and skilled labour. 

• Not only that, the current hydraulic jack is easy to use but not as convenient as it may be if it is needed to change both tires at once since you have to jack up your car twice. It would cost more time and extra work is done unnecessarily.

• In order to avoid all such disadvantages, the automated motorized object lifting jack has been designed in such a way that it can be used to lift the vehicle very smoothly without any impact force. 

• They might face some difficulty to jack up their car safely as some jack would not work as expected in any ground condition as the car would be unstable once it has lifted as it would be lifted one side.

2. Proposed design "Specifications"- Features, Parameters

a. Dimensions of Structure 
    Not in use : 90cm (L) x 20cm (W) x 20cm (H)
    In use : 210cm (L) x 20cm x 20cm  [MAXIMUM EXTENSION-LONGEST ROD]

b. Weight of Structure
    
    10 kg

c. Lifting Capacity

    Min:  <= 5 ton
    Max: 5 ton 

d. Colour
   
    Comes in 2 : Red Black, Blue Black, 

e. Material

   Stainless steel Type 304


3. Expected Outcome

    Efficiency: will be updated
  
     Cost : Approximately RM 350

     




    


 


    

DEVELOPMENT PHASES (DP) -PHASE 1

PHASE 1: RECOGNIZATION OF NEEDS

• ISSUE/PROBLEM STATEMENT
  • Why did we came up with a double car jack?
    • TO overcome major problem of lifting vehicle in automobile industry
      • Labor problem
      • Huge effort
      • Uneven ground condition
      • Save time
      • Make it convenient for use

• SCOPE OF WORKS
  • This project was done based on the mechanism of hydraulic power system method, fabrication processes of marking out, cutting, assembling and finishing were employed where necessary. All the analysis and results such as the required torque and gearing ratio which are important in this project where all determined before the development and incorporations. This project entirely designs hydraulic jack by incorporating a motor and double hydraulic jack all together in order to make load lifting easier and safer. In this design, the plunger is actuated through a connecting gear with the pinion gear when electrical power flows through the lighter receptacle connected to the motor, plugged to the automobile battery source to generate power for the prime mover (motor), which transmits its rotating speed to the pinion gear meshing with the bigger gearconnected to the plunger lever to be oscillated with required speed reduction and increased torque to drive the hydraulic piston totally displacing manual handling of hydraulic jacks. It works on the mechanism of converting rotary motion of the motor into reciprocating motion of the hydraulic jack plunger. 

• OBJECTIVES
  • To design and implement a safe car jack system which is stable in all conditions and is usable all the time.
  • To reduce time for the handlers and energy consumption for the users especially for the elderly and woman as it is designed to be operated automatically through motor.
  • To come up with a specific machine for lifting cars which is portable and economical which would make it easy for all the people to own one and use them when it is needed.

PROPOSAL & SLIDES

To get the project done and to carry on with the next step in our task, proposal on the topic of our project and a brief explanation on it as well as a short presentation on the proposal is needed. Therefore we have prepared our slides and proposals. Click on the link below to view or proposal and powerpoint slides.

PRESENTATION SLIDES: https://drive.google.com/file/d/0B5RCdxDiYP4JRzNTQ3JGcHpYam8/view?usp=sharing

PROPOSAL:https://drive.google.com/file/d/0B5RCdxDiYP4JM3I3enBoMVREV2s/view?usp=sharing

PROJECT CONCEPT

The motorized hydraulic jack system has been designed with the application of the power window system and hydraulic fluid. It has the ability to lift cars easily and safely at any ground condition without much time.

This motorized hydraulic jack works with two cylinders (a large and a small one) are connected and force is applied to one cylinder, equal pressure is generated in both cylinders.

However, because one cylinder has a larger area, the force the larger cylinder produces will be higher, although the pressure in the two cylinders will remain the same. Hydraulic jacks which is to be designed works and depend on this basic principle to lift heavy loads and it is operated with a power window system.

The machine to be designed consist of:

MOTOR-Make the jack work automatically once the switch is turned on. Uses the same principle as the power window system.

HYDRAULIC FLUID-To convey power to lift the car. Force is transferred through the pressure and area of the jack via the fluid exist.

ROD-Extendable rod to extend the needed length according to the size of car. Portable and easy to keep in car.

SWITCH-To turn on and off the motor so that the jack works. Separate switch to lift car up and down.

CYLINDER-Two separate bottle cylinders with two cylinder in each side of the hydraulic jack.

COMPRESSOR-To fill in air in the spare tire in case of emergency when changing punctured tires.

TOOL SPACE

CURIOUS TO KNOW HOW WOULD IT LOOK LIKE?

SCROLL !!

SKETCH OF THE PORTABLE MOTORIZED DOUBLE HYDRAULIC CAR JACK

AN OVERVIEW ON THE PROJECT- DOUBLE CAR JACK

One of the major problems with the servicing and maintenance of an automobile is in lifting the vehicle for many purposes specially to check lower parts of the car in details and also to change tires.

As a user, we would usually have the conventional device which is the screw jack in our car in case of emergency; this would cause some difficulty in lifting the car for reconditioning especially for the women and elderly users.

In current market and in conventional practice of automobile industry, bottle jack and screw jack is widely used. It lifts the car on the side where the work is to be done. This takes time as the mechanic or handler needs to change tire one by one on each side or need to lift car one side by another if necessary

SO, WHAT ARE WE GOING TO DO ?

• Design and implement a safe car jack system which is stable in all conditions and is usable all the time.
• Reduce time for the handlers and energy consumption for the hydraulic jack users especially for the elderly and woman as it is designed to be operated automatically through motor.
• Come up with a specific machine for lifting cars which is portable and economical which would make it easy for all the people to own one and use them when it is needed

A LITTLE INTRO ABOUT US

Hi there..!! We are Mechanical Engineering students from Faculty of Enginering (FOE) UNISEL currently enrolled in the subject Machine Design (KJS 3143) which is lectured by Prof. Madya Ir Muhidin Arifin. We have been given a task of designing a machine which is related to automobile servicing and maintenance. This project is to give exposure on designing as well as to overcome complex engineering problems in the field. So, what are we going to do? Let's take a look on the other posts for a clearer picture on it...:)

WHO ARE WE ??

SETHALA

NATASHA

RAZIHAN

AMIRUL