FABRICATION OF MOTORIZED LIFT

CONTENTS

C.NO PARTICULARS PAGE NO

SYNOPSIS 1
1. PROJECT PLANNING 2
2. INTRODUCTION OF THE MATERIAL HANDLING 5
EQUIPMENT
3. NEED FOR AUTOMATION 16
4. POWER SCREW 18
5. X FLAT FORM&SCISSOR JACK 23
6. MAJOR COMPONENTS OF THE MOTORIZED LIFT 25
7. SPECIFICATION OF THE MOTORIZED LIFT 46
8. FUNCTIONAL DIAGRAM OF THE X FLAT FORM 47

9 WORKING PRINCIPLE 48
10. ADVANTAGES&APPLICATION 49
11 COST ESTIMATION 50
CONCLUSION 51
BIBLOGRAPHY 52

1
SYNOPSIS

2
 SYNOPSIS

SYNOPSIS

This project work titled “FABRICATION OF MOTORIZED

LIFT” has been conceived having studied the difficulty in lifting the any
type of light vehicles.

Our survey in the regard in several automobile garages, revealed the

facts that mostly some difficult methods were adopted in lifting the vehicles
for reconditioning. Now the project has mainly concentrated on this
difficulty, and hence a suitable device has been designed. Such that the
vehicle can be lifted from the floor land without application of any impact
force.

The fabrication part of it has been considered with almost case for its
simplicity and economy, such that this can be accommodated as one of the
essential tools on automobile garages.

3
 CHAPTER-1
1. PROJECT PLANNING

4
 1. PROJECT PLANNING

Before starting every project its planning is to be done. Planning is very

important task and should be taken with great care, as the efficiency of the whole
project largely depends upon its planning while planning a project each and every
details should be worked out in anticipation and should carefully is considered
with all the relating provisions in advance. Project planning consists of the
following steps.

PROJECT CAPACITY
The capacity of the project must be decided considering the amount of
money which can be invested and availability of material and machines.

DRAWINGS
Drawing been decided for the project to be manufacture. Its detailed
drawing specification for raw material and finished products should be decided
carefully along with the specification of the machines required for their
manufacture.

MATERIAL EQUIPMENT
The list of materials required for manufacture is prepared from the
drawings. The list of is known as “BILL OF MATERIALS”. This passes to the store
keeper and the required materials taken from the store under permission of store
keeper operation, the necessity of operation, the person to do the job, machine
to be used to do the job are considered while planning the operation.

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MACHINE LOADING
While planning proper care should be taken to find the machining time for
each operation as correct as possible. So that the arrangement for full utilization
of machine can be made machine loading programmed is also known.

PURCHASE CONSIDERATION
It is different to manufacture all the component needed for the equipment
in the workshop itself. The decision about a particular item whether to purchase
or to manufacture is taken by planning after making through study of relative
merits demerits.

EQUIPMENT CONSIDERATION
Result obtained from “PROCESS PLANNING” and “MACHINE LODING” helps
in calculating the equipment requirement specification of the equipment should
be laid down by considering the drawing. Drawing will also help in deciding and
necessary requirement of tools, accessories.

COST CALCULATION
The cost of the project can be calculated by adding following.

1. Material Cost
2. Machining Cost
3. Overhead Expenses.
COMPARISION
The various items in the finished project are compared to the standards for
the further correction.

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REPORT
At the end of the project work report is prepared for future references. The
report consists of all the items done the project work.

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 CHAPTER-2
2. INTRODUCTION OF THE MATERIAL
HANDLING EQUIPMENT

8
 2. INTRODUCTION OF THE MATERIAL HANDLING EQUIPMENT

Material handling equipment is all equipment that relates to the movement,

storage, control and protection of materials, goods and products throughout the
process of manufacturing, distribution, consumption and disposal. Material
handling equipment is the mechanical equipment involved in the complete system.
Material handling equipment is generally separated into four main categories:
storage and handling equipment, engineered systems, industrial trucks, and bulk
material handling.

Ways in which material handling equipment can improve

efficiency

Material handling equipment is used to increase throughput, control costs, and

maximize productivity. There are several ways to determine if the material
handling equipment is achieving peak efficiency. These include capturing all
relevant data related to the warehouse’s operation (such as SKUs), measuring how
many times an item is “touched” from the time it is ordered until it leaves the
building, making sure you are using the proper picking technology, and keeping
system downtime to a minimum.

Types of material handling equipment

Storage and handling equipment

Storage and handling equipment is a category within the material handling

industry. The equipment that falls under this description is usually non-automated
storage equipment. Products such as Pallet rack, shelving, carts, etc. belong to
storage and handling. Many of these products are often referred to as "catalog"
9
items because they generally have globally accepted standards and are often sold
as stock materials out of Material handling catalogs.

Engineered systems

Engineered systems are typically custom engineered material handling systems.

Conveyors, Handling Robots, AS/RS, AGV and most other automated material
handling systems fall into this category. Engineered systems are often a
combination of products integrated to one system. Many distribution centers will
optimize storage and picking by utilizing engineered systems such as pick modules
and sortation systems.

Equipment and utensils used for processing or otherwise handling edible product
or ingredients must be of such material and construction to facilitate thorough
cleaning and to ensure that their use will not cause the adulteration of product
during processing, handling, or storage. Equipment and utensils must be
maintained in sanitary condition so as not to adulterate product.

Industrial trucks

Industrial trucks usually refer to operator driven motorized warehouse vehicles.

Industrial trucks assist the material handling system with versatility; they can go
where engineered systems cannot. Forklift trucks are the most common example of
industrial trucks but certainly aren't the extent of the category. Tow tractors and
stock chasers are additional examples of industrial trucks.

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Bulk material handling

Bulk material handling equipment is used to move and store bulk materials such as
ore, liquids, and cereals. This equipment is often seen on farms, mines, shipyards
and refineries. This category is also explained in Bulk material handling.

GENERAL OPERATIONS OF VARIOUS FLAT FORM

A tracked AWP at a building site

. An aerial work platform (AWP), also known as an aerial device or elevating

work platform, is a mechanical device used to provide temporary access for
people or equipment to inaccessible areas, usually at height. There are distinct
types of mechanized access platforms and the individual types may also be known
as a "cherry picker" or a "scissor lift".

They are generally used for temporary, flexible access purposes such as
maintenance and construction work or by firefighters for emergency access, which
distinguishes them from permanent access equipment such as elevators. They are
designed to lift limited weights — usually less than a ton, although some have a
higher safe working load (SWL)[1] — distinguishing them from most types of
cranes. They are usually capable of being set up and operated by a single person.

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Regardless of the task they are used for, aerial work platforms may provide
additional features beyond transport and access, including being equipped with
electrical outlets or compressed air connectors for power tools. They may also be
equipped with specialist equipment, such as carrying frames for window glass.[1]

Lifting mechanisms

There are several distinct types of aerial work platforms, which all have specific
features which make them more or less desirable for different applications. The
key difference is in the drive mechanism which propels the working platform to the
desired location. Most are powered by either hydraulics or possibly pneumatics.
The different techniques also reflect in the pricing and availability of each type.

Articulated lift being demonstrated.

Aerial device
Main article: Cherry Picker

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Aerial devices were once exclusively operated by hydraulic pistons, powered by
diesel or gasoline motors on the base unit. Lightweight electrically powered units
are gaining popularity for window-cleaning or other maintenance operations,
especially indoors and in isolated courtyards, where heavier hydraulic equipment
cannot be used. Aerial devices are the closest in appearance to a crane- consisting
of a number of jointed sections, which can be controlled to extend the lift in a
number of different directions, which can often include "up and over" applications.

"Spider" set up outside a building.

This type of AWP is the most likely of the types to be known as a "cherry picker",
owing to its origins, where it was designed for use in orchards (though not just
cherry orchards). It lets the picker standing in the transport basket pick fruit high in
a tree with relative ease (with the jointed design ensuring minimum damage to the
tree). The term "cherry picker" has become generic, and is commonly used to
describe articulated lifts (and more rarely all AWPs).

13
This type of AWP is now widely used for maintenance and construction of all
types, including extensively in the power and telecommunications industries to
service overhead lines, and in arboriculture to provide an independent work
platform on difficult or dangerous trees. A specialist type of the articulated lift is
the type of fire apparatus used by firefighters worldwide as a vehicle to provide
high level or difficult access. These types of platforms often have additional
features such as a piped water supply and water cannon to aid firefighters in their
task.

Some articulated lifts are limited to only the distance accessible by the length of
each boom arm, however, by the use of telescoping sections, the range can be
vastly increased. Some large hydraulic platforms mounted on a lorry can reach
heights of over 100 metres.[2]

The majority of articulated lifts require a wide supportive base to operate safely,
and most models have extending legs/struts to help accomplish this. These legs can
be manual or hydraulic (usually depending on size and price of the machine).
Some AWPS are classified as "spiders" due to the appearance of these legs.
Spiders are also available in especially compact form, to fit through doorways for
use inside buildings.

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An extended scissor lift

Scissor lift

A scissor lift is a type of platform that can usually only move vertically. The
mechanism to achieve this is the use of linked, folding supports in a criss-cross "X"
pattern, known as a pantograph. The upward motion is achieved by the application
of pressure to the outside of the lowest set of supports, elongating the crossing
pattern, and propelling the work platform vertically. The platform may also have
an extending "bridge" to allow closer access to the work area, because of the
inherent limits of vertical-only movement.

The contraction of the scissor action can be hydraulic, pneumatic or mechanical

(via a leadscrew or rack and pinion system). Depending on the power system

15
employed on the lift, it may require no power to enter "descent" mode, but rather a
simple release of hydraulic or pneumatic pressure. This is the main reason that
these methods of powering the lifts are preferred, as it allows a fail-safe option of
returning the platform to the ground by release of a manual valve.

Hotel lift

There are a number of smaller lifts that use mechanical devices to extend, such as
rack and pinion or screw threads. These often have juxtaposed sections that move
past each other in order to create the movement, usually in a vertical direction
only. This lifts usually have limited capability in terms of weight and extension,
and are most often used for internal maintenance tasks, such as changing
incandescent light bulbs.

Motive mechanisms

AWPs, by their nature, are designed for temporary works and therefore frequently
require transportation between sites, or simply around a single site (often as part of
the same job). For this reason, they are almost all designed for easy movement.

Unpowered

These usually smaller units have no motive drive and require external force to
move them. Dependent on size and whether they are wheeled or otherwise
supported, this may be possible by hand, or may require a vehicle for towing or
transport. Small non-powered AWPs can be light enough to be transported in a
pickup truck bed, and can usually be moved through a standard doorway.

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Self-propelled

These units are able to drive themselves (on wheels or tracks) around a site (they
usually require to be transported to a site, for reasons of safety and economy). In
some instances, these units will be able to move whilst the job is in progress,
although this is not possible on units which require secure outriggers, and therefore
most common on the scissor lift types. The power can be almost any form of
standard mechanical drive system, including electric or gasoline powered, or in
some cases, a hybrid (especially where it may be used both inside and outside).

Telescoping articulated platform mounted on firefighting appliance. These

provide more flexibility than ladder engines.

Vehicle-mounted

Some units are mounted on a vehicle, usually a truck or it can be mounted on a flat
back pick up van known as a self drive),[3] though other vehicles are possible, such
as railway cars. This vehicle provides mobility, and may also help stabilize the
unit — though outrigger stabilizers are still typical, especially as vehicle-mounted
AWPs are amongst the largest of their kind. The vehicle may also increase
functionality by serving as mobile workshop or store.

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Control

The power assisted drive (if fitted) and lift functions of an AWP are controlled by
an operator, who can be situated either on the work platform itself, or at a control
panel at the base of the unit. Some models are fitted with a panel at both locations
or with a remote control, giving operator a choice of position. A control panel at
the base can also function as a safety feature if for any reason the operator is at
height and becomes unable to operate his controls. Even models not fitted with a
control panel at the base are usually fitted with an emergency switch of some sort,
which allows manual lowering of the lift (usually by the release of hydraulic or
pneumatic pressure) in the event of an emergency or power failure.

Controls vary by model, but are frequently either buttons or a joystick. The type
and complexity of these will depend on the functions the platform is able to
perform. The controls can control features such as:

 Vertical movement
 Lateral movement
 Rotational movement (cardinal direction)
 Platform / basket movement — normally, the system automatically levels
the platform, regardless of boom position, but some allow overrides, tilting
up to 90° for work in difficult locations.
 Ground movement (in self propelled models)

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Safety

Aerial work platforms in use.

Scissor lift table

The majority of manufacturers and operators have strict safety criteria for the
operation of AWPs. In some countries, a licence and/or insurance is required to
operate some types of AWP. Most protocols advocate training every operator,
whether mandated or not. Most operators also prescribe a range of pre-usage
checks of the unit, and manufacturers recommend regular maintenance schedules.

Work platforms are fitted with safety or guard rails around the platform itself to
contain operators and passengers. This is supplemented in most models by a
restraining point, designed to secure a harness or fall arrester. Some work
platforms also have a lip around the floor of the platform itself to avoid tools or

19
supplies being accidentally kicked off the platform. Some protocols require all
equipment to be attached to the structure by individual lanyards.

Extreme caution must be taken when using AWPs in the vicinity of overhead
power lines, as electrocution may result if the lift comes in contact with energized
wiring. Non-conductive materials, such as fiberglass, may be used to reduce this
hazard.

AWPs often come equipped with a variety of tilt sensors. The most commonly
activated sensor (especially with two people on a lift), will cause the machine to
refuse to raise the platform beyond a certain height. Sensors within the machine
detect that weight on the platform is off balance to such a point as to risk a possible
tip-over if the platform is raised further. Another sensor will refuse to extend the
platform if the machine is on a significant incline. Some models of AWPs
additionally feature counterweights, which extend in order to offset the danger of
tipping the machine inherent in extending items like booms or bridges. Some lifts
are also fitted with sensors which will prevent operation if the weight on the
platform exceeds the safe working load.

As with most dangerous mechanical devices, all AWPs are fitted with an
emergency stop button or buttons for use in the event of a malfunction or danger.
Best practice dictates fitting of emergency stop buttons on the platform and at the
base as a minimum. Other safety features include automatic self-checking of the
AWP's working parts, including a voltmeter that detects if the lift has insufficient
power to complete its tasks and preventing operation if supply voltage is
insufficient. Some AWPs provide manual lowering levers at the base of the
machine, allowing operators to lower the platform to the ground in the event of a

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power or control failure or deliberate use of the machine, e.g., by unauthorized
persons

CHATER-3
NEED FOR AUTOMATION

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 3. NEED FOR AUTOMATION

Automation can be achieved through computers, hydraulics, pneumatics, robotics,

etc. Automation plays an important role in mass production.
For mass production of the product, the machining operations decide the sequence
of machining. The machines designed for producing a particular product are called
transfer machines. The components must be moved automatically from the bins to
various machines sequentially and the final component can be placed separately for
packaging. Materials can also be repeatedly transferred from the moving conveyors
to the work place and vice versa.
Nowadays, almost all the manufacturing processes are being atomized in order to
deliver the products at a faster rate. The manufacturing operation is being atomized
for the following reasons:
1. To achieve mass production

2. To reduce man power

3. To increase the efficiency of the plant

4. To reduce the work load

5. To reduce the production cost

6 .To reduce the production time

7. To reduce the material handling

8. To reduce the fatigue of workers

9. To achieve good product quality

10 Less Maintenance

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 3.1. POWER SCREWS
A power screw is a mechanical device used for converting rotary motion into linear
motion and transmitting power. A power screw is also called translation screw. It
uses helical translatory motion of the screw thread in transmitting power rather
than clamping the machine components.
3.1 Applications
The main applications of power screws are as follows:
(i) To raise the load, e.g. screw-jack,
(ii) To obtain accurate motion in machining operations, e.g. lead-screw of lathe,
(iii) To clamp a workpiece, e.g. vice, and
(iv) To load a specimen, e.g. universal testing machine.
There are three essential parts of a power screw, viz.screw, nut and a part to hold
either the screw or the nut in its place. Depending upon the holding arrangement,
power screws operate in two different ways. In some cases, the screw rotates in its
bearing, while the nut has axial motion. The lead screw of the lathe is an example
of this category. In other applications, the nut is kept stationary and the screw
moves in axial direction. Screw-jack and machine vice are the examples of this
category.

3.2 Advantages
Power screws offer the following advantages:
(i) Power screw has large load carrying capacity.
(ii) The overall dimensions of the power screw are small, resulting in compact
construction.
(iii) Power screw is simple to design

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(iv) The manufacturing of power screw is easy without requiring specialized
machinery. Square threads are turned on lathe. Trapezoidal threads are
manufactured on thread milling machine.
(v) Power screw provides large mechanical advantage. A load of 15 kN can be
raised by applying an effort as small as 400 N.Therefore, most of the power screws
used in various applications like screw-jacks, clamps, valves and vices are usually
manually operated.
(vi) Power screws provide precisely controlled and highly accurate linear motion
required in machine tool applications.
(vii) Power screws give smooth and noiseless service without any maintenance.

3.3 Disadvantages
The disadvantages of power screws are as follows:
(i) Power screws have very poor efficiency; as low as 40%.Therefore, it is not used
in continuous power transmission in machine tools, with the exception of the lead
screw. Power screws are mainly used for intermittent motion that is occasionally
required for lifting the load or actuating the mechanism.
(ii) High friction in threads causes rapid wear of the screw or the nut. In case of
square threads, the nut is usually made of soft material and replaced when worn
out. In trapezoidal threads, a split- type of nut is used to compensate for the wear.
Therefore, wear is a serious problem in power screws.

3.4 Forms of Threads

There are two popular types of threads used for power screws viz. square and I.S.O
metric trapezoidal.

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Advantages of square threads
The advantages of square threads over trapezoidal threads are as follows:
(i) The efficiency of square threads is more than that of trapezoidal threads.
(ii) There is no radial pressure on the nut. Since there is no side thrust, the motion
of the nut is uniform. The life of the nut is also increased.

Disadvantages of square threads

The disadvantages of square threads are as follows:
(i) Square threads are difficult to manufacture. They are usually turned on lathe
with single-point cutting tool. Machining with single-point cutting tool is an
expensive operation compared to machining with multi-point cutting tool. (ii) The
strength of a screw depends upon the thread thickness at the core diameter. Square
threads have less thickness at core diameter than trapezoidal threads. This reduces
the load carrying capacity of the screw.
(iii) The wear of the thread surface becomes a serious problem in the service life of
the power screw. It is not possible to compensate for wear in square threads.
Therefore, when worn out, the nut or the screw requires replacement.

Advantages of Trapezoidal Threads

The advantages of trapezoidal threads over square threads are as follows:
(i) Trapezoidal threads are manufactured on thread milling machine. It employs
multi-point cutting tool. Machining with multi-point cutting tool is an economic
operation compared to machining with single point-cutting tool. Therefore,
trapezoidal threads are economical to manufacture.
(ii) Trapezoidal thread has more thickness at core diameter than that of square
thread.Therfore; a screw with trapezoidal threads is stronger than equivalent screw
with square threads. Such a screw has large load carrying capacity.
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(iii) The axial wear on the surface of the trapezoidal threads can be compensated
by means of a split-type of nut. The nut is cut into two parts along the diameter. As
wear progresses, the looseness is prevented by tightening the two halves of the nut
together, the split-type nut can be used only for trapezoidal threads. It is used in
lead-screw of lathe to compensate wear at periodic intervals by tightening the two
halves.

Disadvantages of Trapezoidal Threads

The disadvantages of trapezoidal threads are as follows:
(i) The efficiency of trapezoidal threads is less than that of square threads.
(ii) Trapezoidal threads result in side thrust or radial pressure on the nut. The radial
pressure or bursting pressure on nut affects its performance.
There is a special type of thread called acme thread. Trapezoidal and acme threads
are identical in all respects except the thread angle. In acme thread, the thread
angle is 29° instead of 30°.The relative advantages and is advantages of acme
threads are same as those of trapezoidal threads. There is another type of thread
called buttress thread. It combines the advantages of square and trapezoidal
threads. Buttress threads are used where heavy axial force acts along the screw axis
in one direction only.

Advantages of Buttress Threads

The advantages of buttress threads are as follows:
(i) It has higher efficiency compared to trapezoidal threads.
(ii) It can be economically manufactured on thread milling machine.
(iii) The axial wear at the thread surface can be compared by means of spit-type
nut.

26
(iv) A screw with buttress threads is stronger than equivalent screw with either
square threads or trapezoidal threads. This is because of greater thickness at the
base of the thread.
The buttress threads have one disadvantage. It can transmit power and motion only
in one direction. On the other hand, square and trapezoidal threads can transmit
force and motion in both directions.
Square threads are used for screw-jacks, presses and clamping devices.
Trapezoidal and acme threads are used for lead-screw and other power
transmission devices in machine tools. Buttress threads are used in vices, where
force is applied only in one direction. Buttress threads are ideally suited for
connecting tubular components that must carry large forces such as connecting
the barrel to the housing in anti air-craft guns.

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 CHAPTER-4
4.X FLAT FORM&SCISSOR JACK

28
 4.X FLAT FORM&SCISSOR JACK

Scissors jacks are also mechanical and have been in use at least since the 1930s.
A scissor jack is a device constructed with a cross-hatch mechanism, much like a
scissor, to lift up a vehicle for repair or storage. It typically works in just a vertical
manner. The jack opens and folds closed, applying pressure to the bottom supports
along the crossed pattern to move the lift. When closed, they have a diamond
shape.

Scissor jacks are simple mechanisms used to drive large loads short distances. The
power screw design of a common scissor jack reduces the amount of force required
by the user to drive the mechanism. Most scissor jacks are similar in design,
consisting of four main members driven by a power screw.

A scissor jack is operated simply by turning a small crank that is inserted into one
end of the scissor jack. This crank is usually "Z" shaped. The end fits into a ring
hole mounted on the end of the screw, which is the object of force on the scissor
jack. When this crank is turned, the screw turns, and this raises the jack. The screw
acts like a gear mechanism. It has teeth (the screw thread), which turn and move
the two arms, producing work. Just by turning this screw thread, the scissor jack
can lift a vehicle that is several thousand pounds.

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Construction
A scissor jack has four main pieces of metal and two base ends. The four metal
pieces are all connected at the corners with a bolt that allows the corners to swivel.
A screw thread runs across this assembly and through the corners. As the screw
thread is turned, the jack arms travel across it and collapse or come together,
forming a straight line when closed. Then, moving back the other way, they raise
and come together. When opened, the four metal arms contract together, coming
together at the middle, raising the jack. When closed, the arms spread back apart
and the jack closes or flattens out again.
Design and Lift
A scissor jack uses a simple theory of gears to get its power. As the screw
section is turned, two ends of the jack move closer together. Because the gears of
the screw are pushing up the arms, the amount of force being applied is
multiplied. It takes a very small amount of force to turn the crank handle, yet that
action causes the brace arms to slide across and together. As this happens the
arms extend upward. The car's gravitational weight is not enough to prevent the
jack from opening or to stop the screw from turning, since it is not applying force
directly to it. If you were to put pressure directly on the crank, or lean your weight
against the crank, the person would not be able to turn it, even though your
weight is a small percentage of the cars.

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 4.1. MAJOR COMPONENTS OF THE X FLAT FORM

 DC MOTOR
 SCISSOR JACK
 POWER SUPPLY
 SENSOR WITH TIMER CONTROL
 STEEL STRUCTURE

DC ELECTRIC MOTOR:

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Operation:

Most electric motors work by electromagnetism, but motors based on other

electromechanical phenomena, such as electrostatic forces and the
piezoelectric effect, also exist. The fundamental principle upon which
electromagnetic motors are based is that there is a mechanical force on any
wire when it is conducting electricity while contained within a magnetic
field. The force is described by the Lorentz force law and is perpendicular to
both the wire and the magnetic field. In a rotary motor, there is a rotating
element, the rotor. The rotor rotates because the wires and magnetic field
are arranged so that a torque is developed about the rotor's axis.

Most magnetic motors are rotary, but linear types also exist. In a rotary
motor, the rotating part (usually on the inside) is called the rotor, and the
stationary part is called the stator. The motor contains electromagnets that
are wound on a frame. Though this frame is often called the armature, that

32
term is often erroneously applied. Correctly, the armature is that part of the
motor across which the input voltage is supplied or that part of the
generator across which the output voltage is generated. Depending upon the
design of the machine, either the rotor or the stator can serve as the
armature.

DC motors

One of the first electromagnetic rotary motors was invented by Michael

Faraday in 1821 and consisted of a free-hanging wire dipping into a pool of
mercury. A permanent magnet was placed in the middle of the pool. When a
current was passed through the wire, the wire rotated around the magnet,
showing that the current gave rise to a circular magnetic field around the
wire. This motor is often demonstrated in school physics classes, but brine is
sometimes used in place of the toxic mercury. This is the simplest form of a
class of electric motors called homopolar motors.

The modern DC motor was invented by accident in 1873, when Zénobe

Gramme connected a spinning dynamo to a second similar unit, driving it as
a motor.

The classic DC motor has a rotating armature in the form of an

electromagnet with two poles. A rotary switch called a commutator reverses
the direction of the electric current twice every cycle, to flow through the
armature so that the poles of the electromagnet push and pull against the
permanent magnets on the outside of the motor. As the poles of the
armature electromagnet pass the poles of the permanent magnets, the
commutator reverses the polarity of the armature electromagnet. During

33
that instant of switching polarity, inertia keeps the classical motor going in
the proper direction. (See the diagrams below.)

Fig 6 Simple DC electric motor

A simple DC electric motor. When the coil is powered, a magnetic field is

generated around the armature. The left side of the armature is pushed
away from the left magnet and drawn toward the right, causing rotation. The
armature continues to rotate. When the armature becomes horizontally
aligned, the commutator reverses the direction of current through the coil,
reversing the magnetic field. The process then repeats.

DC motor speed generally depends on a combination of the voltage and

current flowing in the motor coils and the motor load or braking torque. The
speed of the motor is proportional to the voltage, and the torque is
proportional to the current. The speed is typically controlled by altering the
voltage or current flow by using taps in the motor windings or by having a
variable voltage supply.

34
As this type of motor can develop quite high torque at low speed it is often
used in traction applications such as locomotives.

However, there are a number of limitations in the classic design, many due
to the need for brushes to rub against the commutator. The rubbing creates
friction, and the higher the speed, the harder the brushes have to press to
maintain good contact. Not only does this friction make the motor noisy, but
it also creates an upper limit on the speed and causes the brushes eventually
to wear out and to require replacement. The imperfect electric contact also
causes electrical noise in the attached circuit. These problems vanish when
you turn the motor inside out, putting the permanent magnets on the inside
and the coils on the outside thus designing out the need for brushes in a
brushless design. However such designs need electronic circuits to control
the switching of the electromagnets (the function that is performed in
conventional motors by the commutator).

Universal motors

A variant of the wound field DC motor is the universal motor. The name
derives from the fact that it may use AC or DC supply current, although in
practice they are nearly always used with AC supplies. The principle is that in
a wound field DC motor the current in both the field and the armature (and
hence the resultant magnetic fields) will alternate (reverse polarity) at the
same time, and hence the mechanical force generated is always the same. In
practice the motor must be specially designed to cope with the AC current
(impedance/reluctance must be taken into account), and the resultant

35
motor is generally less efficient than an equivalent pure DC motor. The
advantage of the universal motor is that AC supplies may be used on motors
which have the typical characteristics of DC motors, specifically high starting
torque and very compact design if high running speeds are used. The
negative aspect is the maintenance and reliability problems caused by the
commutator, and as a result such motors will rarely be found in industry but
are the most common type of AC supplied motor in devices such as food
mixers and power tools which are only used intermittently.

Continuous speed control of a universal motor running on AC is very easily

accomplished using a thyristor circuit while stepped speed control can be
accomplished using multiple taps on the field coil. Household blenders that
advertise many speeds frequently combine a field coil with several taps and
a diode that can be inserted in series with the motor (causing the motor to
run on half-wave DC with half the RMS voltage of the AC power line).

Unlike the other common forms of AC motors (induction motors and

synchronous motors), universal motors can easily exceed one revolution per
cycle of the mains current (that is, exceed 3000 rpm on a 50 Hz system or
3600 rpm on a 60 Hz system). This makes them especially useful for certain
appliances such as blenders, vacuum cleaners, and hair dryers where high-
speed operation is desired.

With the very low cost of semiconductor rectifiers, some applications that
would have previously used a universal motor now use a pure DC motor,

36
usually with a permanent magnet field. This is especially true if the
semiconductor circuit is also used for variable-speed control.

SCREW JACK

A scissor jack assembly with double-lead Acme threaded screw. Through use of
urethane or similar material as a braking means, the jack assembly is operable
with a self locking action over a wider range of loads and especially at lower loads
where an Acme loading phenomenon that results in said self locking action has
previously been unattainable. Faster and smoother jack operation is made
possible by employing a thrust bearing, including a plurality of roller or ball
bearings, with the jack assembly. A spacing washer is also provided to retain the
threaded shaft within the trunnions of the jack assembly, in order that the ends of
each of the trunnions need not be machined or stamped to retain the trunnions
within the jack assembly. Utilizing such a spacing washer decreases the costs

37
involved with manufacturing the jack assembly, while increasing the ability to
repair the jack assembly.

Screw-operated scissor jacks have long been known to be useful in lifting

applications and especially in situations where it may be desired to level heavy
objects. A particular type of well known screw-operated scissor jack employs a
double lead Acme screw which traditionally has proven to be particularly
advantageous where extremely massive objects need to be raised quickly. One
industry in which jacks having the double lead Acme screw have been widely used
is the railroad industry, where the need often has arisen to lift locomotives and rail
cars from train tracks. For this and similar types of lifting jobs, the double lead
Acme screw has been shown to be capable of raising loads up to three times faster
than a standard SAE screw that has been used in other jacks.

In addition to providing a faster operating jack, the Acme double lead screw
exhibits a further operational advantage that derives from the physical
characteristics which are unique to the Acme screw thread. Such operational
advantage is the ability for the Acme screw to become self-locking when the jack
is subjected to loads generally in excess of one thousand pounds. Where loading is
above the stated level, it has been determined that frictional forces developed
among the thread lands or roots become sufficiently large to prevent the vertically
downward directed force of the lifted object from causing the screw to unwind and
prematurely allow the lifted object to descend. As already suggested, the described
advantage, which also may be termed an “Acme loading phenomenon,” requires
that a minimum load be lifted by the jack before the Acme loading phenomenon
takes effect and becomes of any benefit to the jack operator. Thus, the advantage to
be gained from discovery of a means to lower the minimum load at which the jack

38
will become self-locking has been recognized, and the present invention provides a
simple and inexpensive jack construction that is aimed at achieving that end.

A scissor jack assembly comprising: a base member for resting the jack assembly
against a substantially flat surface; a support bracket assembly; first and second
lower arm members each of an open channel construction with outer sidewalls
and having one end connected to said base plate; first and second upper arm
members each of an open channel construction with outer sidewalls and having
one end connected to said support bracket assembly; first and second trunnions
connecting said upper arms with said lower arms, each said trunnion including a
bore; a rotatable shaft member extending into the bores of said first and second
trunnions; at least one spacer dimensioned to substantially occupy the space
between the sidewalls of an upper or lower arm member for maintaining the
position of said rotatable shaft within the area between planes created by the
sidewalls of said upper or lower arm members; and a means for locking at least
said spacer on said rotatable shaft member.

39
 CHAPTER-5

5. POWER SUPPLY

5. POWER SUPPLY

DEFINITION:

It is an electronics unit. This is used to give regulated power to any

electronics system.

BLOCK DIAGRAM DESCRIPTION:

40
1. Transformer : This block consist step-down transformer

for our required ratings.

2. Rectifier : This block consist diode based rectifier

Circuit

3. Filter circuit : This block consist capacitor based filter

Circuit.

4. Regulator : This block consists +ve (and) – ve three

Terminal regulators

POWER SUPPLY:

There are many types of power supply. Most are designed to convert high
voltage AC mains electricity to a suitable low voltage supply for electronics circuits
and other devices. A power supply can by broken down into a series of blocks,
each of which performs a particular function.

For example a 5V regulated supply Functional Diagram:

41
 Power supply functional diagram

Circuit Diagram:

Fig 12. Power supply circuit diagram

Transformer:
The instrument transformer for power supply in this project is to convert
AC from 230V to required low level such as 5V AC. This transformer apart from
stepping down AC voltage gives isolation between power source and power
supply circuitries.

The low voltage AC output is suitable for lamps, heaters and special AC
motors. It is not suitable for electronic circuits unless they include a rectifier and a
smoothing capacitor.

RELAY AND TRANSFORMER

42
 Fig 8. Basic relay operation

The electromagnetic relay consists of a multi-turn coil, wound on an iron

core, to form an electromagnet. When the coil is energized, by passing current
through it, the core becomes temporarily magnetized. The magnetized core
attracts the iron armature. The armature is pivoted which causes it to operate
one or more sets of contacts. When the coil is de-energized the armature
and contacts are released.

The coil can be energized from a low power source such as a transistor
while the contacts can switch high powers such as the main supply. The
relay can also be situated remotely from the control source. Relays can generate a
very high voltage across the coil when switched off.

This can damage other components in the circuit. To prevent this diode is
connected across the coil. The cathode of the diode is connected to the most
positive end of the coil.

43
 . Relay contacts

The spring sets (contacts) can be a mixture of N.O, N.C and c.o. look at the
page on switches to see how they can be used in circuits. Various coil-operating
voltages (ac and dc) are available. The actual contact points on the spring sets are
available for high current and low current operation. The REED RELAY has a much
faster operation than the relays described above.

Internal Operation of Mechanical Relays:

1. Standard: Single Side Stable with any of the following three different
methods for closing contacts:

i. Flexure Type: The armature actuates the contact spring directly, and
the contact is driven into a stationary contact, closing the circuit
ii. Lift-off Type: The moveable piece is energized by the armature, and
the contact closes
iii. Plunger Type: The lever action caused by the energization of the
armature produces a long stroke action

44
 2. Reed: A Single Side Stable Contact that involves low contact pressure and a
simple contact point
3. Polarized: Can be either a single side stable or dual-winding. A
permanent magnet is used to either attract or repel the armature that
controls the contact. A definite polarity (+ or -) is required by the relay coil.
The latching option makes a polarized relay dual-winding, meaning it
remains in the current state after the coil is de-energized.

Types of Relays:

There are two basic classifications of relays: Electromechanical and Solid

State. Electromechanical relays have moving parts, whereas solid-state relays
have no moving parts. Advantages of Electromechanical relays include lower cost,
no heat sink is required, multiple poles are available, and they can switch AC or
DC with equal ease.

 Electromechanical Relays:

General Purpose Relay: The general-purpose relay is rated by the amount of

current its switch contacts can handle. Most versions of the general-purpose relay
have one to eight poles and can be single or double throw. These are found in
computers, copy machines, and other consumer electronic equipment and
appliances.

 Power Relay:

The power relay is capable of handling larger power loads – 10-50

amperes or more. They are usually single-pole or double-pole units.

45
 Contactor:

A special type of high power relay, it’s used mainly to control high voltages
and currents in industrial electrical applications. Because of these high power
requirements, contactors always have double-make contacts.

 Time-Delay Relay:

The contacts might not open or close until some time interval after the coil
has been energized. This is called delay-on-operate.Delay-on-release means that
the contacts will remain in their actuated position until some interval after the
power has been removed from the coil. A third delay is called interval timing.

Contacts revert to their alternate position at a specific interval of time after

the coil has been energized. The timing of these actions may be a fixed parameter
of the relay, or adjusted by a knob on the relay itself, or remotely adjusted through
an external circuit.

 Solid State Relays:

These active semiconductor devices use light instead of magnetism to

actuate a switch. The light comes from an LED, or light emitting diode. When
control power is applied to the device’s output, the light is turned on and shines
across an open space. On the load side of this space, a part of the device senses
the presence of the light, and triggers a solid-state switch that either opens or
closes the circuit under control. Often, solid-state relays are used where the
circuit under control must be protected from the introduction of electrical noises.

46
 Advantages of Solid State Relays include low EMI/RFI, long life, no moving
parts, no contact bounce, and fast response. The drawback to using a solid-state
relay is that it can only accomplish single pole switching.

Advantages of relays:

 Relays can switch AC and DC

 Relays can switch high voltages
 Relays are a better choice for switching high currents
 Relays can switch many contacts at once

Applications:

 General Purpose Relays:

HVAC, Appliances, Security, Pool & Spa, Industrial Controls, Office

Equipment.

 Low Signal Relays:

Telecommunications, Datacom, CP/OA, Security

 Power Relays:

Office Automation, Process Control, Automotive, Energy

Management Systems, HVAC, Motor Drives/Controls, Appliance Controls.

Solid State Relays:

Industrial Control, Motors, Timers

47
  4. SENSOR WITH TIMER CONTROL
TIMER CONTROLLER UNIT(555-TIMER CIRCUIT]

 The 555 timer IC is an integrated circuit (chip) used in a variety of timer,

pulse generation, and oscillator applications. The 555 can be used to
provide time delays, as an oscillator, and as a flip-flop element.
Derivatives provide up to four timing circuits in one package.
 Introduced in 1972 by Signetics, the 555 is still in widespread use, thanks
to its ease of use, low price, and good stability. It is now made by many
companies in the original bipolar and also in low-power CMOS types. As of
2003, it was estimated that 1 billion units are manufactured every year

WORKING PRINCIPLE OF 555 TIMER

 The 555 came in two packages, the standard DIP package and the metal
round package, also called the 'T' package, which was prety much the
standard package the first decades that the 555 was first produced. The
most popular packages today are the 555 and 556 DIP packages. The 'T'
package is no longer produced and the 558 is about to be discontinued
due to minimum usage. The pin-outs are shown bellow. The 556 is a Dual
555 and the 558 is a Quad 555:

STRUCTURE

Structural steel is steel construction material, a profile, formed with a specific

shape or cross section and certain standards of chemical composition and

48
strength. Structural steel shape, size, composition, strength, storage, etc, is
regulated in most industrialized countries.

Structural steel members, such as I-beams, have high second moments of area,
which allow them to be very stiff in respect to their cross-sectional area.

A steel I-beam, in this case used to support wood beams in a house.

Structural steel in construction: A primed steel beam is holding up the floor

above, which consists of a metal deck (Q-Deck), upon which a concrete slab has
been poured.

Steel beam through-penetration with incomplete fireproofing.

Metal deck and OWSJ (Open Web Steel Joist), receiving first coat of spray
fireproofing plaster, made of polystyrene leavened gypsum. Contents

1 Common structural shapes

2 Standards

2.1 Standard structural steels

2.2 Standard structural steels

2.2.1 Carbon steels

2.2.2 High strength low alloy steels

2.2.3 Corrosion resistant high strength low alloy steels

2.2.4 Quenched and tempered alloy steels

3 Steel vs. concrete

49
4 Thermal properties

5 Fireproofing of structural steel

COMMON STRUCTURAL SHAPES

In most developed countries, the shapes available are set out in published
standards, although a number of specialist and proprietary cross sections are also
available.

I-beam (I-shaped cross-section - in Britain these include Universal Beams (UB) and
Universal Columns (UC); in Europe it includes the IPE, HE, HL, HD and other
sections; in the US it includes Wide Flange (WF) and H sections)

Z-Shape (half a flange in opposite directions)

HSS-Shape (Hollow structural section also known as SHS (structural hollow

section) and including square, rectangular, circular (pipe) and elliptical cross
sections)

Angle (L-shaped cross-section)

Channel ( [-shaped cross-section)

Tee (T-shaped cross-section)

Rail profile (asymmetrical I-beam)

Railway rail

Vignoles rail

Flanged T rail

Grooved rail

50
Bar a piece of metal, rectangular cross sectioned (flat) and long, but not so wide
so as to be called a sheet.

Rod, a round or square and long piece of metal or wood, see also rebar and
dowel.

Plate, sheet metal thicker than 6 mm or 1/4 in.

Open web steel joist

While many sections are made by hot or cold rolling, others are made by welding
together flat or bent plates (for example, the largest circular hollow sections are
made from flat plate bent into a circle and seam-welded).

Standard structural steels

Most steels used throughout Europe are specified to comply with the European
standard EN 10025. However, many national standards also remain in force.

Typical grades are described as 'S275J2' or 'S355K2W'. In these examples, 'S'

denotes structural rather than engineering steel; 275 or 355 denotes the yield
strength in newtons per square millimetre or the equivalent megapascals; J2 or
K2 denotes the materials toughness by reference to Charpy impact test values;
and the 'W' denotes weathering steel. Further letters can be used to designate
normalized steel ('N' or 'NL'); quenched and tempered steel ('Q' or 'QL'); and
thermo mechanically rolled steel ('M' or 'ML').

The normal yield strength grades available are 195, 235, 275, 355, 420, and 460,
although some grades are more commonly used than others e.g. in the UK,
almost all structural steel is grades S275 and S355. Higher grades are available in

51
quenched and tempered material (500, 550, 620, 690, 890 and 960 - although
grades above 690 receive little if any use in construction at present).

Thermal properties

The properties of steel vary widely, depending on its alloying elements.

The austenizing temperature, the temperature where a steel transforms to an

austenite crystal structure, for steel starts at 900°C for pure iron, then, as more
carbon is added, the temperature falls to a minimum 724°C for eutectic steel
(steel with only .83% by weight of carbon in it). As 2.1% carbon (by mass) is
approached, the austenizing temperature climbs back up, to 1130°C. Similarly, the
melting point of steel changes based on the alloy.

The lowest temperature at which a plain carbon steel can begin to melt, its
solidus, is 1130 °C. Steel never turns into a liquid below this temperature. Pure
Iron ('Steel' with 0% Carbon) starts to melt at 1492 °C (2720 °F), and is completely
liquid upon reaching 1539 °C (2802 °F). Steel with 2.1% Carbon by weight begins
melting at 1130 °C (2066 °F), and is completely molten upon reaching 1315 °C
(2400 °F). 'Steel' with more than 2.1% Carbon is no longer Steel, but is known as
Cast iron. http://www.msm.cam.ac.uk/phase-trans/images/FeC.gif

Fireproofing of structural steel

In order for a fireproofing product to qualify for a certification listing of structural

steel, through a fire test, the critical temperature is set by the national standard,
which governs the test. In Japan, this is below 400°C. In China, Europe and North
America, it is set at ca. 540°C. The time it takes for the steel element that is being

52
tested to reach the temperature set by the national standard determines the
duration of the fire-resistance rating.

Care must be taken to ensure that thermal expansion of structural elements does
not damage fire-resistance rated wall and floor assemblies. Penetrants in a
firewalls and ferrous cable trays in organic firestops should be installed in
accordance with an appropriate certification listing that complies with the local
building code

53
 CHAPTER-6

SPECIFICATION&DESIGN OF MOTORIZED LIFT

54
 6. SPECIFICATION&DESIGN OF MOTORIZED LIFT

Lift height = 30cm

Length of rod = 27cm

No of threads = 105

Length of threaded area = 24cm

Depth of cut = 0.7cm

SPECIFICATION OF DC MOTOR:
Type - PM114

Volts - 12V DC

RPM - 30

Watts - 18

Duty - CONT

55
DESIGN

TONNAGE CALCULATION:

A=π/4*d2

A=π/4*122

=113.09mm2

P=F/A

=500/113.09

P= 4.42Kg/mm2

W= Total wt ram including the weight of load on ram

=P*A

=4.42*113.09

W =500 Kg

56
6.1. FUNCTIONAL DIAGRAM OF MOTORIZED LIFT

57
 6.2WORKING PRINCIPLE

A Motorized lift assembly comprising: a base member for resting the jack
assembly against a substantially flat surface; a support bracket assembly; first and
second lower arm members each of an open channel construction with outer
sidewalls and having one end connected to said base plate; first and second upper
arm members each of an open channel construction with outer sidewalls and
having one end connected to said support bracket assembly; first and second
trunnions connecting said upper arms with said lower arms, each said trunnion
including a bore; a rotatable shaft member extending into the bores of said first
and second trunnions; at least one spacer dimensioned to substantially occupy
the space between the sidewalls of an upper or lower arm member for
maintaining the position of said rotatable shaft within the area between planes
created by the sidewalls of said upper or lower arm members; and a means for
locking at least said spacer on said rotatable shaft member.

58
 CHAPTER-7

ADVANTAGES&APPLICATION

59
 7. ADVANTAGES&APPLICATION

1. It reduces the burden of the worker

2. It is easy to operate

APPLICATIONS:

This type of system will be useful in workshop areas, car manufacturing

areas etc, This will have significant importance in these places.

7.1. COST ESTIMATION

MATERIAL
S.NO COMPONENT NOS COST(RS)
USED

1 BATTERY 2 - 900

2 SCREW JACK 1 MILD STEEL 600

3 D.C MOTOR - 1200

OVER HEAD
4 CHARGES&FABRICATI 1 2000
ON CHARGES

TOTAL 4700

Total cost =4700

60
CONCLUSION:

The motorized lift at form are the ideal product to push, pull, lift, lower and
position loads of anything from a couple of kilograms to hundreds of tonnes.The
need has long existed for an improved portable jack for automotive vehicles. It is
highly desirable that a jack become available that can be operated alternatively
from inside the vehicle or from a location of safety off the road on which the
vehicle is located. Further, it should be stable and easily controllable by a switch so
that jacking can be done from a position of safety. It should be easily movable
either to a position underneath the axle of the vehicle or some other reinforced
support surface designed to be engaged by a jack. Thus, the product has been
developed considering all the above requirements. This particular design of the X
flat form will prove to be beneficial in lifting and lowering of loads.

61
REFERENCES

1. Design of machine elements by V.B.Bhandari

2. A text book of machine design by Rajendra Karwa

3. Analysis and Design of Machine Elements by V K Jadon, Suresh Verma
4. Tribology in Machine Design by T. A. Stolarski
5. A text book of Machine Design by R.S.Khurmi,J.K.Gupta
6. Design of Machine Elements by Farazdak Haideri
7. Machine Design by S.G.Kulkarni
8. Design of machine elements by K.Rao

62