HYDRAULIC FORKLIFT

PROJECT 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

PLACE

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

Submitted for the Practical Examinations of the board of Examinations, State Board of Technical Education, Chennai, and TamilNadu. On -------------- (date) held at the ------------ (college name), Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED PARENTS

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At 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 professor., 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).

HYDRAULIC FORKLIFT

CONTENTS

CONTENTS

CHAPTER NO TITLE

SYNOPSIS

LIST OF FIGURES

1Introduction

2Literature review

3Description of equipments

3.1Hydraulic bottle jack

3.2Wheel

3.3Loading plate

4Design and drawing

4.1Drawing for hydraulic forklift

5Working principle

6Merits & demerits

7Applications

8List of materials

9Cost Estimation

10Conclusion

BIBLIOGRAPHY

PHOTOGRAPHY

LIST OF FIGURES

LIST OF FIGURES

Figurenumber

Title

1Drawing for hydraulic forklift

SYNOPSISSYNOPSISIn this project we are designed in pallet truck. It is operated by hydraulic method. It is a hand operated. It is very useful for loading and unloading for warehouse and platform places.CHAPTER I

INTRODUCTION

CHAPTER I

INTRODUCTION

A forklift (also called a lift truck, a high/low, a stacker-truck, trailer loader, side loader or a fork hoist) is a powered industrial truck used to lift and transport materials. The modern forklift was developed in the 1920s by various companies including the transmission manufacturing company Clark and the hoist company Yale & Towne Manufacturing. The forklift has since become an indispensable piece of equipment in manufacturing and warehousing operations.HISTORY

The middle 19th century through the early 20th century saw the developments that led to today's modern forklifts. The Pennsylvania Railroad in 1906 introduced battery powered platform trucks for moving luggage at their Altoona, Pennsylvania train station. World War I saw the development of different types of material handling equipment in the United Kingdom by Ransomes, Sims and Jeffries of Ipswich. This was in part due to the labor shortages caused by the war. In 1917 Clark in the United States began developing and using powered tractor and powered lift tractors in their factories. In 1919 the Towmotor Company and Yale & Towne Manufacturing in 1920 entered the lift truck market in the United States.Continuing development and expanded use of the forklift continued through the 1920s and 1930s. World War II, like World War I before, spurred the use of forklift trucks in the war effort. Following the war, more efficient methods for storing products in warehouses were being implemented. Warehouses needed more maneuverable forklift trucks that could reach greater heights. New forklift models were made that filled this need. In 1956 Toyota introduced its first lift truck model, the Model LA, in Japan and sold its first forklift in the United States in 1967.CHAPTER II

LITERATURE REVIEW

CHAPTER II

LITERATURE REVIEW

HYDRAULICS

The word "hydraulics" originates from the Greek word (hydraulikos) which in turn originates from (hydraulos) meaning water organ which in turn comes from (hydor, Greek for water) and (aulos, meaning pipe).

Hydraulics Lauras bum is huge is a topic of science and engineering dealing with the mechanical properties of liquids. Hydraulics is part of the more general discipline of fluid power. Fluid mechanics provides the theoretical foundation for hydraulics, which focuses on the engineering uses of fluid properties. Hydraulic topics range through most science and engineering disciplines, and cover concepts such as pipe flow, dam design, fluidics and fluid control circuitry, pumps it ups, turbines, hydropower, computational fluids called dynamics, flow measurement, river channel behavior and erosion. However if used incorrectly, hydraulic instruments can result in weird occurrences because of the nature of high pressure fluids.

HYDRAULIC POWERHydraulic fluids are a large group of fluids used as the motive medium in hydraulic machinery. Fluid types include synthetic compounds, mineral oil, water, and water-based mixtures. The fluids are found in machinery and equipment ranging from brakes, power steering systems, and transmissions to backhoes, excavators, garbage trucks and industrial shredders. Hydraulic systems are very common in aircraft flight control systems. Fluid is a medium of power transmission in a hydraulic system, mineral or petroleum oils of various grades are used as the certain service properties for maximum power transmission. They are;

VISCOSITYViscosity of oil is defined as the resisting property of the fluid to its flow. Thick oil is possessing high viscosity whiles a thin oil low viscosity. Viscosity is an important property of the fluid. If the viscosity of the fluid is more than required, then

1. The fluid may find it difficult to flow through the minute clearance between the matting parts

2. The consumption of power will be more, to overcome the internal friction.

3. The temperature of the system will be increased due to internal friction.

Similarly if the fluid is having low viscosity than required then:

1. Leakages will be more. Thus there will be wastage of oil.

2. The system pressure reduces due to leakage and hence the power transmitted is reduced.

Therefore, fluid used in the system possesses a specified viscosity range, which will assure maximum results.

VISCOSITY INDEX

One of the property of the hydraulic oil that it must retain the same viscosity at all temperatures. But the viscosity of oil changes with system temperature. The rate of change of viscosity, corresponding to the change in temperature is known as viscosity index. It is measured on, an arbitrary scale. If the change in viscosity is very very small, for a particular change in temperature, then that oil is represented by a maximum valve of viscosity index.

If the change in viscosity of oil is considerable, even for a small change in value of its temperature then that oil is represented by a minimum valve of then that oil is represented by a minimum valve viscosity index. The higher the numerical of this index the smaller is the change in viscosity, corresponding to a given change in temperature and vice versa. Hence, the oil having higher viscosity index is preferable to use it in a hydraulic system.

DE- EMULSIBILITY:

The capacity of the oil to separate rapidly and completely form water is know as de- emulsibility. The property resists emulsification (mixing of oil with water). This property is important to avoid foaming.

OXIDATION STABILITY:

Oxidation is taken place due to chemical action between oil and oxygen. When oxidation of oil taken place, impurities like insoluble gum, sludge, soluble acidic oil is depending on this property. Oxidation stability is defined as the fluids ability to resist oxidation. Complete prevention of oxidation is impossible but it can be reduced by adding additives.

LUBRICITY:

It is defined as the capacity of the oil to lubricate the moving components. If there is wear, clearance will be increased, which will then produce noises and vibrations. So, while selecting the oil care is taken, to select suitable oil which lubricates the moving parts effectively.

REST AND CORROSION PREVENTATION:

The moisture entering into the system along with the air produces rusting. This rust if passed through the precession components like valves, pumps may scratch the surface. The oil selected to the hydraulic system must have a capacity to resist rust and corrosion.

FLASH, FIRE AND CLOUD POINT:

The lowest temperature of the hydraulic oil at which the oil vapour ignites momentarily, when a frame is introduced, is know as flash point. The lowest temperature, at which the oil vapour continuously burns, when a flame is introduced, is known as fire point of the oil. The lowest temperature at which the hydraulic oil crystallises into wax is known as cloud point.

The system temperature will be raised due to friction heat developed in the moving part. If the temperature of the system is more than that of flash and fire point, then there will be a danger of firing. Similarly if the temperature is attaining the cloud point, waxes are formed which may clog the narrow passages. Therefore the oil selected for a hydraulic system, must have suitable flash, fire the cloud point.

ADVANTAGES AND DISADVANTAGES OF A HYDRAULIC SYSTEM:

ADVANDAGES:

It is more compact and eliminates the mechanical complicated linkages like gears, cams and levers.

It does not require any lubrication as a result wear and tear of the moving components are considerably reduced.

The hydraulic system components are connected by pipeline. Hence it provides flexibility in locating the components at any desired place.

By varying the quantity of oil by means of a valve any amount of step-less speed can easily be obtained.

The oil used in the system, provides cushioning effect for the shock loads. Hence the life of the components is increased.

Very large forces can be easily obtained and force multiplication is also possible with the minimum changes and losses

Whenever the hydraulic systems are over loaded the pressures are immediately relieved, thus the system components are protected against the breakages and overstrain.

The hydraulic oil is incompressible, hence the system is very sensitive for instantaneous operations, and thus backlashes in mechanical system will not exist in hydraulic system.

This system requires very simple maintenance cares

The heat generated in the bearings and moving parts are carried away by the oil itself. Thus the system does not require any cooling arrangements.

The system provides quick return motion of the components with the simple arrangements, thus idle time of machining operations are reduced

The hydraulic system provides very high degree of dependability.

DISADVANTAGES:

Since the hydraulic fluid is transmitted through pipe lines under pressure there is a greater possibility of leakages

Leakage of fluid reduces the force, thus sometimes system fails

Leakages are always there, which makes the machines ugly and dust and dirt adhering to them

The life of the parts like seals, packing and gaskets etc., are very short, but they are essential to prevent leakages

The oil cost is fluctuating and hence the system becomes costlier

CHAPTER III

DESCRIPTION OF EQUIPMENTS

CHAPTER III

DESCRIPTION OF EQUIPMENTS3.1. HYDRAULIC BOTTLE JACK

Bottle jacks are hydraulic jacks that are placed in a horizontal position. These jacks push against a lever, which lifts the main lift arm. Bottle jacks have a longer handle than most hydraulic jacks, however, and it is possible to get more lift per stroke with the increased leverage they provide when compared to regular models of jacks. Bottle jacks are versatile because their horizontal position makes it possible to place them in tight spots and provides good leverage. Recently bottle jacks have proven useful in search and rescue missions following earthquake damage. As a result, bottle jacks are standard equipment in firehouses and for search and rescue teams. They are also used for lifting, spreading, bending, pushing, pressing, or straightening requirements. The base and cylinders of bottle jacks are electrically welded for strength, and all models are capable of working in upright, angled, or horizontal positions.1 SAFETY INSTRUCTIONS

1.1 Park the vehicle or load to be lifted on a flat firm surface and place wedges under the wheels to stop movement.

1.2 Position de jack on a solid, even and horizontal surface, never use the jack on a slope.

1.3 The jack should be positioned so as to avoid the user from having to operate it under the vehicle. Every vehicle lifted by a jack should always have a secondary safety support such as mechanical stands.

1.4 It is imperative that all possible precautions are taken to avoid unexpected movement of the load when it is being lifted.

1.5 The load to be lifted should never exceed the rated capacity of the jack.

1.6 Never operate the jack beyond its maximum stroke.

1.7 If these basic rules are not followed, injury to the user, the jack or the load being lifted may result.

1.8 As an additional safety feature the jack is equipped with a valve to prevent the unit from being overloaded. This unit is factory set and must no be tampered with.2. USE AND OPERATION

2.1 Before operating the jack you must purge its hydraulic circuit in order to eliminate any possible air in the system. To purge the system open the release valve, turning it anti-clockwise. Then with the aid of the lever operate the pump several times.

2.2 Close the release valve with the lever in a clockwise direction until it is fully closed. The jack is now ready for use.

2.3 To lower the jack, turn the release valve very slowly in an anti-clockwise direction.

2.4 Always keep the jack in vertical position, with the ram, extension screw and pump retracted after use.

2.5 If you require operating the jack in a horizontal manner the pump should be located on the lower side of the jack.

3. MAINTENANCE

3.1 Lubricate all moving parts at regular intervals.

3.2 Always keep the jack clean and protected from aggressive conditions.

3.3 If you have to replace the oil, the correct volume is indicated in the parts list. Make sure the piston is fully retracted.IMPORTANT: An excess of oil will render the jack inoperative.

3.4 Use only hydraulic oil, type HL or HM, with an ISO grade cinematic viscosity of 30 c St at 40 C or an Engler viscosity of 3 at 50 C.VERY IMPORTANT: Never use brake fluid.

3.5 When ordering spare parts, please make note of the part number as shown in the exploded view drawing provided. A repair kit is available containing all the common spare parts.

4. REPAIR

Both maintenance and repair of this jack shall be carried out by qualified persons who on base of their education and experience have enough knowledge in jacks and associated equipment.3.2. BOTTLE3.3. LOADING PLATECHAPTER IV

DESIGN AND DRAWING

CHAPTER IV

DESIGN AND DRAWING4.1. DRAWING FOR HYDRAULIC FORKLIFT

CHAPTER V

WORKING PRINCIPLE

CHAPTER V

WORKING PRINCIPLE

Here we are using hydraulic bottle jack. It is operated by fluid power. It operated hydraulic power. Hydraulic piston end connected to plate. And the cylinder side carry the handle assemble and the moving purpose wheels are assembled by angle plates and clamp. This loading and unloading purpose using for horizontal plates. It is fixed to supporting plate and the loading plate moving purpose fixed wheel. This is use for platform and railway station and ware house these places it is use. This is the project is pallet jack or pallet truck.

CHAPTER VI

MERITS & DEMERITS

CHAPTER VI

MERITS & DEMERITS

MERITS

It is handling easy

Low cost

Low maintenance

Less skilled operator enough

DEMERITS

It is hand operated

Pallet move reversible direction it is difficult

CHAPTER VII

APPLICATIONS

CHAPTER VII

APPLICATIONS

It is useful for loading and unloading goods for warehouse and platform place.

CHAPTER VIII

LIST OF MATERIALS

CHAPTER VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

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

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

Physical

Mechanical

From manufacturing point of view

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, torsion and buckling load, fatigue resistance, impact resistance, elastic 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 CONSIDERATIONSometimes high strength materials have to be selected because the forces involved are high and space limitations are there.

6. COSTAs 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.CHAPTER IX

COST ESTIMATION

CHAPTER IX

COST ESTIMATION

1. MATERIAL COST2. LABOUR COST

Lathe, drilling, welding, drilling, power hacksaw, gas cutting cost

3. OVERGHEAD CHARGES

The overhead charges are arrived by manufacturing costManufacturing Cost = Material Cost + Labor Cost

=

=

Overhead Charges = 20%of the manufacturing cost

=

4. TOTAL COSTTotal cost = Material Cost +Labor Cost +Overhead Charges

=

=Total cost for this project =CHAPTER X

CONCLUSION

CHAPTER X

CONCLUSION

This project is made with pre planning, that it provides flexibility in operation.

This innovation has made the more desirable and economical. This project HYDRAULIC FORKLIFT is designed with the hope that it is very much economical and useful for loading and unloading goods for warehouse and platform place.

This project helped us to know the periodic steps in completing a project work. Thus we have completed the project successfully.BIBLIOGRAPHY

BIBLIOGRAPHY

1. Design data book

-P.S.G.Tech.

2. Machine tool design handbook Central machine tool Institute,

Bangalore.

3. Strength of Materials- R.S.Kurmi

4. Manufacturing Technology - M.Haslehurst.

5. Design of machine elements - R.S.Kurmi

PHOTOGRAPHY

COLLEGE LOGO

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