.

Bahirdar University
Bahirdar Institute of TechnologY
Fuculty of Mechanical and Industrial Engineering
Automotive Engineering Internship Report

Hosting Company: AMHARA ROAD CONSTRUCTION AGENCY

Project Title: Design Gearbox Hoist

Internship Duration: June 10, 2024- July 25, 2024

BY:
ID
ABOSET MULATU…………………….…………….……………1308451
MIGBARU KINDE……………………………………………....……1202437

Mentor: Mr.Tewodros.T
Company Supervisor: Getane Yasab

November 4, 2024

i
 Declaration
I declare that this internship report and project paper is my original work, except for some
references and manuals used. The references used are cited throughout the paper. The paper has
been submitted to the Faculty of Mechanical Engineering, Bahirdar Institute of Technology.
Name Signature Date

___________ ________________

Advisor Approval

I certify that the above statement made by the candidate is correct to the best of my knowledge
and belief. This paper is submitted for submission with my approval.
Name of Advisor________________________________ Signature _____________

ii
 Acknowledgement

First, I would like to thank my God for allowing me to successfully complete my internship and
go through difficult times during my internship. Second, my advisor Mr. Destaw B. helped me
choose the title of my project and gave me information on how to write a report. I would also like
to thank AMHARA ROAD CONSTRUCTION AGENCY, the company that gave me the
opportunity to do my internship with them. I am very happy to say that the AMHARA ROAD
CONSTRUCTION AGENCY staff not only for their hospitality but also for their positive
feedback to let me know what I was looking for, their approach was so good that it made me feel
at ease when I worked for the company. . They were not only AMHARA ROAD
CONSTRUCTION AGENCY workers, but also good friends to me, especially Migbaru who is in
charge of the unit reconstruction workshop and Meles who is in charge of the general department.
In general, gratitude is the most difficult emotion to express and often we cannot find the right
words to express all this feeling. I had the opportunity to meet many volunteers during my work
on the project, although it is impossible to include everyone's names here. I warmly thank the
employees of AMHARA ROAD CONSTRUCTION AGENCY for their valuable help and advice
in acquiring general technical knowledge.

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 Executive Summary

This internship report is based on the 1.5 months internship program that I successfully completed
at AMHARA ROAD CONSTRUCTION AGENCY. In total, this report contains four chapters.
In the first chapter, I briefly describe the background of the company, which includes a brief
history of the company, the main services, the main customers, the organizational structure, the
work flow, the mission, the vision and the value of the company . . . The second chapter of the
report discusses the general experience and the benefits of the internship, which briefly talks
about the section of the company where I worked, the work flow
and work tasks, and the types of tools, methods and techniques which I use to do my work. work
work professional work. . This chapter also talks about the main problems encountered in the
work and their proposed solution and then concludes with the benefits in general that I had from
the internship in different aspects. The third chapter of this report discusses the project that I
carried out for the problem of the company, which is the design of a mechanically operated
mechanical elevator, which is used to reduce and increase the speed of all models of box gears,
which reduces work and people. time with its simple and innovative design and is also committed
to finding the solution that is the main challenge of AMHARA ROAD CONSTRUCTION AGENCY.
This designed gear lifter is able to lower all kinds of gears that have a maximum weight of 1471.5
N, using only one manpower, thus reducing the work spent to lower and raise this gear and
synchronization. I have completely realized this project to make it as clear and understandable as
possible by clearly describing it, starting with the identification of
the problem and its justification, describing the objective and the methodology followed by a
design analysis and then ending with the creation of a elevator prototype. . The analysis of the
design is carried out by repeating the analysis of each component and assembly
of the CATIA program. The principle of work and the analysis of the cost of my project are also
clearly discussed. The material of each lifting part is selected to make the product durable, efficient
and safe with a total cost of 6350 birr. The last chapter ends with a general
conclusion and a recommendation for practice

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 Table content

Contents
Declaration .................................................................................................................................................... ii

Executive Summary ............................................................................................................................. iv

Table content................................................................................................................................................. v

List of Figures Figure................................................................................................................................... ix

List of Table .................................................................................................................................................. x

CHAPTER ONE ........................................................................................................................................... 1

Company Background .................................................................................................................................. 2

1.1. Brief History of Company.................................................................................................................. 2

i. Mission............................................................................................................................................. 4

ii. Vision.............................................................................................................................................. 4

iii. Values ........................................................................................................................................... 5

1.3.Main Customers and End Users .............................................................................................................. 6

1.4.Organizational Structure ..................................................................................................................... 6

1.5. Work Flow of the Company................................................................................................................... 7

THE OVERALL INTERNSHIP EXPERIANCE ................................................................................. 8

2.1 The section of Company I have been working in ................................................................................ 8

2.2 The work task I have performed in each section..................................................................................... 8

Maintenance and Repair Assistance: ............................................................................................................ 9

• Component Replacement and Repair: ...................................................................................................... 10

• Record Keeping and Documentation:....................................................................................................... 10

• Collaboration with Mechanics: ................................................................................................................. 11

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2.3 Engineering Methods, Techniques and Tools for executing tasks ........................................................ 11

2.3.1. Engineering Methods and Techniques for executing ....................................................................... 11

Engine Analyzers: ....................................................................................................................................... 11

Multimeters: ................................................................................................................................................ 12

Hydraulic Pressure Gauges: ........................................................................................................................ 12

Adjustable Wrench...................................................................................................................................... 13

Socket: ........................................................................................................................................................ 13

Ratchet: ....................................................................................................................................................... 14

Challenges and Problem Identification ....................................................................................................... 15

2.5. Problem-Solving Measures and Solutions ........................................................................................... 15

2.6. Overall Internship Benefits .................................................................................................................. 16

2.6.1. In terms of Practical Skills Development ......................................................................................... 16

2. 6.2. In terms of Upgrading Theoretical Knowledge ............................................................................... 17

2.6.3. In terms of Improving Team-Playing Skills..................................................................................... 17

2.6.4. In terms of Improving Leadership Skills .......................................................................................... 18

2.6.5. In terms of Understanding Work Ethics, Industrial Psychology, and Related Issues ....................... 18

2.6.6. In terms of Entrepreneurship Skills Development ........................................................................... 19

2.6.7. In terms of Interpersonal Communication Skills Improvement ........................................................ 19

Conclusion and Recommendations: ............................................................................................................ 19

CHAPTER THREE .................................................................................................................................... 21

DESIGN OF MECANICALLY OPERATING GEARBOX HOIST ......................................................... 21

3.1. Presentation of the problem and reasoning .......................................................................................... 21

3.1.1. Problem Statement ............................................................................................................................ 21

3.1.2.Justification ........................................................................................................................................ 21

3.2. The purpose of the project ................................................................................................................... 22

3.2.1. General purpose ................................................................................................................................ 22

3.2.2. Specific objective .............................................................................................................................. 22

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3.3. The purpose of the study ...................................................................................................................... 22

3.4. Working Principle ................................................................................................................................ 22

3.5. limitation .............................................................................................................................................. 23

3.6. Methodology ........................................................................................................................................ 24

3.6.1. Choice of material ............................................................................................................................. 24

3.6.2. Design analysis of major components .............................................................................................. 25

i. Bed console beam design......................................................................................................................... 25

Shear Force and Bending Moment Diagram of cantilever beam ................................................................ 29

iii. Design of caster beam............................................................................................................................ 35

Calculation of bending moment and shear force......................................................................................... 37

iv. Design of Rope ...................................................................................................................................... 40

vii. Design of Pillar ..................................................................................................................................... 49

Design to buckling ...................................................................................................................................... 51

3.7.1. Cost analysis ..................................................................................................................................... 53

Conclusion: ................................................................................................................................................. 55

Recommendations: ...................................................................................................................................... 55

CHAPTER FOUR ....................................................................................................................................... 56

GENERAL CONCLUSION AND RECOMMENDATION ...................................................................... 56

4.1. Conclusions .......................................................................................................................................... 56

4.2. Recommendation ................................................................................................................................. 57

Reference .................................................................................................................................................... 58

Appendices.................................................................................................................................................. 59

Part drawing ................................................................................................................................................ 59

i.Bed ............................................................................................................................................................ 59

ii. Rope drum .............................................................................................................................................. 60

iii. Pulley ..................................................................................................................................................... 61

iv. Shaft ....................................................................................................................................................... 62

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vi. Worm gear ............................................................................................................................................. 63

Assembly drawing ...................................................................................................................................... 64

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 List of Figures

Figure 1:Logo of AMHARA ROAD CONSTRUCTION AGENCY ......................................................................... 2

Figure 2: Head office of AMHARA ROAD CONSTRUCTION AGENCY ............................................................. 4
Figure 3: Overall organization structure. ...................................................................................................... 7
Figure 4: General workflow of Company ...................................................................................................... 7
Figure 5: Equipment Inspection and Diagnosis ............................................................................................. 9
Figure 6: auto repair ..................................................................................................................................... 9
Figure 7: the replaceable automoble ......................................................................................................... 10
Figure 8: Record Keeping and Documentation ......................................................................................... 11
Figure 9: the engine analyzers capture data............................................................................................... 12
Figure 10:The multimeter measuring ......................................................................................................... 12
Figure 11: Hydraulic pressure with five gauges .......................................................................................... 13
Figure 12: Open wrench and Combination wrench ................................................................................... 13
Figure 13: Close wrench and Adjustable wrench........................................................................................ 14
Figure 14: Socket and Ratchet ................................................................................................................... 14
Figure 15: Mechanically operating gearbox hoist....................................................................................... 23
Figure 16- 3D CATIA Design of Bed Cantilever beam .................................................................................. 25
Figure 17: 3D CATIA design of beam ........................................................................................................... 31
Figure 18: 3D CATIA Design of Caster beam ............................................................................................... 36
Figure 19: 3D CATIA Design of Shaft ........................................................................................................... 47
Figure 20: 3D CATIA Design of pillar .......................................................................................................... 49
Figure 21: fabrication process of my project prototype ............................................................................. 53

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 List of Table
Table 1 Indian standard designation of steel .............................................................................................. 26
Table 2: Standard Wire rope table .............................................................................................................. 43
Table 3: Actual and equivalent length of pillar ........................................................................................... 51
Table 4: Standard Table of Channel section ............................................................................................... 51
Table 5: cost analysis table ......................................................................................................................... 54

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 Abstract

This internship report details my experience at the Amhara Road Construction Agency
(ARCA), where I gained practical experience in heavy equipment maintenance and
management. The internship focused on assisting with equipment inspection and diagnosis,
maintenance and repair, component replacement, record keeping, and collaborating with
experienced mechanics. Through this hands-on experience, I developed proficiency in using
diagnostic tools, understanding maintenance schedules, and identifying various components.
I also gained valuable insights into the challenges faced by the maintenance department, such
as equipment downtime, parts availability, and safety concerns. Based on my observations,
I proposed solutions to address these challenges, including implementing a more structured
maintenance schedule, exploring additional parts suppliers, and investing in training
programs for mechanics. This internship provided invaluable practical experience,
enhanced my theoretical knowledge, and fostered my professional development.

1
 CHAPTER ONE

Company Background
1.1. Brief History of Company
The Amhara Road Construction Agency (ARCA) plays a crucial role in developing and
maintaining a robust road network within the Amhara Region of Ethiopia. Established in 1995,
ARCA has been instrumental in connecting communities, facilitating economic growth, and
contributing to the overall development of the region. This document provides a comprehensive
overview of ARCA, exploring its history, core operations, organizational structure, and key
workflows.

Figure 1:Logo of AMHARA ROAD CONSTRUCTION AGENCY

• 1995: ARCA was established by the Amhara Regional Government to address the growing need
for improved road infrastructure within the region. The agency began by focusing on repairing and
upgrading existing roads, improving connectivity and access for local communities.
• 2000-2010: ARCA expanded its scope, taking on larger and more complex road construction
projects. This period saw the construction of vital regional highways, connecting major towns and
cities within the Amhara Region.

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• 2010-Present: ARCA continued to strengthen its position as a leading road construction agency
in Ethiopia, undertaking increasingly sophisticated projects. The agency focused on improving
road quality, incorporating sustainable practices, and implementing new technologies to enhance
efficiency and durability. Specialized units were established for road maintenance and
rehabilitation, ensuring the longevity of the constructed infrastructure.

Amhara Road Construction Agency (ARCA) Today

While ARCA has a solid foundation established over its 28 years, the landscape of road
construction and infrastructure development in Ethiopia, and globally, is constantly evolving.
Here's a look at some key aspects of ARCA today, considering recent developments
1. Focus on Sustainability and Climate Resilience:
• Shifting Priorities: ARCA is increasingly focusing on building roads that are resilient to climate
change impacts, such as droughts, heavy rainfall, and extreme temperatures. This involves using
environmentally friendly materials and techniques.
• Examples: ARCA might be using:
Recycled materials: Recycled asphalt and aggregate in road construction.
Improved drainage systems: To manage water runoff and prevent erosion.
Climate-resistant designs: Employing design features that minimize environmental impact and
increase road longevity.
2. Increased Use of Technology:
• Modernization: ARCA is embracing technology to improve efficiency and project management.
3. Expanding Scope and Partnerships:• Beyond Regional Focus: ARCA may be expanding its
scope to include projects outside the Amhara Region, partnering with other agencies and
organizations.
• International Collaboration: Seeking partnerships with international organizations for technical
assistance, funding, and knowledge sharing on sustainable and climate-resilient infrastructure .

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 .

Figure 2: Head office of AMHARA ROAD CONSTRUCTION AGENCY

Mission, Vision, and Values of the company

You're asking for the . It's important to note that ARCA is primarily a road construction agency.
While they likely manage a fleet of heavy vehicles, it's unlikely they have a separate, distinct
automotive company. However, I can provide you with a hypothetical mission, vision, and values
that could be relevant to ARCA's automotive operations :
i. Mission
• To provide reliable, safe, and cost-effective automotive services that support the efficient
operation of ARCA's construction projects, contributing to the development of high-quality road
infrastructure in the Amhara Region.
ii. Vision
• To be recognized as the leading provider of automotive services within the Amhara Region,
known for its expertise, professionalism, and commitment to sustainability.

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iii. Values
• Safety First: Prioritize the safety of all personnel, equipment, and the environment.
• Reliability and Quality: Strive for high-quality maintenance and repair services,
ensuringreliable and dependable operation of equipment.
• Efficiency and Cost-Effectiveness: Optimize resource utilization, minimize downtime, and strive
for cost-effective maintenance practices.
• Sustainability: Promote environmentally friendly practices, reduce waste, and utilize sustainable
solutions in automotive operations.
• Continuous Improvement: Continuously seek opportunities to improve skills, processes, and
technologies to enhance service quality.
• Teamwork and Collaboration: Foster a positive and collaborative work environment among
mechanics, technicians, and other staff.
1.2 Main Products and Services
ARCA's primary products and services revolve around road infrastructure development:
• New Road Construction: ARCA constructs a wide range of roads, including:
• National Highways: Connecting major cities and regions across Ethiopia, facilitating long-
distance travel and trade.
•Regional Roads: Connecting towns and districts within the Amhara Region, improving
connectivity and access for local communities.
•Feeder Roads: Providing access to rural areas and agricultural zones, supporting economic
activities and agricultural development.
• Road Rehabilitation & Maintenance: ARCA ensures the longevity and functionality of existing
road infrastructure through:

•Routine Maintenance: Regular inspections, minor repairs, and preventative measures to maintain
the road's condition.
•Periodic Maintenance: Major rehabilitation work, resurfacing, and structural repairs to restore the
road to its original condition.
• Bridge Construction: ARCA builds and maintains bridges across rivers and ravines, providing
essential connectivity and facilitating transportation across geographical barriers.
• Drainage Systems: ARCA designs and constructs drainage systems to manage water runoff,
protecting the integrity of the road infrastructure and preventing erosion.
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 1.3.Main Customers and End Users
• Direct Customers:
Amhara Regional Government: The primary customer for all road infrastructure projects within
the Amhara Region, providing funding and oversight.
-Federal Government: For national highway projects and strategic infrastructure development
that extends beyond the regional scope.
• Indirect Customers/End Users:
-Citizens of Amhara Region: Beneficiaries of improved transportation and connectivity,
facilitating access to education, healthcare, markets, and economic opportunities.
-Businesses and Industries: Improved access to markets, raw materials, and workforce, fostering
economic growth and industrial development in the region.
-Agriculture and Farming: Enhanced access to markets for agricultural products, promoting
economic prosperity in rural areas and supporting the agricultural sector.

1.4.Organizational Structure
AMHARA ROAD CONSTRUCTION AGENCY Company is currently organized in four
divisions and nine Departments that enable toits customers and avail modern after sales facility; it
has established four branches in four corners of the country in the last seven years. Following the
establishment of branches and sub-dealers network, our customers have been privileged to have
easy access to genuine spare partsales and maintenance services provided by the company. These
four divisions and nine maindepartments and their sub departments are explained in the overall
organization structure. AccountantJunior Accountant Cashier warehouseman Senior sales person
Sales person Lead technician Senior service advisor Senior Technician Service advisor
TechnicianJunior Service advisor Lead body technician Senior body technician Body technician

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.

Figure 3: Overall organization structure.

1.5. Work Flow of the Company

The general work flow of the company includes the whole processes done while one car is being
serviced. Most of the time governmental cars are serviced at the company which need a fastest
service time. For this reason the work is divided into different sections.The figure below shows
the general work flow diagram of the company.

Figure 4: General workflow of Co

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 CHAPTER TWO
THE OVERALL INTERNSHIP EXPERIANCE
My internship at the Amhara Road Construction Agency (ARCA) provided an invaluable
opportunity to gain practical experience in automotive engineering, specifically within the context
of heavy equipment maintenance and management. This report details my journey, highlighting
my responsibilities in the Equipment Maintenance Department, the skills I acquired, the challenges
I encountered, and the overall impact of this experience on my professional development.

2.1 The section of Company I have been working in

Their are many section of work in this company among these
• Equipment Inspection and Diagnosis
• Maintenance and Repair Assistance
• Component Replacement and Repair
• Record Keeping and Documentation
• Collaboration with Mechanics

2.2 The work task I have performed in each section

i.Equipment Inspection and Diagnosis: I learned to conduct thorough inspections of various types
of heavy machinery, including excavators, bulldozers, graders, and dump trucks, identifying
potential mechanical issues, wear and tear, and potential safety hazards. I utilized diagnostic tools
like engine analyzers, hydraulic pressure gauges, and multimeters to analyze engine performance,
hydraulic systems, and electrical components.

8
 .

Figure 5: Equipment Inspection and Diagnosis

Maintenance and Repair Assistance:

I assisted experienced mechanics in performing routine maintenance tasks, including oil changes,
filter replacements, lubrication, and general inspections. I also learned to troubleshoot and repair
basic mechanical issues, including engine problems, hydraulic leaks, and electrical malfunctions,
gaining practical experience in diagnosing and resolving common issues .

.
Figure 6: auto repair

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• Component Replacement and Repair:
I gained experience in replacing worn-out parts and components, such as brake pads, filters, belts,
hoses, and various other mechanical components. I learned the correct procedures for removing,
installing, and adjusting these components, developing a strong understanding of the assembly and
disassembly of heavy equipment systems.

Figure 7: the replaceable automoble

• Record Keeping and Documentation:

I helped maintain detailed records of equipment maintenance, repairs, and parts usage, contributing
to the overall tracking of equipment performance and maintenance history. This experience
highlighted the importance of accurate documentation for managing a large equipment fleet and
improving maintenance planning.

10
 Figure 8: Record Keeping and Documentation

• Collaboration with Mechanics:

I worked closely with experienced mechanics, observing their techniques, asking questions, and
learning from their expertise. This collaborative environment fostered a learning atmosphere and
allowed me to develop my problem-solving skills, gaining practical knowledge and a deeper
understanding of heavy equipment maintenance.

2.3 Engineering Methods, Techniques and Tools for executing tasks

2.3.1. Engineering Methods and Techniques for executing

The internship provided me with valuable exposure to engineering methods and tools used in
automotive maintenance:
• Diagnostic Tools: I learned to utilize various diagnostic tools, including engine analyzers,
multimeters, hydraulic pressure gauges, and scan tools to pinpoint problems within various
systems of the heavy equipment.
You're right to focus on the functions of these tools, as understanding their specific roles is key to
using them effectively. Here's a breakdown of their primary functions:

Engine Analyzers:
Engine analyzers are designed to measure and analyze various parameters related to an engine's
operation, providing a detailed snapshot of its performance. They capture data from sensors placed
on the engine and display it in a way that makes it easy for technicians to interpret.

.
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 Figure 9: the engine analyzers capture data

Multimeters:
Multimeters are versatile electrical testing instruments used to measure a range of electrical
quantities. They are essentially a combination of different meters in one compact device.

Figure 10:The multimeter measuring

Hydraulic Pressure Gauges:

Hydraulic pressure gauges are specialized devices used to measure the pressure within hydraulic
systems. They are crucial for diagnosing and troubleshooting issues related to hydraulic fluid flow
and pressure.

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 .

Figure 11: Hydraulic pressure with five gauges

Adjustable Wrench:
An adjustable wrench is a versatile tool that can tighten or loosen nuts and bolts of various sizes.
Its most defining feature is its adjustable jaw, which can be opened and closed to fit different nut
sizes.

Figure 12: Open wrench and Combination wrench

Socket:
A socket is a hollow, cylindrical tool designed to fit over a nut or bolt head. It provides a secure
grip and allows for efficient torque application when tightening or loosening fasteners.

13
 .

Figure 13: Close wrench and Adjustable wrench

Ratchet:
A ratchet is a tool with a handle and a mechanism that allows for continuous turning in one
direction while preventing movement in the opposite direction.

Figure 14: Socket and Ratchet

• Technical Manuals and Service Literature: I familiarized myself with technical manuals, service
literature, and repair guides specific to the different types of heavy equipment used by ARCA,
developing a solid understanding of the equipment's specifications and repair procedures.
• Maintenance Schedules and Procedures: I learned about different maintenance schedules and
procedures based on operating hours, environmental conditions, and specific equipment
requirements, gaining a deeper understanding of preventive maintenance best practices.
• Material and Component Identification: I learned to identify different types of materials,
components, and fluids used in heavy equipment, developing knowledge about the properties and
functions of various parts.
• Basic Welding and Fabrication: I gained basic experience in welding and fabrication techniques
used in repairing damaged parts and components, enhancing my understanding of metalwork and
the repair process.

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 Challenges and Problem Identification
The internship also presented various challenges that I learned to address:

• Equipment Downtime: Frequent equipment breakdowns and repairs resulted in downtime,

disrupting construction schedules and impacting project timelines. This highlighted the importance
of preventive maintenance, effective troubleshooting, and swift repair procedures.
• Parts Availability and Delays: Obtaining specific parts and components for heavy equipment
could be challenging, especially in a remote location. This situation underscored the importance
of managing parts inventory, exploring alternative suppliers, and implementing effective supply
chain management.
• Limited Resources and Expertise: Sometimes, the maintenance department faced limitations in
resources, such as specialized tools, skilled personnel, and technical documentation. This
emphasized the need for continuous training, resource optimization, and efficient management
within the department.
• Safety Concerns: Ensuring the safety of mechanics, equipment operators, and others working on
the construction site was a paramount concern. This highlighted the importance of adhering to
safety protocols, using appropriate personal protective equipment, and fostering a culture of safety
awareness.
• Environmental Considerations: The maintenance process often generated waste materials, posing
environmental challenges. This highlighted the need for environmentally responsible practices,
proper waste disposal, and the exploration of sustainable solutions for equipment maintenance.

2.5. Problem-Solving Measures and Solutions

To address these challenges, I actively contributed to the implementation of solutions:
• Improved Maintenance Schedules: I proposed implementing a more structured and proactive
preventive maintenance schedule, based on operating hours, environmental conditions, and
specific equipment requirements. This aimed to reduce breakdowns and minimize downtime.
• Parts Sourcing and Inventory Management: I suggested exploring additional parts suppliers and
developing a more robust inventory management system to ensure the availability of critical
components, reducing delays and minimizing downtime.

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• Skill Development and Training: I advocated for investing in training programs for mechanics to
enhance their skills and knowledge, specifically in the areas of troubleshooting, repair techniques,
and the use of advanced diagnostic tools.
• Safety Audits and Training: I participated in safety audits and helped conduct safety training
sessions for mechanics, highlighting the importance of safe work practices, proper use of safety
equipment, and hazard awareness.
• Environmental Practices: I researched and proposed environmentally friendly practices for waste
disposal, recycling of used fluids, and reducing the environmental impact of maintenance activities.

2.6. Overall Internship Benefits

In internship program or university industry linkage program I developed knowledge.
Generally,when I was in AMHARA ROAD CONSTRUCTION AGENCY I observed some
application of vehicle production factory and personal communication skill would be improved
peacefully with staff members and other work partners. Some of benefits I gained during my
internship periods are discussed as follow:

2.6.1. In terms of Practical Skills Development

This internship significantly enhanced my practical skills, bridging the gap between theoretical
knowledge and real-world applications:
• Hands-on Mechanical Skills: I gained practical experience in identifying, diagnosing, and
resolving various mechanical issues, developing my troubleshooting skills and hands-on
experience with heavy equipment systems.
• Diagnostic Tool Proficiency: I learned to use various diagnostic tools effectively, analyzing data,
interpreting results, and pinpointing problems within different equipment

strong understanding of routine maintenance procedures, preventive maintenance schedules, and

best practices for ensuring equipment longevity and operational efficiency.

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• Component Identification and Repair: I gained practical experience in identifying, removing,
installing, and adjusting various components and parts, improving my understanding of the
assembly and disassembly of heavy equipment systems.
• Basic Welding and Fabrication: I acquired basic welding and fabrication skills, enhancing my
understanding of metalwork and repair techniques used in the maintenance process.

2. 6.2. In terms of Upgrading Theoretical Knowledge

The internship provided opportunities to deepen my theoretical knowledge:
• Diesel Engine Systems: I gained a deeper understanding of diesel engine operating principles,
including combustion cycles, fuel systems, lubrication systems, and cooling systems.
• Hydraulic Systems: I learned about hydraulic systems in heavy equipment, including hydraulic
pumps, cylinders, valves, and control circuits.
• Electrical Systems: I gained knowledge of the electrical systems in heavy equipment, including
generators, alternators, starters, wiring, and control circuits.
• Maintenance Planning and Scheduling: I learned about effective maintenance planning strategies,
including preventive maintenance schedules, corrective maintenance protocols, and the use of
software for tracking maintenance records.
• Safety and Environmental Regulations: I became familiar with safety protocols and
environmental regulations relevant to heavy equipment maintenance and operation, understanding
the importance of safety and environmental responsibility.

2.6.3. In terms of Improving Team-Playing Skills

Working in a collaborative environment with experienced mechanics fostered essential teamwork
skills:
• Effective Communication: I learned to communicate effectively with mechanics, supervisors,
and other team members, using clear language, active listening, and visual aids to ensure shared
understanding.
• Problem-Solving as a Team: I worked collaboratively with mechanics to diagnose and resolve
complex issues, learning to share knowledge, perspectives, and ideas effectively.

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• Building Respect and Trust: I developed a strong sense of respect and trust with the mechanics,
fostering a positive work environment and encouraging open communication.

2.6.4. In terms of Improving Leadership Skills

This internship provided opportunities for leadership development:
• Taking Initiative: I sought out opportunities to contribute, took responsibility for tasks, and
demonstrated initiative in problem-solving, showcasing my willingness to step up and take
ownership of my work.
• Mentoring and Guidance: I helped to mentor and guide less experienced mechanics, sharing my
knowledge and skills, contributing to a positive learning environment within the team.
• Decision-Making and Problem-Solving: I participated in discussions regarding equipment
maintenance, offering my perspective, and contributing to decision-making processes,
demonstrating my ability to contribute to a team's problem-solving efforts.

2.6.5. In terms of Understanding Work Ethics, Industrial Psychology, and

Related Issues
The internship provided valuable insights into work ethics, industrial psychology, and related
issues:
• Work Ethic and Professionalism: I learned the importance of a strong work ethic, punctuality,
professionalism, and a dedication to safety within a demanding environment.
• Team Dynamics and Collaboration: I observed the importance of effective team dynamics, the
value of communication, and the role of mutual respect in fostering a productive work environment.
• Employee Motivation and Productivity: I gained an understanding of how factors such as training,
recognition, and a positive work environment contribute to employee motivation and productivity.
• Safety Culture and Practices: I observed how safety protocols, regular safety audits, and a
proactive approach to safety contribute to a safe work environment for everyone involved in heavy
equipment maintenance.

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2.6.6. In terms of Entrepreneurship Skills Development
The internship fostered an entrepreneurial mindset:
• Problem Identification and Solution: I learned to identify problems related to equipment
maintenance and proactively suggested potential solutions, demonstrating a willingness to seek
improvements.
• Resource Management and Optimization: I participated in discussions regarding the efficient
use of resources, such as tools, parts, and time, understanding the importance of cost-effectiveness
and resource allocation.
• Innovation and Creativity: I encouraged the team to think creatively about solutions, explore
new technologies, and implement innovative approaches to maintenance practices.

2.6.7. In terms of Interpersonal Communication Skills Improvement

The internship significantly improved my interpersonal communication skills:
• Effective Listening: I developed active listening skills, understanding perspectives, and fostering
open communication within the team, demonstrating my ability to listen attentively and engage in
meaningful dialogue.
• Clear and Concise Communication: I learned to communicate clearly and concisely, both
verbally and in writing, ensuring messages are understood effectively, demonstrating strong
communication skills.
• Building Relationships: I developed strong relationships with colleagues, supervisors, and
stakeholders, fostering trust and collaboration, demonstrating my ability to build rapport and foster
positive relationships.

Conclusion and Recommendations:

My internship at the Amhara Road Construction Agency was an invaluable learning experience. I
highly recommend this internship program to engineering students seeking practical exposure and
real-world application of their knowledge in automotive engineering, especially within the context
of heavy equipment maintenance.

19
The internship not only enhanced my technical skills and knowledge but also fostered essential
soft skills, such as teamwork, leadership, communication, and problem-solving. It instilled a deep
appreciation for the importance of ethical considerations, workplace dynamics, and the role of
infrastructure development in societal progress.
This internship experience has equipped me with the necessary skills and knowledge to pursue a
successful career in automotive engineering, contributing meaningfully to the field of heavy
equipment maintenance and making a positive impact on the construction industry.

20
 CHAPTER THREE

DESIGN OF GEARBOX HOIST

3.1. Presentation of the problem and reasoning

3.1.1. Problem Statement

In this company, there is no lifting device used to lower and raise the transmission box of all
vehicle models when removing and installing the vehicle transmission box. In fact, the company
has a transmission jack that is used to lower and raise the transmission case, but these transmission
jacks are not lowered and raised in all vehicle models. Used for Land Cruiser Model 79
Transmission Only Although these transmission jacks are used for the Model 79 transmission, do
not lower the transmission until it is on the ground. After landing in the distance, hold the gearbox
because it is not able to put the gearbox on the ground, which may cause the failure of the jack
because the gearbox is heavy, so the jack is not allowed to hold the gearbox to a long time Remove
the gearbox from the transmission jack and put the gearbox on the ground to do the work. Other
vehicle transmission models require a lot of work and up to 8 mechanics to lower and raise the box
during removal and assembly of the vehicle. All that time spent by mechanics disassembling and
reassembling the box leads to decreased productivity and is also a safety hazard for the mechanics.

3.1.2.Justification
reason To solve all the AMHARA ROAD CONSTRUCTION AGENCY problems related to
lowering and raising any kind of merchandise, I had a good idea that would solve all the difficulties.
I designed a mechanical lifter that is used for all models of vehicle transmission boxes, which is

21
easy to use, safe to use, saves energy and time spent earlier, resulting in increased productivity
rates, reduce the direct labor of a single mechanic and also reduce. gearbox on the ground or until
it rests on its support.

3.2. The purpose of the project

3.2.1. General purpose

-To design mechanically operating gearbox hoist

3.2.2. Specific objective

Design the basic components of the hoist
-Reduce labor
-Improve your productivity rate
-Choose the right material for production
-Analyze the cost required for the design

3.3. The purpose of the study

The design focuses only on the design of a gearbox lifting machine that is used to lower and raise
the gearbox while removing and reassembling it from a vehicle in the AMHARA ROAD
CONSTRUCTION AGENCY company. This project went through several phases. it is about: -
finding the problem, designing each component with the right formula, showing the car with
CATIA software and finally creating the prototype of my car 3.4. Concept design Before choosing
the right design for my car, I tested three different concept models. Finally, review each product
one by one and choose the best one based on the following criteria:
-cost
-Manufacturability
-Maintainabilty

3.4. Working Principle

The elevator has six main mechanical parts. These are the two poles on the left and right, the upper
beam on which the pulley is fixed, the bed, which consists of a thin thin plate and balls attached to
movable rods, the shaft on which the drum cable, gears, worm is. fixed, the worm, the bearing, the
22
handle and the rotating beam on which the wheel is fixed. To raise and lower the bed we use the
handle that is connected to the worm and this worm translates the direction of movement of the
handle into the direction of movement of the shaft through the gear at the end of the worm that is
connected to the tree , so that the rotation of the handle turns the shaft. When the shaft rotates, the
cable that is attached to the bed is wound on the drum (the bed goes up) or released from the drum
(the bed goes down) that is attached to the shaft and this winding or release of the cable it hangs .
of the direction of rotation of the handle. When we turn the handle clockwise, the bed moves, and
when we turn the handle clockwise, the bed moves. So to lower or raise the reducer, simply place
the reducer on the bed and turn the handle in the desired direction.

Figure 15: Mechanically operating gearbox hoist

3.5. limitation
Since my car is operated mechanically, it uses labor force and the bed in the bed also takes time.
So I want to comment on the design of a building that works with pneumatic, hydraulic or electrical
energy and also reduces the time to transform the bed.

23
3.6. Methodology
The design and production procedures of my project are as follows:
-design analysis
-material selection
-modeling of major components using the CATIA V5
-prototyping process
-cost analysis

3.6.1. Choice of material

Care must be taken to choose the right material. Suitability of the material for the transformation
process and the compatibility of the material with the environment. The choice of the right material
for the best material engineering is the one that saves the design objective and maximizes the cost.
Several production factors are considered during the selection of material, which is the main
purpose of designing or manufacturing a machine. The selection of the material must take into
account the needs or properties of the material, sufficient strength and ease of use. The most
economical material that meets the processing and mechanical requirements should be considered
the material that offers:
-Safety during work
-Tool capacity
-Low life cost
-Availability of the material
-Adaptability of the material for service work
-Cost of the material and ease of production or processing
The properties of the material are very important in the choice of the material. Some important
mechanical properties that are considered in the selection of the material are:
- Roughness, i.e. resistance to breakage
-Strength
-Hardness, i.e. resistance to wear
-Corrosion resistance

24
3.6.2. Design analysis of major components

i. Bed console beam design

The bed is the seat of the reducer that moves up and down several places. The lifting bed is
composed entirely of thin plates, spheres and two cantilever beams on the left and right on which
the plate is fixed. The balls are inserted between the slabs and allow the upper floor to slide on
them while the lower floor is attached to the cantilever beam bed. This beam is subjected to
bending moment and shear force due to reducer load.

Material Selection

Figure 16- 3D CATIA Design of Bed Cantilever beam

I have chosen "Mild Steel, Specification Fe 410" for this beam design for the following reasons: -
-It provides a high surface hardness and a soft core for the parts.
-It is used to avoid collisions in tight curves .
-has an excellent welding and produces a uniform and stronger shell and is considered the best
steel for carburized parts.
-It also has a good balance between toughness, strength and ductility.
Its mechanical property
-Tensile strength = 410 Mpa

25
 -Yield strength = 250Mpa
-Modulus of elasticity (E) = 200 Gpa

Table 1 Indian standard designation of steel

Specification
-Cross with a rectangular hole
-Length = 500 mm
-Weight carried (in W = p * g = 75 * 9.81 735
The weight of the reducer is distributed as, W = 735.75 / 0.3 = 2452.
Calculation of the bending moment and shear force
Step 1: Calculate the negative external force

26
∑Fy= 0; R A-2452.5(0.3) = 0

R A=735.75N

∑MA=0: Mo – 2452.5(0.3)(0.25)=0

Mo= 183.94Nm

Step 2: Calculate the bending moment and the shear force to obtain the maximum moment
To obtain the maximum moment, divide the beam into three sections and calculate the bending
moment and shear force in each section.

Bending moment Shear Force

∑M1@o=0 ∑Fy = 0
M1-735.75x + 183.94=0 -V1 + 735.75N
M1=735.75x + 183.94 V1 = 735.75N
Where : X = 0, M1 = 18394Nm
X = 0.1, M1 = -110.365Nm
Section 2-2 [0.1≤x≤0.4m]

27
 .

Bending moment Shear Force

∑Mo = 0 ∑Fy = 0
M2−735.75x +183.94 + 2452.5(x-0.1)(x - 0.1)/2=0 , -V2 + 735.75−2452.5(x−0.1)=0
M2=735.75x−183.94−1226.25(x^2−0.2x+0.01) , V2=735.75−2452.5(x−0.1)
M2=−1226.25x^2+981x−196.2025 V2=−2452.5x + 981
ℎ=0.1
where: x = 0.1m, M2=−110.365Nm where: x = 0.1m, V2= 735.75N
x=0.4m, M2= −0.0025Nm x =0.4m , V2= 0

Section 3-3 [0.4m≤x≤0.5m]

Bending moment Shear Force

∑Mo = 0 ∑Fy = 0
M3−735.75x+183.94+2452.5(0.3)(x−0.25)=0 , -V3+735.75−2452.5(0.3)=0
M3=735.75x+183.94−735.75x−183.9375 , V3=735.75−735.75
M3=−0.0025 V3=0
Where X = 0.4m, M3 = -0.0025Nm Where X = 0.4m, V3 = 0
X = 0.4m M3 = -0.0025Nm X = 0.5m, V3 = 0
-From the above calculation I get the bending moment and the Shear force in each sectionof the
beam the results are:-
Bending moment Shear Force

28
 Where X = 0m M1=−183.94Nm Where X1 = 0m, V1=735.75
X = 0.1m M1=−110.365Nm X2 = 0.1m, V2=735.75
X = 0.1m M2=−110.365Nm X = 0.4m V3=0
X = 0.4m M2= −0.0025Nm X = 0.5m V4 =0
x = 0.4m M3= −0.0025Nm
x = 0.5m M3= −0.0025Nm
The maximum bending moment is 183.94Nm=183940Nm
The Shear Force and Bending Moment diagram of the beam is

Shear Force and Bending Moment Diagram of cantilever beam

Failure check

Check for failurity of beam due to induced bending stress in the beam.

29
Where : ℎ=100mm and b=60mm
Then ∶ w=b−2t and d=ℎ−2t
W=60−2×6=48mm and=100−2×6=88mm c=0.5 ℎ=50mm
I=1/12[(bℎ^3−wd^3)]
I =[(60× 100^3) – (48×88^3)] =2274112mm4
From bending formula:

.
The design analysis for the rest of the cantilever beam is the same as the equal load is distributed
in them.
ii. Beam design
This is the upper lifting bar to which the pulley is attached and which connects the two posts.
This beam is a structural element that is subjected to negligible transverse loads and axial loads.
The transverse load causes an internal shear force and bending moment in the beam.

30
 .

Figure 17: 3D CATIA design of beam

material selection

I chose “Mild Steel, Specification Fe 410” for this beam design for the following reasons: -
-It provides high surface hardness and a soft core to the parts
- It used to improve. Boring, threading and boring processes.
-Used to avoid run-outs in sharp bends.
-Has excellent weldability and produces a uniform and stronger shell and is considere the best
steel for carburized parts.
-Also has good weldability . Balance between durability, strength and ductility.
mechanical property:-
-Ultimate tensile strength = 410Mpa
-Yield strength = 250Mpa
-Modulus of elasticity (E) = 200Gpa

Specification
-Rectangular hole cross section
-Length = 800mm
-The weight carried = weight of gearbox(150kg) + weight of bed(5kg) + weight of beam,rope
and pulley(2kg) = 157kg
Total load on the hoist = w*g = 1540.17N
Calculation of bending moment and shear force
Step1: To calculate the external support force

31
∑Fy= 0
R1+R2=1540.17
∑MA=0 , R2×800−1549.17×400=0, R2=616068/800=770.085N
R1=R2 because of symmetry then R1=R2 =770.085N
Step2: Bending moment and shear force to get maximum moment
To get the maximum moment section the beam in to two parts and calculates the bending moment
and shear force in each section.

Section 1-1 [0≤X≤0.4m] 

Bending moment Shear Force

∑Mo = 0 ∑Fy = 0
M1-770.085x=0 -V1+770.085=0
M1=770.085x V1=770.085 N
Where : x=0, M1=0

32
 X=0.4, M1=308034 Nm
Section 2.2[0.4<x<0.8m]

Bending moment Shear Force

∑Mo = 0 ∑Fy = 0
M2-770.085x+1540.17(x-0.4)=0 -V2+770.085-1540.17=0
M2=770.085x+616.068 V2=770.085N
Where: X=0.4, M2=308034Nm
X=0.8, M2=0Nm
From the above calculation I get the bending moment and shear force in each section of the shaft
the results are:-
Bending moment Shear Force
∑Mo = 0 ∑Fy = 0
Where X=0, M1=0 Where X=0, V1=770.085N
X=0.4, M1=308.034Nm X=0.85, V2=-770.085N
X=0.4, M2=308.034Nm
X=0.8, M2=0Nm
The maximum bending moment is 308.034Nm=308034Nm
The Shear Force and Bending Moment diagram of the beam is

33
 .

Shear Force and Bending Moment Diagram of beam

Failure check
Check for failurity of the beam due to induced bending stress in the beam

34
 Where:h=100mm and b=60mm
Then:w=b-2t and d=h-2t
W=60-2*6=48mm and d=100-2*6=88mm,c=0.5h=50mm
I=1/12[(bh^3-wd^3)]
I=1/12([60*100^3)-(48*88^3)]=2274112MM^4
From bending formula:

iii. Design of caster beam

Caster beam is a structural member that is subjected to transverse loads and negligible axialloads.
There is two caster beams that is the left and right pillars are welded on it. The transverseload
causes internal shear force and bending moment in the caster beam. The wheels thatenabling the
hoist to move place to place are attached on this beam.

35
 .

Figure 18: 3D CATIA Design of Caster beam

Material selection

I select “mild steel, specification of Fe 410 “ for this beam design due to the following reason:-
-It provides high surface hardness and a soft core to parts
-It is used to improve drilling machining, threading and punching processes.
-It is used to prevent crashing in sever bends.
-It has excellent weld ability and produces a uniform and harder case and itis considered as
the best steel for carburized parts.
-And also has a good balance of toughness, strength and ductility
Its mechanical property:-
-Ultimate tensile strength=410Mp
-Yield strength = 250Mpa
-Modulus of elasticity (E) = 200Gpa
Specification
-Rectangular hole cross section
-Length = 1200mm
-The weight carried = weight of gearbox(150kg) + weight of bed(5kg) + weight of beam,rope
and pulley(2kg) + weight of pillar and beam(3kg) = 160kg
Total load on the hoist = w*g = 1569.6NSince there is two caster beam, the total load is divided
into two W=1569.6/2=784.8N

36
Calculation of bending moment and shear force
Step1: To calculate the external support force

∑Fy= 0
R1+R2=784.8

∑MA=0 ,R2×1200−784.8×400=0, R2=313920/1200=261.6N

R1=784.8−261.6=523.2N
Step2: Bending moment and shear force to get maximum moment
To get the maximum moment section the beam in to two parts and calculates the bendingmoment
and shear force in each section.

Section 1-1 [0≤X≤0.4m]

37
Bending moment Shear Force
∑Mo=0 ∑Fy=0
M1−523.2x=0 −V1+523.2=0
M1=x V1=523.2N
X=0 , M1=0
X=0.4 , M1=209.28Nm

Section 2-2 [0.4≤x≤1.2m]

Bending Moment Shear Force

∑Mo=0 ∑Fy=0
M2−523.2x+784.8(x−0.4)=0 −V2+523.2−784.8=0
M2=−261.6x+313.92 V2=−261.6N
Where: x=0.4 , M2=209.28Nm
x=1.2, M2=0
From the above calculation I get the bending moment and the Shear force in each sectionof the
shaft the results are:-

Bending Moment Shear Stre

Where:x=0, M1=0 Where:X=0, V1=523.2N
X=0.4 , M1=209.28Nm X=1.2 , V2=−261.6N
X=0.4 , M2= 209.28Nm

38
X=1.2 , M2= 0

-The maximum bending moment is 209.28Nm=209280Nmm

The Shear Force and Bending Moment diagram of the beam is

Shear Force and Bending Moment Diagram of caster beam

Failure check

Check for failurity of the beam due to induced bending stress in the beam.

39
Where: ℎ=100mm and b=60mm
Then w=b−2t and d=ℎ−2t
w=60−2×6=48mm and d=100−2×6=88mm, c=0.5ℎ=50mm
I=1/12[(bℎ^3-wd^3)
I=1/12[(60×100^3)-(48*88^3)]=2274112mm4
From bending formula:

iv. Design of Rope

The rope drives are widely used where a large amount of weight is to be transmitted. In mydesign
I use a rope for lowering and lifting of the bed. This rope is first attached to the bed and
by passing on the pulley it is fixed on the drum of the rope which is welded on the shaft. so,when
the bed is moved up the rope is winded on the drum and when the bed is lowered the ropeis released
from the drum. The rope drives use the following two types of ropes :
1.Fibre ropes, and 2.Wire ropes.

40
Material selection
I select “a steel wire rope, due to the following reason:-
1.These are lighter in weight, 2.These offer silent operation,
3.These can withstand shock loads, 4.These are more reliable,
5.These are more durable, 6.They do not fail suddenly,
7.The efficiency is high, and 8.The cost is low
Specification:
-total weight on the rope (p) = weight of gearbox(150kg) + weight of bed(5kg)= 155kgW= p*g
= 155x9.81 = 1520.55N
Procedure for Designing a Wire Rope
1 .First of all, select a suitable type of rope from standard rope design tables(SRDT) for the given
application.
2.Find the design load by assuming a factor of safety 2 to 2.5 times the factor of safety givenin
SRDT.
3.Find the diameter of wire rope (d ) by equating the tensile strength of the rope selected to
thedesign load.
4.Find the diameter of the wire (dw) and area of the rope ( A) from SRDT.
5.Find the various stresses (or loads) in the rope.

41
.

42
D=Tff

Table 2: Standard Wire rope table

30d= 30 × 6 = 180 mm
∴ Bending stress,
. and the equivalent bending load on the rope, for steel wire rope)
W b= σ b × A= 176.4× 13.68 =2413.152 N
(d )the impact load during starting (when there is no slackness in the rope),
Wst= 2 (W + w) = 2(1520.55 + 4.14) =3049.38 N
6.the effective load on the rope during normal working (i.e. during uniform lifting or lowering of
the load)
=W+w+Wb= 1520.55 + 4.14 + 2413.152 =3937.84 N
∴ Actual factor of safety during normal working
= 1064385/393784=2.7
Effective load on the rope during starting=Wst+Wb= 3049.38 + 2413.152 =5462.5 N ∴
Actual factor of safety during starting
1064385/54625 =1.95

43
Since the actual factor of safety as calculated above are safe, therefore a wire rope of diameter6mm
and 6 × 19 type is satisfactory.
v. Design of Worm gearing
The worm gearing is

consists of worm and a worm wheel or gear. The worm (which is thedriving member) is usually
of a cylindrical form having threads of the same shape as that of aninvolute rack. The threads of
the worm may be left handed or right handed and single or multiplethreads. The worm wheel or
gear (which is the driven member) is similar to a helical gear with a face curved to conform to the
shape of the worm. The worm is generally made of steel while the worm gear is made of bronze
or cast iron for light service. I select steel for worm and phosphor bronze for the worm gear.

44
Specification

-20° involute worm and gear to transmit 20W

- V.R = 4
-The distance between the shafts is 100mm
The worm and gear is designed as discussed below:
1 Design of worm
Let lN = Normal lead, and
λ = Lead angle.
the value of x/l N will be minimum corresponding to cot3 λ =V.R. = 4 or cot λ = 1.59
∴ λ = 32.2°
We know that

.From Table , I find that for a velocity ratio of 4, the number of starts or threads on the
worm, n=Tw = 6
∴ Axial pitch of the threads on the worm,
pa=l/ 4 = 17.9 / 4 = 4.47 mm
∴ m= pa/ π = 4.47 / π = 1.42 mm
Let us take the standard value of module,m= 2 mm
∴ Axial pitch of the threads on the worm, pa= πm=3.13x2 =6.28 mm
Axial lead of the threads on the worm,
l= paxn= 6.28 × 6 =37.68 mm
and normal lead of the threads on the worm,
lN=lcos λ = 37.68 cos 32.2° =31.88 mm
We know that the centre distance,

45
 .
Since the velocity ratio is 4 and the worm has sextuple threads (i.e.n=T W = 6), therefore number
of teeth on the worm gear,
T G= 4 × 6 = 24
From Table, I find that the face length of the worm or the length of threaded portion is
LW= pc(4.5 + 0.02T W)= 6.28 (4.5 + 0.02 × 6) =29mm ...( pc= pa)
This length should be increased by 25 to 30 mm for the feed marks produced by the vibrating
grinding wheel as it leaves the thread root. Therefore let us take
LW= 50 mm
We know that depth of tooth,h= 0.623 pc= 0.623 × 6.28 = 3.9 mm...
(From Table )
and addendum,a= 0.286 pc= 0.286 × 6.28 =1.79mm
∴ Outside diameter of worm,
DOW = DW + 2a= 19 + 2 × 1.79 =22.6 mm
2. Design of worm gear
We know that pitch circle diameter of the worm gear,
DG =m x T G = 2 × 24 = 48 mm =0.048 m
From Table, I find that outside diameter of worm gear,
DOG = DG + 0.8903 pc= 48 + 0.8903 × 6.28 =53.59 mm
Throat diameter, DT = DG + 0.572 pc= 48 + 0.572 × 6.28 =51.59 mm
and face width,b= 2.15 pc+ 5 mm = 2.15 × 6.28 + 5 =18.5 mm
now check the designed worm gearing from the standpoint of tangential load, dynamic load and
static load or endurance strength.
(a)Check for the tangential load
Let N G = Speed of the worm gear in r.p.m.
velocity ratio of the drive,
V.R =Nw/NG ==>NG =Nw/VR =80/4 =20 rpm
∴ Torque transmitted,
T=p*60/2*3.14NG=20*60/2*3.14*20 =9.55Nm

46
and tangential load acting on the gear,
W T =2*T/DG=2*9.55/0.048 =397.9N
pitch line or peripheral velocity of the worm gear,
v = 3.14*DG*NG/60=3.14*0.048*20/60=0.05m/s
∴ Velocity factor,
Cv=6/6+V=6/6+0.05=0.99
and tooth form factor for 20°involute teeth, y= 0.154 –0.912/TG = 0.154 –0.912/24=0.116 Since
the worm gear is generally made of phosphor bronze, therefore taking the allowable staticstress
for phosphor bronze, σo = 84 MPa or N/mm2.
the designed tangential load,
W T = (σo xC v)b. πm. yW T = (84 × 0.99) 18.5 × π × 2 × 0.116=1120.7 N
Since this is more than the tangential load acting on the gear (i.e. 397.9 N), therefore the designis
safe from the standpoint of tangential load.
(b)Check for dynamic load
the dynamic load,
W D=W T /C v = 1120.7 / 0.99 =1132.2 N
Since this is more thanW T = 397.9 N, therefore the design is safe from the standpoint of
dynamic load.
(c)Check for static load or endurance strength
the flexural endurance limit for phosphor bronze is σe = 168 MPa or N/mm2
∴ Static load or endurance strength,
W S= σe.b. πm. y= 168 × 18.5 × π × 2 × 0.116 =2264.11 N
Since this is much more thanW T = 397.9 N, therefore the design is safe from the standpoint of
static load or endurance strength.
Vi Design of worm gear shaft

.
Figure 19: 3D CATIA Design of Shaft

47
Let d W = Diameter of worm shaft.
torque acting on the worm gear shaft,
Tgear=125P*60/2*3.14NG=12520*60/2*3.14*20=11.9 Nm
∴ Torque acting on the worm shaft,
Tworm = Tgear/V.R*efficiency ratio=11.9/4*0.89=3.35Nm
tangential force on the worm,
W T= Axial force on the worm gear
WT =2*Tworm/Dw=2*3.35/0.019 =352.6N
Axial force on the worm,
W A = Tangential force on the worm gear
WA=2*Tgear/DG=2*11.9/0.048=495.8 N
and radial or separating force on the worm
W R = Radial or separating force on the worm gear
=W A . tan φ = 495.8 × tan 20° =180.45N
so, the total force on the worm transmitted to the handle of the hoist =1028.85N from 1520.5N
total load need to operate the hoist 1028.85N force is covered by the worm gearing mechanism,
the rest 491.7N force is filled by man power.
the distance between the bearings of the worm shaft ( x1) equal to the diameter of the worm gear
( DG),i.e. x1=100mm
∴ Bending moment due to the radial force (W R ) in the vertical plane
=WR*X1/4=18045* 100/4=4511.4 Nmm
and bending moment due to axial force (W A) in the vertical plane
=WA*Dw/4=495.8*19/4 =2355.05Nmm
∴ Total bending moment in the vertical plane,
M 1 = 4511.4 + 2355.05 =6866.45 N-mm bending moment due to tangential force (W T) in the
horizontal plane,
M 2 =WT*DG/4=352*48/4=4231.2 Nmm
∴ Resultant bending moment on the worm gear shaft,
Mwgs =√M1^2+M2^2=√ 6866.45^2+4241.2^2
Mwgs =8065.43 N-mm
equivalent twisting moment on the worm gear shaft,

48
Tew =√Tgear^2+Mgear^2 =√ 11900+8065.43 = 14375.7 N-mm
14375.7 =3.14/16* τ(dG)^3 =3.14/16* 50(dG )^3 ...(Taking τ = 50 MPa or N/mm2)
dG3 = 1465dG= 11.36 = 12 mm
check the maximum shear stress induced.
the actual shear stress,
τ = 16Tew/3.14Dg^3=16*14375.7/3.14*12^3=42.39N/mm2
and direct compressive stress on the shaft due to the axial force,
σc =WA/3.14/4 (dG)^2 = 495.8/3.14/4 (12)^2 =4.38 N/mm2
∴ Maximum shear stress,
τmax =1/2√σc^2+4(τ)^2=1/2√4.38^2+4(42.39)^2
τmax = 42.45N/mm2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the design of
worm gear shaft is satisfactory.

vii. Design of Pillar

The pillar is the support that carries the all load of the machine. In my machine I use two support
pillars. The two pillars are carries the load of the gearbox, the load of the beam and the load of the
bed. The pillar have channel like cross section which is the bed is move up and down inside of the
channel. This pillar may be designed to normal stress and buckling.

.
Figure 20: 3D CATIA Design of pillar

Material selection

I select “mild steel, specification of Fe 410 “for this pillar design due to the following reason:-

49
 -It provides high surface hardness and a soft core to parts
- It is used to improve drilling machining, threading and punching processes.
-It is used to prevent crashing in sever bends.
- It has excellent weld ability and produces a uniform and harder case and itis considered as
the best steel for carburized parts.
-And also has a good balance of toughness, strength and ductility.
Its mechanical property:-
-Ultimate tensile strength = 410Mpa
-Yield strength = 250Mpa
-Modulus of elasticity (E) = 200Gpa
Specification
-channel cross section
-Length = 1600mm
-The load carried =gearbox load(150kg) + bed load(5kg) + beam and rope load(2kg)
W=g(157) ……g =gravity 9.81m/s^2
The Total load applied on the beam is,
W=9.81(157) ,W= 1540.17N 
- Load on each pillar, P=1540.17/2=770.085N
Length,L=1600mm and thickness, t=6mm
Where:B=100mm and H=60mm 
a=12mm, h = 18.58mm and h1= 41.42mm
cross sectional area, A=[Bt+(H−t)a]
A = [100x6+ (60-6)12] = 1248mm^2
Normal stress on the pillar is,σall=p/A =770.085N/1248mm^2=0.62Mpa
Designed stress; σmax=σall*n = 0.62Mpa x 4=2.47Mpa
Therefore I select Fe410 from Indian standard steel table
-Ultimate tensile strength = 410Mpa
-Yield strength = 250Mpa
-Modulus of elasticity (E) = 200Gp

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 Design to buckling

Table 3: Actual and equivalent length of pillar

Effective length for two sides of fixed ends column are get the formula from table
Le=0.5L Le=0.5*1600=800mm
Moment of inertia due to x-axis

Table 4: Standard Table of Channel section

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3.7. Fabricating process of prototype

The processes used in fabrication of my project prototype are Cutting, Welding, Drilling and
Fastening: first start by outlaying everything and deciding on a design. Before welding all the
pieces together, I first sketch my hoist to make it compatible by free hand drawing. Then after
finishing the sketch, I begin my manufacturing process starting from cutting pieces of square
hollow tube steel at designed dimension of height, length and width of the frame. After cuttingthe
pieces I proceed to welding process of the frame. The bed which consists of balls and the two
upper and lower plates are joined together as enabling the upper plate to mobile on the lower plate
by mechanism of inserting those balls in between the plates. Then the bed is welded on the
cantilever beam frame. The shaft, the rope, the pulley and the handle is also attached on their place
as it makes the machine functional. Totally the manufacturing process like welding,drilling, cutting
and fastening is used in the place I wanted and finally I finished my work by making my hoist
workable.

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 .

Figure 21: fabrication process of my project prototype

3.7.1. Cost analysis

Cost analysis is an art or finding the cost, which is likely to be incurred on the manufacture of an
article, after it actually manufactured. Thus, it is the calculation of a probable cost of an article
after the manufacturing ends. It also includes predetermination of the quantity and quality of
materials, labour required, etc. estimating requires highly technical knowledge about
manufacturing methods and operation times etc.

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.

Table 5: cost analysis table

54
 Conclusion:

• The project successfully developed a conceptual design for a mechanically operated gearbox
hoist system for the ARCA workshop.
• The design analysis demonstrates its ability to improve efficiency, enhance safety, and provide
a more ergonomic work environment for mechanics.
• The preliminary cost estimation provides a foundation for determining the project's financial
feasibility.

Recommendations:
• Based on the project findings, it is recommended that ARCA consider implementing a
mechanically operated gearbox hoist system within their workshop.
• Further design optimization can be explored to enhance the system's performance, safety, and
cost-effectiveness.
• ARCA should consider conducting pilot testing or prototyping to further validate the design
and address potential implementation challenges.

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 CHAPTER FOUR

GENERAL CONCLUSION AND RECOMMENDATION

4.1. Conclusions
In general, the internship and the project were done in very good conditions. During the last 1.5
months of working at AMHARA Road Construction Agency, I have acquired many skills. It gave
me a vision for my future as an automotive engineer. It also gave me an opportunity to review
what I have learned in the last four years, directly or indirectly. It was a big step forward to improve
my communication, teamwork and leadership skills, improve practical skills, improve theoretical
knowledge, understand work ethics and entrepreneurial skills, and problem-solving skills
industrial problems. It was the best way to put my theoretical knowledge and experiences into
practice. During my stay in this company, I respected the rules and regulations of the company,
for example, I came early in the morning and respected the work discipline of the company. This
helps me to be a good disciplined worker for future work experience in any environment. Overall,
my stay in this company fulfills the main objective of the internship program, which helps a student
well-equipped with theoretical and practical knowledge. The project was successfully completed
in terms of analysis of the design of various components, time consumption and human effort
requirements. The designed box lift is very efficient and easy to use. He is supposed to solve the
company's problems and keep the mechanics healthy. Thus, the building that holds the gearbox
with a maximum weight of 1471.5 N can be used In the analysis part, it is found that most of the
dimensions and parameters have been respected, stability and other criteria are been checked. Also,
a clear and readable assembly drawing with 3D views and detailed drawings is included. All the
materials used are available locally and at a low price of 6350 birr, making the lift economically
viable. But I didn't use the right materialsduring the design due to lack of materials, so I made the
height prototype.

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 4.2. Recommendation
I recommend the university to ask and inform the company if they want or accept our internship
when they join the company. Since it is difficult for a student to be accepted by some companies,
the university must create a new system to easily reach companies. I also recommend the
university to regularly monitor the status of the student. In my opinion, it is beneficial for a student
to study more practical knowledge than theoretical knowledge. And I saw in this internship
program really useful to create a very competent student, so I recommend the university to prepare
an internship program under the BSC program more than once. Commercial recommendations: -
An oil drain pan must be used in the maintenance and repair workshop for safety reasons. - A chart
must be made to place the disassembled parts of an engine, transmission, differential in the unit
rebuilding depot. - The company must provide
sufficient training to each employee to familiarize themselves with the tools available in the OHS
room (special service tools). - The company should have an attractive car in its premises instead
of wasting the time and energy of the workers. - The designed lift must be put into practice for the
desired work task. I recommend everyone who is interested in this topic to upgrade to a more user-
friendly version by adding functions such as fully hydraulic, electric or pneumatic, to increase the
efficiency and performance of the machine. I suggest that the automobile company like AMHARA
ROAD CONSTRUCTION AGENCY should use simple and newer machines to improve and
increase productivity by saving time and energy. This machine is very useful for AMHARA
ROAD CONSTRUCTION AGENCY , which provides the maintenance of various models of
vehicles. The cost of this machine is much lower than the profit we get
from the elevator, so the company should use this elevator in production. It can also be used as a
lifting machine for other purposes.

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Reference
1. Beer, Ferdinand, P., Mechanics of Materials, Second Edition, McGraw-Hill, Inc.: Santa Fe, NM
1992.

2. History of a Company Service and Repair Manual.

3. https://t.me/arrcao and https://www.youtube.com/channel/UChvlxpLEzgiq4Ui2qcGrayg

4. R.S Khuri, J.K. Gupta, “ A Text book on Machine Design” 2002, 13th edition & fifth edition

5. Shigley's Automotive Engineering Design, edizione publicata Testu: da Budynas–Nisbet.

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Appendices

Part drawing

i.Bed

59
ii. Rope drum

60
iii. Pulley

61
iv. Shaft

62
vi. Worm gear

63
Assembly drawing

64
65
66