Fabrication of Motorized Screw Jack

A PROJECT REPORT
Submitted by

Aakash.J (210616114001)
Beniel.C (210616114015)
Daniel Richards (210616114018)
Sai Suriya (210616114054)
In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING

JEPPIAAR INSTITUTE OF TECHNOLOGY, CHENNAI 631 604

ANNA UNIVERSITY:: CHENNAI 600 025

APRIL 2019

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 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “FABRICATION OF MOTORIZED SCREW

JACK” is the bonafide work of “Aakash.J (210616114004), Beniel.C

(210616114015), DanielRichards (210616114018), SaiSuriya (210616114054)”

who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr.D.Muruganandam, M.E., Ph.D., Dr.Pk.Chidhambaram, M.E., Ph.D.,

HEAD OF THE DEPARTMENT SUPERVISOR

Mechanical Engineering Associate Professor

Mechanical Engineering
Jeppiaar Institute of Technology, Kunnam, Jeppiaar Institute of Technology, Kunnam,
Sunguvarchatram, Sriperumbudur. 631604. Sunguvarchatram, Sriperumbudur. 631604.
Submitted for the Examination held on ………………………

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT

We would like to express our deepest sincere appreciation and gratitude to

our beloved DIRECTOR Dr. N. Marie Wilson, B.Tech., M.B.A., Ph.D., for his

encouragement towards our project work and for providing necessary

requirements in college campus. We thank our Principal Dr. L. M. Merlin

Livingston, M.E., Ph.D., for providing the resources available in our college.

We thank our Head of the Department Dr. D, Muruganandam, M.E., Ph.D., for his

complete and whole hearted support, motivation, guidance and help in making

our project activities. We thank him for spending his valuable time in supporting

and guiding us. We thank our project coordinators for giving his valuable thoughts

and ideas to motivate us during project period and we really thank to our project

guide Dr.Pk.Chidambaram, M.E.,Ph.D., for giving us all guidance we require

during our project course of time. It is a pleasure to express our heartfelt thanks

to all our mechanical department teaching and nonteaching staff members and

beloved friends for their support, directly and indirectly to us during the tenure of

our project and course.

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 ABSTRACT

Car jack is device used to lift up the car while

changing the tires during an emergency. Car jacks are
available at the market has some disadvantage such as
required more energy to operate, are not suitable for the
women and cannot be used on the un even surface, the
purpose of this project is to modify the design of the exiting
car jack in term of this functionality and human factors
considerations. To optimize the exiting design, the hand
lifter has been replaced by the use of pedal lever as it can
reduce energy usage. Screw Jacks are used to lift a load by
using lead screws. Power screws are used to convert rotary
motion into a reciprocating motion. With the increasing
levels of technology, the effort is being put to produce any
kind of work that has been continuously decreasing. The
efforts required in achieving the desired output can be
effectively and economically be decreased by the
implements of better designs. In this fabricated model, an
electric motor will be integrated with the object lifting jack
and the electricity needed for the operation will be taken
from the D.C battery and thereby the mechanical advantage
will be increased.

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 LIST OF CONTENTS

CHAPTER CONTENTS PAGE NUMBER

ABSTRACT i
LIST OF TABLE v
LIST OF FIGURE vi
LIST OF SYMBOL / ABBREVIATION vii

1 INTRODUCTION 1
1.1 Car jack
1.2 Problem statement
1.3 Objective
1.4 Previous methods
1.5 Scope

2 LITERATURE STUDY 4
2.1 Exiting car jack
2.2 CATIA OVERVIEW
2.2.1 CATIA
2.3 Structural Analysis
2.3.1 Types of structural analysis
2.4 Numerical methods

3 POWER SCREWS 8
3.1 Application
3.2 Advantage
3.3 Disadvantage

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 3.4 Form of threads
3.5 Terminology of power screws
3.6 Self locking screws
3.7 Efficiency of self locking screws

4 DESIGN OF POWER SCREWS 14

4.1 Power screw jack
4.2 Material used
4.3 Assumption
4.4 Design calculation

5 DRAWINGS 17
5.1 Power screw
5.2 Top arm
5.3 Bottom arm
5.4 Assembly drawing
5.4.1 Scissor jack
5.4.2 Bill of materials

6 EXPERIMENTAL SETUP 21
6.1 Working
6.2 Photo grapy
6.3 Cost estimation

7 COMPONENTS USED 24
7.1 Wiper motor
7.2 Scissor jack
7.3 12V DC battery
7.4 Wires and switches

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8 ADVANTAGES & DISADVANTAGE 27
8.1 Advantage
8.2 Disadvantage
8.3 Application

9 CONCLUTION AND SCOPE 28

10 REFERENCE 29

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 LIST OF TABLES

TABLE TITLE PAGE NUMBER

1 COST ESTIMATION 23

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 LIST OF FIGURE
FIGURE TITLE PAGE NUMBER
1 HYDRALIC JACK 04

2 NOMENCALTURE OF SQUARE THREAD 10

3 NORMENCLATURE OF SCREW THREAD 11

4 COEFFICENT OF FRICTION AND LEAD ANGLE 12

5 EFFICIENCY AND HELIX ANGLE 13

6 LAYOUT OF SCISSOR JACK 14

7 POWER SCREW 17

8 TOP ARM 18

9 BOTTOM ARM 18

10 ASSEMBLY DRAWING OF SCREW JACK 19

11 ASSEMBLY DRAWING OF WIPER MOTOR 19
12 BILL MATERIAL OF SCREW JACK 20
13 WORKING OF MOTORIZED SCREW JACK 21
14 SCREW JACK SETUP 22
15 WELDING SETUP 22
16 WIPER MOTOR 24
17 SCISSOR JACK 25
18 DC BATTER 26

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 LIST OF SYMBOLS / ABBREVIATION

F = Force (N)

Fm = Force produce by men (N)

Fw = Force produce by women (N)

Wm = Weight average for men (kg)

Ww = Weight average for women (kg)

A = Area (m2)

M = Mass (kg)

P = Pressure (N/m2)

D = Diameter

DC = Direct current

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 CHAPTER 1

INTRODUCTION

1.1 CAR JACK

A jack is a mechanical device used to lift heavy loads or

apply great force. Jacks employ a screw thread or hydraulic

cylinder to apply very high linear force. The motorized screw jack

has been developed to cater to the needs of small and medium

automobile garages, which are normally man powered with

minimum skilled labor. In most of the garages the vehicles are

lifted by using screw jack. In order to avoid all such disadvantages,

the motorized jack has been designed in such a way that it can be

used to lift the vehicle very smoothly without any impact force.

The operation is made simple so that even unskilled labor can use

it with ease. The D.C motor is coupled with the screw jack . The

operation remains to be an essential part of the system although

with changing demands on physical input, the degree of

mechanization is increased.

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1.2 PROBLEM STATEMENT

Now a days in this country, most of the cars were equipped with

the scissor car jacks, we found that the scissor jack were very difficult to

be used especially by women because his types of jack needed more

strength and energy to operate this jack by turning the lead screws. Thus,

we want to develop a product based from the problem faced by the users

who drive a car regarding to this issue. To overcome this problem, a

research has been conduct to find the solution on how to design a carjack

for the car using the simplest and cheapest way while it is energy

saving. During the research, we have found that most of the car user has

difficulties in maintaining their vehicle breakdown especially cars in

scope of changing tires. Hence, this report had been prepared to

recommend the design of the car jack that is user friendly and easier to

operate as do not required too much money to develop this product.

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1.3 OBJECTIVE

Design improvement the exiting car jack in terms of its

functionality and human factor consideration.

1.4 PREVIOUS METHOD

Motorized screw jack worked on the wiper motor

mechanism. Automobile garages have been developed to meet the

needs of small and medium automobile garages. Which is normally

man powered with very minimum of skilled labors. In most of

garages the vehicle are lifted by using screw jacks. This needs high

man power skilled labors. In order to avoid all such disadvantages.

This motorized screw jack has been designed in such a way that it

can be used to lift the vehicle very smoothly without any impact

force.

1.5 SCOPES

Permanently mounted jacks on the vehicle can be developed so

that the tire change can be completely automated.

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 CHAPTER 2

LITERATURE STUDY

2.1 EXITING CAR JACK

The most common form is a car jack , floor jack and garage jack

which lift vehicle so that maintenance can be performed. Car jack

usually use mechanical advantage to allow a human to lift a vehicle by

manual force alone. The jack shown in figure is made for a modern

vehicle and the notch fits into a hard point on a body. Earlier versions

have a platform to lift on the vehicle frame or axle.

Fig.1 HYDRALIC JACK

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2.2 CATIA OVERVIEW

It’s a general purpose finite element modeling package for

numerical solving a wide variety of mechanical problems. These

problems include static/dynamic structural analysis, heat transfer and

fluid problems, as well as electromagnetic problems. To produce this

drawings in this project, us CATIA version 5 release 15 software. Under

this software, we were able to use many types of functions such as line,

circle, trim, extrude, edit, poly line, arc, fillet, pad and others.

(Dr.R.Ganesan, 2007)

2.21 CATIA

Finite element analysis software enables engineers to perform the

followings

 Build computer models or transfer CAD models of structures,

products, components, or systems.

 Apply operating loads or other design performance conditions.

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 2.3 STRUCTURAL ANALYSIS

It is probably the most common application of the finite element

method. The term structural analysis implies not only civil engineering

structures such as bridges and buildings, but also naval, aeronautical and

mechanical structures such as ship, hulls, aircrafts, as well as mechanical

components such as pistons, machine parts, and tools. ( Chennakesava

R. Alavala , 2009)

2.3.1 Types of structural analysis

The primary unknown calculated in a structural analysis is

displacement. Other quantities, such as strains, stresses, and reaction

forces, are then derived from the nodal displacement, static loading

conditions , both the linear and non-linear static analyses. Transient

dynamic analysis used to determine the response of a structure to

arbitrarily time-varying loads. All non-linearity mentioned under static

analysis above are allowed.

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2.4 NUMERICAL METHODS ANALYSIS

In engineering analysis a theoretical model was the first

choice for researchers and scientists because of accurate and
unique solutions. But in pragmatic design problems, the
theoretical model was scarily utilized to predict physical
response because of the complex geometrical design and path.
Therefore powerful numerical methods were introduced to
engineers to overcome difficulty.
Some of the numerical approaches are:
 Finite differences method
 Finite volume method
 Boundary element method
 Finite element method

In the design of engineering structures, numerical simulations

play an increasingly important role. Which have to confront
rapid advances in the computations power and the resulting
decrease in the costs for the computer simulations.

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 CHAPTER 3
POWER SCREWS

3.1 APPLICATIONS

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3.2 ADVANTAGES

3.3 DISADVANTAGES

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3.4 FORM OF THREADS

FIG 2 NOMENCALTURE OF SQUARE THREAD

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 3.5 TERMINOLOGY IN POWER SCREWS
The terminology of the screw thread is shown in figure 3.

FIG.3 NORMENCLATURE OF SCREW THREAD

3.6 SELF LOCKING SCREW
1. Pitch: The pitch is defined as the distance, measured parallel to the axis of the screw,
from a point on one thread to the corresponding point on the adjacent thread. It is
denoted by the letter ‘P’.

2. Lead: The lead is defined as the distance, measured parallel to the axis of the screw that
the nut will advance in one revolution of the screw. It is denoted by the letter ‘L’

3. Nominal Diameter: It is the largest diameter of the screw thread. It is also called major
diameter. It is denoted by the letter ‘dọ’

4. Core Diameter: It is the smallest diameter of the screw thread. It is also called minor
diameter. It is denoted by the letter ‘dḉ’

5. Helix Nagle: It is defined as the angle made by the helix of the thread with a plane
perpendicular to the axis of the screw. Helix angle is related to the lead and the mean
diameter of the screw. It is also called lead angle. It is denoted by ‘α’

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FIG.4 COEFFICENT OF FRICTION AND LEAD ANGLE

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3.6 EFFICIENCY OF SELF LOCKING SCREWS

FIG.5 EFFICIENCY AND HELIX ANGLE

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 CHAPTER 4
DESIGN OF SCREW JACK

4.1 POWER JACK

FIG.6 LAYOUT SCISSOR JACK

4.2 MATERIAL USED

 Mild steel
o It is one of the most common of all materials and one
of the least expensive steels used
o It is to be found in almost every product created from
metal
o It is wieldable, very durable (although it rusts )

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4.3 ASSUMPTIONS

4.4 DESIGN CALCULATION

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26
 CHAPTER 5
DRAWINGS
5.1 POWER SCREW

FIG.7 POWER SCREW

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7.2 TOP ARM

FIG.8 TOP ARM

7.3 BOTTOM ARM

FIG.9 BOTTOM ARM

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7.4 SCREW JACK

FIG.10 ASSEMBLY DRAWING OF SCREW JACK

7.5 WIPER MOTOR

FIG.11 ASSEMBLY OF WIPER MOTOR

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7.6 BILL OF MATERIALS

FIG.12 BILL MATERIAL OF SCREW JACK

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 CHAPTER 6
EXPERIMENTAL SETUP

6.1 WORKING

FIG.13 WORKING OF MOTORIZED SCREW JACK

The lead-acid battery is used to drive the Dc wiper motor. Wiper
motor gives the high torque. Its initial torque is very high compared to
other motors. In the system requires high torque for lifting the high
loads. So, here wiper motor, it will run so that wheel also runs to the
same speed for the motor. Then the wiper motor wheel is connected to
the fork of the car jack when the supply is given then the motors will run
in high torque so that the scissor jack also will slowly moves to upwards
as per the connection of Wiper motor and after the terminal of the motor
has been changes so that jack returns to its original position.

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6.2 PHOTO GRAPY

FIG.14 SCREW JACK SET UP

FIG.15 WELDING SET UP

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6.3 COST ESTIMATION
S.NO CONTENT QUANTITY RATE
1. SCREW JACK 1 800/-
2. WIPER MOTOR 1 750/-
3. 12V DC 1 800/-
BATTERY

4. BATTERY 1 500/-
ADAPTER

5. WIRES AND AS 250/-

SWICHES REQUIRED

TOTAL 3100/-

6.4 LIST OF COMPONENTS

S.NO COMPONENTS SCPECIFICATIONS

1. Wiper Motor Voltage- 12V

Power- 50W
Current- 1.0 to 1.5 A
Speed- 75-80rpm
2. Screw Jack Material- Mild Steel
Type- Scissor
Max Height- 33 cm
Min Height- 10.6 cm
3. DC Battery Lead Acid Battery
Voltage- 12V
Power- 3.3 Amps

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 CHAPTER 7
COMPONENTS REQUIRED
7.1 WIPER MOTOR
There are three major components to a wiper motor. They are
motor, rotary to linear motion converter mechanism, parking switch. The
mechanism to convert rotary motion to linear motion is very straight
forward, and its functionality is apparent from a visual inspection of a
disassembled motor. This article, therefore, will discuss only the
operations of the motor and the park switch. The operation of the
parking switch has no effect in normal operation mode.

FIG.16 WIPER MOTOR

• Nominal Voltage- 12V
• Nominal Power- 50W
• Nominal Current- 1.0-1.5A
• High Speed- 75-76 rpm
• Low Speed- 50 rpm

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7.2 SCREW JACK
A car jack mechanical device used to lift heavy loads or apply
great forces. Jacks employ a screw thread or hydraulic cylinder to
apply very high linear forces. Car jacks usually use mechanical
advantage to allow a human to lift a vehicle by manual force alone.
The mechanical advantage is the factor by which a mechanism
multiplies the force or torque applied to it. Most people are familiar
with the basic auto jack that was still included as std.equipment with
most new cars.

FIG.17 SCISSOR JACK

Body Material- Mild steel Design Profile- Standard Profile

Maximum Height- 33 cm Operating Current- NA
Lifting Capacity- 750 kg Minimum Height- 10.6 cm
Type- Scissor Operating Voltage- NA
Rated Power- NA Color- Gold

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7.3 DC BATTERY 12V

FIG.18 DC BATTERY

 The lead-acid battery is used to drive the DC wiper motor.

 It is cheap and best at low cost.

 Here 12V, 3.3Amps battery is used to run the motor.

7.4 WIRES AND SWITCHES

 Wires are used to transfer the electrical energy , here we used

aluminum and copper wires to transfer the electrical energy.

 Here we are used two way key switch to operate the wiper
motor in upward direction and downward direction.

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 CHAPTER 8
ADVANTAGES AND DISADVANTAGES
8.1 ADVANTAGES
 It is used to lift the light vehicles easily.
 Handling is easy.
 No need for manual power.
 Easy to repair.
 Replacement of parts is easy.
 Checking and cleaning are easy.
 Single person is enough to operate this efficiently to remove
linear
8.2 DISADVANTAGES

 Care must be taken for the handling equipment such as

proper wiring connection.

8.3 APPLICATION
 Thus it can be useful for the following types of vehicle

 BMW
 Ambassador
 Ford
 Wagon R., and Etc….

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 CHAPTER 9
CONCLUSION AND SCOPE
In this project a prototype of motorized screw jack
which can be operated by a Wiper motor has been
designed and fabricated. The salient features of the
present fabrication are elimination of human effort to
operate the jack, through a simple electrical device
which can be actuated by a 12V battery. The
assembly of the components can be achieved in 100
minutes. The elements which are useful are readily
available commerce for each and early replacement
of failed components if required.
Permanently mounted jacks on the vehicle can be
developed so that the tire change can be completely
automated.

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CHAPTER 10
REFERENCE

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HARDWARE SETUP

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