MOTORIZED POWER JACKPROJECT REPORT 2008-2009

Submitted by:

(team name)

Guided by:

Submitted in partial fulfillment of the requirement for the

Award of Diploma in -----------------------------------------

By the State Board of Technical Education Government of

Tamilnadu, Chennai.

Department :

College name:

Place:

COLLEGE NAME

COIMBATORE

DEPARTMENT

PROJECT REPORT-2008-2009

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No.------------ of VI Semester class of this college.

Guide Head of the Department

Submitter for the Practical Examinations of the board of Examinations,State Board of Technical Education,Chennai,

TamilNadu.On --------------(date) held at the ------------(college name),Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED PARANTS

ACKNOWLEDGEMENT

ACKNOWLEDGEMENTAt this pleasing movement of having successfully completed our project, we wish to convey our sincere thanks and gratitude to the management of our college and our beloved chairman------------------------.who provided all the facilities to us.

We would like to express our sincere thanks to our principal ------------------for forwarding us to do our project and offering adequate duration in completing our project.

We are also grateful to the Head of Department prof., for her/him constructive suggestions &encouragement during our project.

With deep sense of gratitude, we extend our earnest &sincere thanks to our guide --------------------, Department of Mechanical for her/him kind guidance and encouragement during this project we also express our indebt thanks to our TEACHING staff of MECHANICAL ENGINEERING DEPARTMENT, ---------- (college Name).NOMENCLATURENOMENCLATURE

= dia of the screw (mm)

L = Length of the base (mm)

W = width of the base (mm)

P =pitch of the screw thread (mm)

MOTORIZED POWER JACKCONTENTS

CONTENTS

CHAPTER NO TITLE

SYNOPSIS

LIST OF FIGURES

NOMENCLATURE

1 Introduction

2Literature review

3Description of equipments

3.1 Dc Motor

3.2starter

3.3rotor

3.4electromagnetic

3.5Scissor jack

3.6Battery

3.7Control unit

4Design and drawing

4.1Dc motor Specification

4.2General machine Specifications

4.3Design calculation

5fabrication

6Working principle

7Merits and demerits

8applications

9List of materials

10Cost Estimation

11Conclusion

Bibliography

photography

LIST OF FIGURES

LIST OF FIGURES

Figure

Number

Title

1Block Diagram

2Base

3Connector

4Motor

5Scissor jack

6Clamp plate

7Lead acid battery

8Overall diagram

SYNOPSIS

SYNOPSIS:This report deals with design and fabrications of motorized power jack which is used for lifting heavy automobiles, using the power from a dc motor. The project helps in reducing the effort as well as time taken to lift the load in comparison to the ordinary screw jack.

A jackscrew is a type of jack which is operated by turning a lead screw. It is also known as a screw jack, and is commonly used as car-jacks.

CHAPTER-1

INTRODUCTION

CHAPTER 1INTRODUCTION

A scissor lift (jack) or mechanism is device used to extend or position a plate form by mechanical means. The term scissor comes as from the mechanical utilized which is configured with linked, folding supports in a criss cross x pattern. The extension or displacement motion is achieved applying of force to one of the support resulting and an elongation of the crossing pattern, the force applied to extend the scissor mechanism may be hydraulic, pneumatic or mechanical (via a lead screw or rack and pinion system).

CHAPTER-2

LITERATURE SURVEY

CHAPTER-IILITERATURE SURVEY

Screw Jack:

When we are traveling in the road for a particular work, if suppose tyre get puncture it will be a big headache to remove the tyre and fixing up the stepney also it is not easy to lift the jack manually in the workshop. This makes the worker to get tired. Its all a tedious work for the worker. In order to overcome this problem we have designed and developed a system called motorized jack operating through keypad by having full control of the jack, we can easily lift it up and down by using the on/off. This helps to reduce the burden of the worker.A jackscrew's compressive force is obtained through the tension force applied by its lead screw. An Acme thread is most often used, as this thread is very strong and can resist the large loads imposed on most jackscrews while not being dramatically weakened by wear over many rotations. These types are self-locking, which makes them more intrinsically safe than other jack technologies like hydraulic actuators which require continual pressure to remain in a locked position. Most jackscrews are lubricated with grease.

Advanced screw mechanisms may use a recirculation-ball nut to minimize friction and prolong the life of the screw threads, but such jackscrews are usually not self-locking. The thread profile of such screws is semicircular, not trapezoidal as in an Acme thread.TYPES OF THREADS: British standard whitworth (B.S.W) thread British association (B.A) thread

American national standard thread

Unified standard thread Square thread

Acme thread

Knuckle thread

Buttress thread

Metric threadULTIMATE AIM

The motorized power jack can be widely used in low cost automation in manufacturing industries. The weight lifting is quick and effortless, which reduces the physical fatigue (tiredness) felt by the worker.

CHAPTER-3

DESCRIPTION OF EQUIPMENT

CHAPTER-III

DESCRIPTION OFEQUIPMENT

3.1 D.C MOTOR:The d.c generators and d.c motors have the same general construction.

MOTOR PRINCIPLE:

An electric motor is a machine which converts a electrical energy to mechanical energy.

All D.C machines have five principal components viz (i) Field system (II) armature core (iii) armature winding (iv) Commutator (v) brushes

(i) Field system:

The function of the field system is to produce Uniform field within which the armature rotates.it consists of a number of salient poles(of course, even number) bolted to the inside of circular frame (generally called yoke).the yoke is usually made of solid cast steel whereas the pole piece are composed of stacked laminations. Field coils are mounted on the poles and carry the d.c exciting current. The field coils are connected in such a way that adjacent poles have opposite polarity.

The m.m.f. developed by the coils produces a magnetic flux that passes through the pole pieces, the air gap, the armature and the frame. Practical d.c machines have air gaps ranging from 0.5mm to 1.5mm.since armature and field systems are composed of materials that have permeability, most of the m.m.f.of field coils is required to set up flux in the air gap. By reducing the length of air gap, we can reduce the size of field coils (number of turns).

(ii) Armature core:

The armature core is keyed to the machine shaft and rotates between the field poles. It consists of slotted soft-iron laminations (about 0.4 to 0.6mm thick) that are stacked to form a cylindrical core. The laminations are individually coated with a thin insulating film so that they do not come in electrical contact with each other. The purpose of laminating the core is to reduce the eddy current loss. The laminations are slotted to accommodate and provide mechanical security to the armature winding and to give shorter air gap for the flux to cross between the pole face and the armature teeth.

(iii) Armature winding:

The slots of the armature core hold conductors that are connected in a suitable manner.this are known as armature winding. This is the winding in which workinge.m.f. is induced.the

The armature conductors are connected inseries-parallel: the conductors being connected in series so as to increase the voltage and in parallel paths so as to increase the current.the armature winding of a d.c.machine is a closed circuit winding:the conductors being connected in a symmetrical manner forming a closed loop or series of closed loops.

(iv) commutator;

A commutator is a mechanical rectifier which converts the alternating voltage generated in the armature winding into direct voltage across the brushes.the commutator is made of copper segments insulated from each other by mica sheets and mounted on the shaft of the machine. The armature conductors are soldered to the commutator segments in a suitable manner to give rise to the armature winding.depending upon the manner in which the armature conductors are connected to the commutator segments, there are tow types of armature winding in a.d.c. machine viz(a) lap winding (b) wave winding.

Great care is taken in building the commutator because any eccentricity will cause the brushes to bounce, producing unacceptable sparking .the sparks may burn the brushes and overheat and carbonize the commutator.

(v) Brushes:

The purpose of brushes is to ensure electrical connections between the rotating commutator and stationary external load circuit. The brushes are made of carbon and rest on the commutator,the brush pressure is adjusted by means of adjustable springs. if the brush pressure is

Very large, the friction produces heating of the commutator and the bruches.on the other hand, if it is too weak, the imperfect contact with the commutator may produce sparking.

3.2 STATOR:The stator is the stationary part of an electric generator or electric motor. The non-stationary part on an electric motor is the rotor.

Depending on the configuration of a spinning electromotive device the stator may act as the field magnet, interacting with the armature to create motion, or it may act as the armature, receiving its influence from moving field coils on the rotor.

The first DC generators (known as dynamos) and DC motors put the field coils on the stator, and the power generation or motive reaction coils are on the rotor. This was necessary because a continuously moving power switch known as the commutator is needed to keep the field correctly aligned across the spinning rotor. The commutator must become larger and more robust as the current increases.

The stator of these devices may be either a permanent magnet or an electromagnet. Where the stator is an electromagnet, the coil which energizes it is known as the field coil or field winding.3.3 ROTOR:

The rotor is the non-stationary part of a rotary electric motor or alternator, which rotates because the wires and magnetic field of the motor are arranged so that a torque is developed about the rotor's axis. In some designs, the rotor can act to serve as the motor's armature, across which the input voltage is supplied. 3.4 ELECTROMAGNETIC COIL:

An electromagnetic coil is formed when a conductor solid copper wire is wound around a core or form to create an inductor or electromagnet. One loop of wire is usually referred to as a turn, and a coil consists of one or more turns. For use in an electronic circuit, electrical connection terminals called taps are often connected to a coil. Coils are often coated with varnish and/or wrapped with insulating tape to provide additional insulation and secure them in place. A completed coil assembly with taps etc. is often called a winding. A transformer is an electromagnetic device that has a primary winding and a secondary winding that transfers energy from one electrical circuit to another by magnetic coupling without moving parts. The term tickler coil usually refers to a third coil placed in relation to a primary coil and secondary coil. A coil tap is a wiring feature found on some electrical transformers, inductors and coil pickups, all of which are sets of wire coils. The coil tap are points in a wire coil where a conductive patch has been exposed. As self induction is larger for larger coil diameter the current in a thick wire tries to flow on the inside. The ideal use of copper is achieved by foils. Sometimes this means that a spiral is a better alternative. Multilayer coils have the problem of interlayer capacitance, so when multiple layers are needed the shape needs to be radically changed to a short coil with many layers so that the voltage between consecutive layers is smaller.

3.5 SCISSOR JACK:Here we are using the jack name scissor to work under the car to change wheels, it is necessary to lift the car for doing this a lifting jack is used which may be mechanically or hydraulically operated. Such a jack is a standard accessory with many cars. It consists of a diamond shaped frame having a nut and on one side and a sleeve on the other side. A screw is supported in the nut and the sleeve. Rotating the screw with a handle moves the nut towards or away from the sleeve depending upon the direction of the rotation, so that the vehicle supported on the jack is lifted or moved down. The jack is so designed that there is always sufficient friction in the screw to hold the jack from moving down under load. But we are using the motor to rotate the screw for lifting the vehicle. PARTS OF A JACK

SHAFT:

Its made up of mild steel. It is straight rod having a step on the one shaft. The shaft is placing for the motor arrangement and also for rotates the gear. The diameter of rod is 8mm for a length of 70mm.

SUPPORTING PLATE:

The plate is made up of m.s plate witch is placing below the belt. It is for to transmit the object to straight bath. It does not affect the belt to be of rest.

WORM GEAR:The worm gears are widely used for transmitting power at high velocity Ratios between non-intersecting shafts that are generally, but not necessarily, at right angles .it can give velocity ratios as high as 300:1 or more in a single step in a minimum of space, but it has a lower efficiency. The worm gearing is mostly used as a speed reducer, which consists of worm and a worm wheel or gear. The worm is usually of a cylindrical form having threads of the same shape as that of an involutes rack. The threads of the worm may be left handed or right handed and single or multiple threads. The worm wheel or gear is similar to a helical gear with a face curved to conform to the shape of the worm. The worm generally made of steel while the worm gear is made of bronze or cast iron for light service.

3.6 BATTERY:Battery is use for storing the energy produced from the solar power. The battery used is a lead-acid type and has a capacity of 12v; 2.5A.the most inexpensive secondary cell is the lead acid cell and is widely used for commercial purposes. A lead acid cell when ready for use contains two plates immersed in a dilute sulphuric acid (H2SO4) of specific gravity about 1.28.the positive plate (anode) is of

Lead peroxide (PbO2) which has chocolate brown colour and the negative plate (cathode) is lead (Pb) which is of grey colour.

When the cell supplies current to a load (discharging), the chemical action that takes place forms lead sulphate (PbSO4) on both the plates with water being formed in the electrolyte. After a certain amount of energy has been withdrawn from the cell,both plates are

Transformed into the same material and the specific gravity of the electrolyte (H2so4) is lowerd.the cell is then said to be discharged.there are several methods to ascertain whether the cell is discharged or not.

To charge the cell, direct current is passed through the cell in the reverse direction to that in which the cell provided current. This reverses the chemical process and again forms a lead peroxide (PbO2) positive plate and a pure lead (Pb) negative plate. At the same time,(H2so4) is formed at the expense of water,restoring the electrolyte (H2so4 ) to its original condition. The chemical changes that

Occur during discharging and recharging of a lead-acid cell.

BATTERY CIRCUIT DIAGRAM:

CIRCUIT DIAGRAM DETAILS:

In our project we are using secondary type battery. It is rechargeable Type. A battery is one or more electrochemical cells, which store chemical energy and make it available as electric current. There are two types of batteries, primary (disposable) and secondary (rechargeable), both of which convert chemical energy to electrical energy. Primary batteries can only be used once because they use up their chemicals in an irreversible reaction. Secondary batteries can be recharged because the chemical reactions they use are reversible; they are recharged by running a charging current through the battery, but in the opposite direction of the discharge current. Secondary, also called rechargeable batteries can be charged and discharged many times before wearing out. After wearing out some batteries can be recycled.Batteries have gained popularity as they became portable and useful for many purposes. The use of batteries has created many environmental concerns, such as toxic metal pollution. A battery is a device that converts chemical energy directly to electrical energy it consists of one or more voltaic cells. Each voltaic cell consists of two half cells connected in series by a conductive electrolyte. One half-cell is the positive electrode, and the other is the negative electrode. The electrodes do not touch each other but are electrically connected by the electrolyte, which can be either solid or liquid. A battery can be simply modeled as a perfect voltage source which has its own resistance, the resulting voltage across the load depends on the ratio of the battery's internal resistance to the resistance of the load. When the battery is fresh, its internal resistance is low, so the voltage across the load is almost equal to that of the battery's internal voltage source. As the battery runs down and its internal resistance increases, the voltage drop across its internal resistance increases, so the voltage at its terminals decreases, and the battery's ability to deliver power to the load decreases.

CHAPTER-4DESIGN AND DRAWING

CHAPTER-IV

DESIGN OF EQUIPMENT AND DRAWINGThe motorized power jack machine consists of the following components to full fill the requirements of complete operation of the machine.

Dc motor Screw jack

battery

4.2 general machine specifications:

Technical data:1.DC MOTORVoltage =12v DC

Rpm =30

Watts =18w

Length of the motor =170mm

Outer dia of motor = 60mm2.BASE OF JACKHeight of base =218 mm

Length of base =340mm

3.CLAMPERLength of clamp =83mm

Width of clamp =70mm

Thickness of clamp =1mm

General unit

Size of machine (L x H) : 700mm*350mm

4.3 CALCULATIONTo find out the power of the motor that can lift load of 750kg We know,Major Screw dia (do) =12mm

Pitch of screw ( p) = 3mm

Mean dia , d = do - p/2

= 12-3/2

d=10.5mm

tan =p/ d

tan=3/ x10.5 tan =0.091

Assuming co efficient of friction,tan =0.1

Load to be raised =750 kg W =7500N

P = effort required to raise the load P = W X tan (+)

= W X (tan + tan )/ (1-tanXtan ) = 7500 X (0.091 +0.1)/ (1-0.091X0.1)

=7500 X (0.191/0.99)

P =1440N

Torque required operating the screw

T=P X d/2

T =1440 X10.5/2T =7560 X10-3 NmSince the screw moves in the nut at a speed of 65mm/min of speed of revolutions is minute is,N =speed in mm/min/pitch in mm

N = 65/3(pitch)

=21.6 (22 rpm)

Power of the motors required,

P = T X Where is = 2 X X N/60

P = T X

P = 7560 X10-3 X 2 X X 22/60 P = 17.41 watts

DRAWING

PNEUMATIC MOTORIZED POWER JACK

Chapter-5FABRICATION

CHAPTER-V

FABRICATION

METHOD OF FABRICATION:

Here the motorized power jack is worked with the help of motor. The name of jack is scissor jack To carry the vehicle load for working in the automobile workshop and in the service station. Chapter -6

WORKING PRINCIPLE

CHAPTER-VI

WORKING PRINCIPLEWe have used ON/OFF switch in this project; the on/off switch keys are interface with control circuit with battery. And we are connecting the DC motor with the mechanical model for the up and down movement. When we switch ON, it will send a high pulse to control circuit then the control circuit activates the corresponding relay to rotate the DC motor in forward direction, so that the jack will move up. When we switch OFF, it will also send a low pulse to the control circuits its activating relay to rotate the DC motor in reverse direction so the jack will move down. Using this we can lift the load using power jack without human effort. CHAPTER -7

MERITS AND DEMERITSCHAPTER-VII

MERITS AND DEMERITSMERITS

Low cast. Easy to work and reduces the manual stress. Reduce the manpower Small size Low power consumptionDEMERITS

There is power loss due to friction since it has rotating components It needs maintenance and periodic lubricationChapter-8

APPLICATIONS

CHAPTER-VIIIAPPLICATIONS

It is using for In all automobile industries

Material transportation application

Used in weight lifting.CHAPTER-9

LIST OF MATERIALSCHAPTER-IX

LIST OF MATERIALSFACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed below.1. Properties:

The material selected must posses the necessary properties for the proposed application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance, impact resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

Cast ability

Weld ability

Surface properties

Shrinkage

Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities obtainable by the application of suitable coating substances may demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material. For example, it would never be desirable to go casting of a less number of components which can be fabricated much more economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply.it then becomes obligatory for the designer to use some other material which though may not be a perfect substitute for the material designed.the delivery of materials and the delivery date of product should also be kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the forces involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an important part and should not be ignored.

Some times factors like scrap utilization,appearance,and non-maintenance of the designed part are involved in the selection of proper materials.

S.NoDESCIRPTION QTYMaterial

1Dc motor1Cast iron

2Jack plate4Mild steel

3Screw rod1Mild steel

4Base 1Mild steel

5Control unit1Electronic

7 Angle plate 3Mild steel

8Supporting plate1M.S

Chapter-10COST ESTIMATION

Chapter-x

COST ESTIMATION1. MATERIAL COST.S.NoDESCIRPTION QTYMaterialAMOUNT (Rs)

1Dc motor1Cast iron

2Jack plate4Mild steel

3Screw rod1Mild steel

4Base 1Mild steel

5Control unit1Electronic

7 Angle plate 3Mild steel

8Supporting plate1M.S

2. LABOUR COST:

Lathe Drilling

welding

Grinding

Power hacksaw

gas cutting cost 3. OVERGHEAD CHARGES:

The overhead charges are arrived bymanufacturing cost

Manufacturing Cost =Material Cost +Labour Cost

=

=

Overhead Charges =20%of the manufacturing cost

=

4.TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

=

=

Total cost for this project =Chapter-11

CONCLUSION

CHAPTER-XICONCLUSION

The project carried out by us made an impressing task in the field of automobile and automobile workshops. It is very usefully for the workers to work in the automobile workshop are in the service station.

This project has also reduced the cost involved in the concern. Project has been designed to perform the entire requirement task which has also been provided.BIBLIOGRAPHYBIBLIOGRAPHY

1. Design data book

-P.S.G.Tech.

2. Automobile Engineering Dr. Kirpal singh (vol- 1&2)3. Machine tool design handbook Central machine tool Institute,

Bangalore.

4. Strength of Materials-R.S.Kurmi

5. Manufacturing Technology-M.Haslehurst.PHOTOGRAPHY

COLLEGE LOGO