MOTORIZED

HYDRAULIC JACK

INTRODUCTION

INTRODUCTION

This is a self – assessment test on the part of the students to assess his

competency in creativity.

During the course of study, the student is put on a sound theoretical

foundation of various mechanical engineering subjects and of course, to a

satisfactory extent. Opportunities are made available to him to work on different

kinds of machines, so that he is exposed to various kinds of manufacturing process.

As a students learn more and more his hold on production technology

becomes stronger. He attains a stage of perfection, when he himself is able to

design and fabricate a device.

This is the project work. That is the testimony for the strenuous training,

which the student had in the institute. This assures that he is no more a student, he

is an engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and

testing.

SYNOPSIS

SYNOPSIS

According to the current situation, scarcity of LABOUR , SALARY, and for

automatic operation elimination of labour work is neccessory for the future days.

In current situation , car tyre is removed for repair work a jack is must and it is

operated by manually and not so easy to handle. Thus to tackle both situation

which is mentioned above. So we selected “MOTORISED HYDRAULIC JACK

”. The working of MOTORISED HYDRAULIC JACK is described below,

It consist of DC motor. The electric power is used to run the motor by the

help of 12 Volt DC supply . One end of jack lever is connected to Dc motor

output shaft through the crank wheel. . The power from the dc supply is given to

electric motor from the 12V DC power supply..

.

Thus, by introducing this project on market dual advantage is obtained one

is the easy operation is made and usage of manual work is avoided..

ADVANTAGES

1. Single person is enough to operate this efficiently to lift the tyre.

2. Easy and efficient handling of this unit without wastage or damage to any

other parts.

3. Increase the unit life.

4. Least maintenance of the equipment.

5. Need not require any individual work place.

6. Can be worked in the work spot.

COMPONENTS USED FOR DIGITAL HYDRAULIC JACK

S.NO COMPONENTS USED

MATERIAL SIZE QUANTITY

1 M.S.FABRICATED BASE 8MM THICKPLATE

MILD STEEL 200X200X8MM (WXHXD)

1

212VDC MOTOR WITH BUILT IN SPEED REDUCTION GEAR BOX

ALUMINIUM 10KG TORQUE

1

3 CRANK DISC MILD STEEL 70MM DIA X8MM THICK

1

4 ELECTRICAL CONTROLPOWER SUPPLY

COPPER 3 AMPS 1

5 HANDLE MILD STEEL 12MM DIA1

6 HYDRAULIC JACK MILD STEEL 2 TON CAPACITY

1

7 METAL PRIMER PAINT ½ LITRE 1

CONSTRUCTION

CONSTRUCTION

The projects consists of

1. M.S . BASE FRAME

2. HYDRAULIC JACK

3. 12 VDC POWER SUPPLY

4. 12 VDC motor.

5. ELECTRIC POWER SUPPLY .

4. 12 DC Motor

This DC motor is shunt type 12 DC motor. It has high torque and low speed

capacity. The DC Motor drives transmitted to the handle of the jack.

. This motor is having built in type speed reduction gear box unit. It has high

torque and low speed capacity. The electrical supply to the motor is from 12 V DC

power supply.

2.Crankand connecting rod mechanism;

A crankshaft has one (or more) offset sections where a connecting rod is

attached around it. The connecting rod moves back-and-forth (or up-and-down)

ONCE for every rotation of the crankshaft. The crank will always move in a circle,

moving the connecting rod in a smooth sine wave like motion. The power can flow

in either direction.

3.Frame Stand

This base frame stand made in 25mm size x 1.8mm thick M.S.square tube

material base plate and is used to hold the entire mechanism and support the

motor also.

WORKING PRINCIPLE

WORKING PRINCIPLE

The working principle of this MOTORISED HYDRAULIC JACK is explained in

block diagram

This MOTORISED JACK has one 12 VDC motor. This DC motor drive is

transmitted to the jack unit through the CRANK mechanism .. The vehicle tyre ias

Power supply

12 VDC

230 V AC

12VDC MOTOR

HYDRAULIC JACK

lifted up and down by pressing the switch in the panel board. The 12 V DC supply

is supplied from the 12 V DC motor. The vehicle tyre is moved up slowly

without any sack .

PRINCIPLE OF DC MOTOR

PRINCIPLE OF DC MOTOR

A DC motor is a dc machine working as a motor to convert dc electrical

energy into mechanical energy (dc) motor are very commonly used in cars, trucks,

aircrafts, etc. They are also used in large ratings, where wide range of speed

control is necessary.

When a conductor is carried a current and in lying in magnetic filed. Force

acting on the conductor. This is the principle of a Dc motor. The conductor is

housed in armature slots and current is applied from the dc source through brushes

and commutator. The field poles provide the magnetic field.

The construction of dc motor and generator are similar. However their

external appearance may be somewhat different. A motor has a rather closed

frame because it is may be operating in dusty environment and unskilled workers

may be working in its vicinity.

TYPES OF DC MOTOR

TYPES OF DC MOTOR

DC Shunt Motor:

This motor has medium starting torque, a speed regulation of 5 – 10 % and

excellent adaptability to adjustable speed service. It can be used for constant speed

drives like pumps, fans blowers, etc,. However for all these applications, a 3 phase

induction motor is preferable, because it ;is cheaper, more rugged and requires

lesser maintenance than dc motor. However a dc shunt motor is cheaper for low

speed drives. Moreover, whenever a wide range of speed control is required, dc

shunt motor is used. The main application of dc shunt motor is in steel and

aluminium, rolling mills and ward – Leonard speed control system.

Dc Series Motor:

This motor has a very high starting torque. Moreover it speed decreases

with increase in load torque. So that its power input remains more or less constant.

It is best suited for hoist cranes and traction. Speed control is generally obtained

through armature control. They are used for battery-powered vehicles.

Compound Motor:

A differential compound is rarely used. The characteristics of a cumulative

compounds motor depend on the relative strength of series and shunt fields. It has

good starting torque and dropping speed – load characteristic. They can be used

for pulsating loads needing flywheel action, viz. shears, conveyors, crushers,

hoists, plunger pumps, etc., Whenever the supply voltage is likely to vary

considerably, a compound motor is preferred. Because its induction and

contribution to back emf, the series field helps in reducing the fluctuations of

current drawn from mains.

POWER SUPPLY UNIT

INTRODUCTION:

All the electronic components starting from diode to Intel IC’s only work

with a DC supply ranging from +5V to +12V. We are utilizing for the same, the

cheapest and commonly available energy source of 230V-50Hz and stepping

down, rectifying, filtering and regulating the voltage.

STEP DOWN TRANSFORMER:

When AC is applied to the primary winding of the power transformer, it can

either be stepped down or stepped up depending on the value of DC needed. In our

circuit the transformer of 230V/15-0-15V is used to perform the step down

operation where a 230V AC appears as 15V AC across the secondary winding.

Apart from stepping down voltages, it gives isolation between the power source

and power supply circuitries.

RECTIFIER UNIT:

In the power supply unit, rectification is normally achieved using a solid

state diode. Diode has the property that will let the electron flow easily in one

direction at proper biasing condition. As AC is applied to the diode, electrons only

flow when the anode and cathode is negative. Reversing the polarity of voltage

will not permit electron flow. A commonly used circuit for supplying large

amounts of DCpower is the bridge rectifier. A bridge rectifier of four diodes (4 x

IN4007) are used to achieve full wave rectification. Two diodes will conduct

during the negative cycle and the other two will conduct during the positive half

cycle, and only one diode conducts. At the same time one of the other two diodes

conducts for the negative voltage that is applied from the bottom winding due to

the forward bias for that diode. In this circuit due to positive half cycle D1 & D2

will conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of

100Hz. Since each alteration produces a resulting output pulse, frequency = 2 x 50

Hz. The output obtained is not a pure DC and therefore filtration has to be done.

The DC voltage appearing across the output terminals of the bridge rectifier

will be somewhat less than 90% of the applied rms value. Normally one alteration

of the input voltage will reverse the polarities. Opposite ends of the transformer

will therefore always be 180 degree out of phase with each other. For a positive

cycle, two diodes are connected to the positive voltage at the top winding.

FILTERING CIRCUIT:

Filter circuits which is usually capacitor acting as a surge arrester always

follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a

bypassing capacitor, is used not only to ‘short’ the ripple with frequency of 120Hz

to ground but also to leave the frequency of the DC to appear at the output. A load

resistor R1 is connected so that a reference to the ground is maintained.

DETAILS OF

HYDRAULIC JACK;

DETAILS OF HYDRAULIC JACK;

HYDRAULIC JACK

A Hydraulic Jack or for that matter any device using Hydraulic Power in its

simplest possible shape consists of five fundamental components.

A. The Hydraulic Reservoir storing the Hydraulic Oil (Oil is used as the

medium to transmit force and motion-such fluids are called Hydraulic Oils)

should be thoroughly clean, whether integrally built-in or used as a separate

tank.

B. Pump, either of the integral or the remote control type, comprises of highly

precision engineered pump plunger, cylinder, suction and delivery valves,

safety valves with conical or steel balls matched with micron tolerances.

Very often O Rings and special seals are used, made from specially treated

leather or synthetic nitrile rubber or Teflon or other modern substitutes for

greater resistance to wear and sealing ower.

It is imperative that these must function at peak efficiency by regular

cleaning and flushing of foreign particles which enter into the hydraulic

system and may clog the delicate valves, damage the seals and affect the

functioning of other elements in the hydraulic circuit.

C. A pump by itself would be useless without a system of VALVES to govern

the flow of hydraulic oil to perform the desired function.

D. The transmission of hydraulic oil from the reservoir by the pump through the

valves to Ram & Cylinder which converts the hydraulic pressure into a

mechanical force is by means of a Hydraulic Circuit which is nothing but a

network of passages in hydraulic systems. These passages are formed with

the help of Steel Tubes, Flexible Hydraulic Hoses or through internal holes

or cavities in metal blocks. It is of the utmost importance that the circuit is

always leak proof as well as free from obstacles. Each joint or coupling

must be securely tightened or replaced forthwith. No air lock or foreign

particles should be allowed to interrupt or block the free flow of hydraulic

oil.

E. All hydraulic cylinders consists of two basic elements – the outer housing is

called the Cylinder body and the inner sliding elements is called the Ram

(or piston or plunger) which actually converts the hydraulic pressure into

mechanical force and transmits to the desired point for performing the

function. The movement of Ram is always in line with cylinder under

pressure.

Hydraulic Oil is pumped into the cylinder and as more and more oil is forced

into the cylinder pressure builds up and when enough oil is forced into the

cylinder the resultant pressure will cause the ram, plunger or piston to move

and consequently lift, press, push, pull or bend any object any object as the

case may be.

The Ram and Cylinder are also precision engineered and mostly fitted with

high quality seals which give it the necessary compression holding capacity

and prevent leakages.

The five fundamental components already illustrated and described

combined together perform the specified job by a synchronous follow

through of their individual functions.

1. The release valve is closed tightly to ensure flow of oil from the pump to the

cylinder only.

2. As soon as the pump is operated oil is sucked in from the reservoir. As the

Pump Plunger is raised up oil passes from the reservoir into the pump

cylinder with the Suction Valve opening up to allow oil from reservoir to

enter into pump cylinder.

3. When the Pump Plunger is pressed down the Delivery Valve opens up to

allow the passage of oil from the pump into the cylinder, at the same time

the suction valve automatically closes to prevent oil returning to the

reservoir.

4. By repeating the above two operations successively more and more oil is

pumped into the cylinder resulting in the generation of pressure by the action

of the load being lifted.

5. When the load is desired to be lowered the pressure within the cylinder is

released by operating the Release Valve. The oil flows back into the

reservoir shown in the diagram in page 1.

6. Due to neglect or other causes pressure within the system may continue to

increase beyond the predetermined safe working limit. To prevent damage to

the system a safety relief valve is located between the cylinder and the

reservoir excessive pressure by the opening up of the safety valve and

discharge of oil into the reservoir (very often the safety overload preventive

relief valve is located in between the reservoir and the pump – the pump

automatically cuts off without delivery of oil to the cylinder due to

generation of excessive pressure within the pump).

The simple diagram shown in page 1 shall help to understand the working of

the hydraulic system in a more graphic manner.

ADVANTAGES

ADVANTAGES

7. Single person is enough to operate this efficiently to remove the tyre.

8. Easy and efficient handling of liner puller without wastage or damage to the

tyre and to any other parts.

9. Increase the puller life.

10.Least maintenance of the equipment.

11.Need not require any individual work place.

12.Can be worked in the work spot.

13.Suited for lifting load.

MECHANICAL SPARE

PARTS DIAGRAM

SAFTY,CARE AND

MAINTENANCE

BASIC SAFETY RULES FOR HYDRAULIC JACKS;

The nature of lifting operation should determine the choice of jacking equipment-

integral or remote control pump type jacks. Capacity and the hydraulic lifting

stroke are vital aspects to be carefully determined before selection.

Lifting any load calls for precise and safe jacking points. Jack should be centrally

loaded eccentric loading causes dangerous accidents and damages beyond repair.

The world over prudent safety minded operators observe the flowing basic safety

rules :

A. To overpower the load, whether one or a dozen cylinders are used to lift the

load, the cylinder lifting capacity should be two times the weight of the load.

This allows for a reduction in the oil pressure, prevents strain and possible

break-down of the cylinder.

B. To balance the load, for large, heavy and uneven loads, it is recommended

dividing the load evenly between a number of cylinders. These cylinders

should be placed beneath the load at points providing the best support, balance

and stability. For example, to lift a 200-tonns load, the necessary 400-tonnes

capacity could be handled by four 100-tonnes cylinders.

C. Never raise the hydraulic ram beyond the specified stroke (lift).

D. Never drop (shock) load on the hydraulic ram.

E. Never go under a load supported by hydraulic ram only.

F. Never extend the hydraulic ram by means other than the pump.

G. Never use hydraulic equipment with observed leakages.

H. Use safety lock nut type jacks for supporting load on jack for long periods.

I. Use steel plates or heavy wooden sleepers where ground surface is soft and

yielding

J. Do not disturb the factory preset internal safety valve provided for preventing

overloading.

K. Do not load more than 50% of the rated head capacity on the toe (claw) of toe

lifting jacks.

Positioning the Jack

Jack should be centrally loaded, jack base and upper jacking point must be in level.

Raising the Jack

Turn the release valve in clockwise direction till tight, use end of slotted operating

handles. Start pumping with a regular handle movement. Make only few fast and

rapid download delivery strokes, Jack handle slightly downward, in case the

delivery does not close instantly. Check that the saddles rests firmly against the

Jacking point.

Lowering the Jack

Turn the release valve SLOWLY anticlockwise.

Jack Storage

Retract ram completely, close oil filler, keep the Jack away in a safe clean place.

Caution

Do not use the Jack beyond rated capacity and lift mentioned on the name plate.

Making Jack ready for use

VANJAX Hydraulic Jacks are supplied ready for use. Unlock the release valve

half a turn and operate the pump few times to flush the hydraulic unit free from

airlocking.

DO’S AND DON’TS

Do’s Don’ts

Air venting is an important

precaution for the successful

performance of any hydraulic jack

or hydraulically operated device,

equipment or system.

Under no circumstances the

equipment should be used beyond

rated capacity or rated stroke. It is

in the interest of the user and for the

protection of his costly equipment to

ensure correct selection of the

capacity and restricting the stroke

within the rated stroke length.

All couplings and other fasteners

should be properly tightened.

Do not forcibly hammer fit

accessories if falling short by a

fraction of the required length or

spread. Use the next higher size

equipment. Abuse of accessories

and attachments are hazardous both

for the equipment and the personnel.

At all times the entire equipments

should be kept free from dust

through regular systematic cleaning.

Do not expose the equipment to

areas of excessive heat or where dirt,

dust and heavily laden fumes /

smoke are prevalent. If the

equipment is used in such areas it is

absolutely essential to service it at

once.

Check oil level each time before

use.

Do not refill without a reliable

strainer

Every time the hydraulic hose is

attached to the pump and the ram

cylinder assembly unit, it should be

thoroughly flushed.

Do not use brake fluid as refill.

Release valve to be properly

tightened by turning it in clock-wise

direction when applying load. For

releasing pressure open release

valve gradually by turning it in anti-

clockwise direction.

Do not hammer to open guide nuts.

Open by guide nut spanner.

The equipment must be centrally loaded. The pressure screw in a hydraulic puller should be absolutely perpendicular to the axis of the load.

Do not apply extra force to close the release valve. Normal hand pressure is enough.

As refill we recommend IOC Code No. Servo System 32 and 46, HPC Hydrol 0232 or any other equivalent.

Do not use fluffy cloth or cotton waste for cleaning cylinder ram, valve, pump and oil tank.

ADVANTAGES

ADVANTAGES

1.Single person is enough to operate this efficiently to lift the load.

2.Easy and efficient handling of this unit without wastage or damage to the

vehicle,machine and to any other parts.

3.low maintenance cost and life of equipment also increased..

4Least maintenance of the equipment.

5.Need not require any individual work place.

6Can be worked in the work spot.

7.Suited for lifting the any light load and heavy load vehicle for removing the

tyre..

DIS ADVANTAGES

1. CARE should be taken for maintenance of batteries..

2. Leakage of oil is not repairable one .

3. The spare parts for the hydraulic jack is not available.

PAINTING AND FINISHING

FINISHING AND PAINTING

JOB PREPARATION

Before welding, remove any bend in the L angle with the sludge hammer on

the anvil block. Then it is cut to the required length with the hacksaw blade and

fabricated to required dimensional shape with arc welding.

FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the chipping

hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed

with the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the metal

primer, the second coating is applied with the paint.

COST ESTIMATION

COST ESTIMATION

1. D.C. MOTOR 12 VDC 1600,00

2. hydraulic jack 1800.00

3 . M.S. Fabricaed housing unit 600.00

4. power supply 12VDC 1600.00

5. Painting cost 200.00

6. transport cost 200.0

TOTAL COST 6000.00

CONCLUSION

CONCLUSION

We make this project entirely different from other projects. Since concepts

involved in our project is entirely different that a single unit is used to various

purposes, which is not developed by any of other team members.

By doing this project we gained the knowledge of fabrication work and how

the welding is doing and material selection for particular components etc.,

It is concluded that any fabrication work can be done with the help of

welding.

We have successfully completed the project work on using welding work at

our Institute.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY -HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY -R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY -S.S.MANIAN

4. JIG AND FIXTURE DESIGN - R.K.JAIN

PHOTO VIEW

PHOTO VIEW