Professional Documents
Culture Documents
Car Jack
Car Jack
SYNOPSIS
1. INTRODUCTION
2. LITERATURE REVIEW
3. FABRICATION UNIT
4. WORKING PRINCIPLE
5. DESCRIPTION OF EQUIPMENT
9. CONCLUSION
11.BIBLIOGRAPHY
12.PHOTOGRAPHS
SYNOPSIS
Think that the driver is in trip when the tyre breaks, he is obliged to replace one
Changing tyre is a very inconvenient thing, especially by open country highway, in the hot,
Using the Manual Jack to change tyre is wasting time and energy. And, some ladies
and gentlemen are not enough strength to jack up the automobile by shaking the Manual
Jack. But using the electric car jack to change tyre is easy, quick and convenient! Only
plug the DC Plug into the vehicle’s cigarette lighter receptacle, set the Electric Jack on the
right position which appointed for Jack, then press the button. The Electric Car Jack can
For the lady, tall or fat person, it is a very hard thing to replace tyre. But if you
have an Electric Car Jack, every question will be solved. It will be relaxing and easy to
replace tyre.
INTRODUCTION
A mechanical jack is a device which lifts heavy equipment. The most common
form is a car jack, floor jack or garage jack which lifts vehicles so that maintenance can
be performed. Car jacks usually use mechanical advantage to allow a human to lift a
vehicle. More powerful jacks use hydraulic power to provide more lift over greater
distances. Mechanical jacks are usually rated for a maximum lifting capacity (for example,
its lead screw. An Acme thread is most often used, as this thread is very strong and can
resist the large loads imposed on most jackscrews while not being dramatically weakened
by wear over many rotations. These types are self-locking, which makes them more
intrinsically safe than other jack technologies like hydraulic actuators which require
continual pressure to remain in a locked position. Most jackscrews are lubricated with
grease.
FABRICATION UNIT
Fabrication Unit is the topic which deals with the information like Material
MATERIAL SELECTION
06 Paint 1 200
Total = Rs.4,270.00
WORKING PRINCIPLE
Car Jack operates nut and bolt mechanism, a lead drive the vise up and down
position. One end of the lead screw is fitted with spur gear speed reduction gears. A 12
D.C gear motor is drive the gears. Gear motor shaft fitted with spur gear shaft.
The motor clockwise rotation and anticlockwise rotation is control by sifting the
switch position. Jack is move up and down easily with help of Battery operated motor.
DESCRIPTION OF EQUIPMENT
JACK (DEVICE)
A jack is mechanical device used to lift heavy loads or apply great forces. Jacks employ a
MECHANICAL JACK
Jackscrews are integral to one of the simplest kinds of car jacks still used.
A mechanical jack is a device which lifts heavy equipment. The most common form is a
car jack, floor jack or garage jack which lifts vehicles so that maintenance can be
performed. Car jacks usually use mechanical advantage to allow a human to lift a vehicle
by manual force alone. More powerful jacks use hydraulic power to provide more lift over
greater distances. Mechanical jacks are usually rated for a maximum lifting capacity (for
example, 1.5 tons or 3 tons). The jack shown at the right is made for a modern vehicle and
the notch fits into a hard point on a unit body. Earlier versions have a platform to lift on
A hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by a
pump plunger. Oil is used since it is self lubricating and stable. When the plunger pulls
back, it draws oil out of the reservoir through a suction check valve into the pump
chamber. When the plunger moves forward, it pushes the oil through a discharge check
valve into the cylinder. The suction valve ball is within the chamber and opens with each
draw of the plunger. The discharge valve ball is outside the chamber and opens when the
oil is pushed into the cylinder. At this point the suction ball within the chamber is forced
HOUSE JACK
2.5 ton house jack that stands 24 inches from top to bottom fully threaded out.
A House jack is a mechanical device primarily used to lift houses from their foundation. A
series of jacks are used and then wood cribbing temporarily supports the structure. This
process is repeated until the desired height is reached. The house jack can be used for
jacking carrying beams that have settled or for installing new structural beams. On the top
of the jack is a cast iron circular pad that the 4" X 4" post is resting on. This pad moves
independently of the house jack so that it does not turn as the acme-threaded rod is turned
up with a metal rod. This piece tilts very slightly but not enough to render the post
STRAND JACK
A strand jack is a sophisticated hydraulic jack that grips and lifts steel cables; often used in
concert, strand jacks can lift hundreds of tons and are used in engineering and construction.
SMOKE JACK
A smoke jack is a jack which gets its energy from a column of rising air or smoke. It is
typically used to turn a spit in a cooking fire. It is considered an early example of a steam
Smoke-jacks were first described by Taqi al-Din in his Al-Turuq al-samiyya fi al-alat al-
ruhaniyya (The Sublime Methods of Spiritual Machines, 1551)[1] and by John Wilkins in
motion. The mechanical advantage of a leadscrew is determined by the screw pitch or lead.
A leadscrew nut and screw mate with rubbing surfaces, and consequently they have
a relatively high friction and stiction compared to mechanical parts which mate with
rolling surfaces and bearings. Their efficiency is typically only between 25 and 70%, with
higher pitch screws tending to be more efficient. A higher performing, and more
The high internal friction means that leadscrew systems are not usually capable of
continuous operation at high speed, as they will overheat. Due to inherently high stiction,
the typical screw is self-locking (ie. when stopped, a linear force on the nut will not apply a
torque to the screw) and are often used in applications where backdriving is unacceptable,
Leadscrews are typically used well greased, but, with an appropriate nut, it may be
run dry with somewhat higher friction. There is often a choice of nuts, and manufacturers
Leadscrew threads typically have an Acme profile. Backlash can be reduced with
the use of a second nut to create a static loading force known as preload.
LEADSCREW MANUFACTURING
Leadscrews are manufactured using various processes. The manufacturing processes can
be categorized within two major groups: material removal (machining) and net shape.
Machining
Net Shape
Net shape processes for leadscrew manufacturing include forming, a cold forging
A lead screw will back drive. A leadscrew's tendency to backdrive depends on its thread
helix angle, coefficient of friction of the interface of the components (screw/nut) and the
included angle of the thread form. In general, a steel acme thread and bronze nut will back
drive when the helix angle of the thread is greater than 20 degrees.
Examples of Use
vice
lathe
BALL SCREW
linear motion. A threaded shaft provides a spiral raceway for ball bearings which act as a
precision screw. As well as being able to apply or withstand high thrust loads they can do
so with minimum internal friction. They are made to close tolerances and are therefore
suitable for use in situations in which high precision is necessary. The ball assembly acts
To maintain their inherent accuracy and ensure long life, great care is needed to
avoid contamination with dirt and abrasive particles. This may be achieved by using rubber
solution is to use a positive pressure of filtered air when they are used in a semi-sealed or
open enclosure.
While reducing friction, ball screws can operate with some preload, effectively
eliminating backlash (slop) between input (rotation) and output (linear motion). This
feature is essential when they are used in computer-controlled motion-control systems, e.g.
CNC machine tools and high precision motion applications (electronics "Wire Bonding").
Due to their low internal friction, ball screws can be back-driven (depending upon
their lead angle). They are usually undesirable for hand-fed machine tools, as the stiffness
of a servo motor is required to keep the cutter from grabbing the work and self feeding,
that is, where the cutter and workpiece exceed the optimum feedrate and effectively jam or
crash together, ruining the cutter and workpiece. Cost is also a major factor as ACME
Low friction in ball screws yields high mechanical efficiency compared to alternatives. A
typical ball screw may be 90 percent efficient, versus 50 percent efficiency of an Acme
lead screw of equal size. The higher cost of ball screws may thus be offset by lower power
Ball screw shafts may be fabricated by rolling, yielding a less precise, but
inexpensive and mechanically efficient product. Rolled ball screws have a positional
precision of several thousandths of an inch per foot. High-precision types are ground, and
change and or torque change a number of options are available controlled by system
layout, economics and power capacity. The drive transmission selection is selected from
2. Chain drive
6. Engineered gears
expensive and inconvenient if a proprietory system is available which will do the job.
TYPES OF GEARS
Pitch Line
Normal Efficiency
Type Velocity
Ratio Range Range
(m/s)
Spur 1:1 to 6:1 25 98-99%
Helical 1:1 to 10:1 50 98-99%
Double
1:1 to 15:1 150 98-99%
Helical
Bevel 1:1 to 4:1 20 98-99%
Worm 5:1 to 75:1 30 20-98%
Crossed
1:1 to 6:1 30 70-98%
Helical
BEVEL GEARS
Unlike spur and helical gears with teeth cut from a cylindrical blank, bevel gears
have teeth cut on an angular or conical surface. Bevel gears are used when input and output
shaft centerlines intersect. Teeth are usually cut at an angle so that the shaft axes intersect
at 90 deg, but any other angle may be used. A special class of bevels called miter gears
have gears of the same size with their shafts at right angles.
Often there is no room to support bevel gears at both ends because the shafts
intersect. Thus, one or both gears overhang their supporting of a pinion in a spiral-bevel
and the extreme top or bottom position of a worm. This geometry allows the driving and
driven shafts to continue past each other so that end-support bearings can be mounted.
These bearings
provide greater rigidity than the support provided by the cantilever mounting used in some
bevel gearing. Also adding to the high strength and rigidity of the hypoid gear is the fact
that the hypoid pinion has a larger diameter and longer base than a bevel or spiral-bevel
gear pinion of equal ratio. Although hypoid gears are stronger and more rigid than most
other types, they are one of the most difficult to lubricate because of high tooth-contact
pressures. Moreover, the high levels of sliding between tooth surfaces are ends. This
configuration allows the worm to engage more teeth on the wheel, thereby increasing load
capacity. In worm-gear sets, the worm is most often the driving member. However, a
reversible worm-gear has the worm and wheel pitches so proportioned that movement of
tops of the teeth curve inward to envelop the worm. As a result, the worm slides rather than
rolls as it drives the wheel. Because of this high level of rubbing between the worm and
wheel teeth, the efficiency of worm gearing is lower than other major gear types.
One major advantage of the worm gear is low wear, due mostly to the full-fluid
lubricant film that tends to be formed between tooth surfaces by the worm sliding action. A
continuous film that separates the tooth surfaces and prevents direct metal-to-metal contact
is typically provided by a relatively heavy oil, which is often compounded with fatty or
fixed oils such as acid less tallow oil. This adds film strength to the lubricant and further
reduces friction by increasing the oiliness of the fluid. reduces efficiency. In fact, the
hypoid combines the sliding action of the worm gear with the rolling movement and high
tooth pressure associated with the spiral bevel. In addition, both the driven and driving
gears are made of steel, which further increases the demands on the lubricant. As a result,
special extreme pressure lubricants with both oiliness and anti-weld properties are required
to withstand the high contact pressures and rubbing speeds in hypoids. Despite these
demands for special lubrication, hypoid gears are used extensively in rear axles of
automobiles with rear-wheel drives. Moreover, they are being used increasingly in
industrial machinery.
STRAIGHT BEVEL
HYPOID GEARS
SPIRAL-BEVEL GEAR
driven device. If the shaft is rotating, it is transferring power and if the shaft operating
without rotary motion it is simply transmitting torque and is probably resisting the
transfer of power.
cams, sprockets, inks and flywheels. A shaft is normally supported on bearings. The
torque is normally transmitted to the mounted components using pins, keys, clamping
bushes, press fits, bonded joints and sometimes welded connections are used.
bending (tensile & compressive loading), direct shear loading, tensile loading and
compressive loading. Design of shafts must include assessment of fatigue loading and
2. Produce a bending moment diagram for the xy plane and the xz plane
Note: The resulting internal moment at any point along the shaft = Mx = Sqrt (Mxy2
+ Mxz2 )
4. Locate the section(s) on the shaft which the internal loading is the
5. Locate the point on the shaft which the internal loading is the
6. Assess the strength of the shaft and determine if the safety margin is
sufficient. The failure criteria (ref Failure theories for the shaft depends on the
mm Nm kW
30 132 1.4
40 313 3.3
50 612 6.4
60 1058 10.6
75 2068 21.6
80 2510 26
q = The skin torsion stress of a solid round shaft : T= The torque transmitted
Worm drives are a compact, efficient [efficient only in terms of volume; heat friction
speed and increasing torque. Small electric motors are generally high-speed and low-
torque; the addition of a worm drive increases the range of applications that it may be
Worm drives are used in presses, in rolling mills, in conveying engineering, in mining
industry machines, and on rudders. In addition, milling heads and rotary tables are
In the era of sailing ships, the introduction of a worm drive to control the rudder was a
significant advance. Prior to its introduction, a rope drum drive was used to control the
rudder, and rough seas could cause substantial force to be applied to the rudder, often
requiring several men to steer the vessel, with some drives having two large-diameter
Worm drives have been used in a few automotive differentials. The worm gear carries the
differential gearing. This protects the vehicle against rollback. This has largely fallen from
favour due to the higher-than-necessary reduction ratios. The exception to this is the
Torsen differential, which uses worms and planetary worm gears in place of the bevel
featured in the HMMWV and some commercial Hummer vehicles, and as a center
differential in some all wheel drive systems, such as Audi's quattro. Very heavy trucks,
such as those used to carry aggregates, often use a worm gear differential for strength. The
worm drive is not as efficient as a hypoid gear, and such trucks invariably have a very
large differential housing, with a correspondingly large volume of gear oil, to absorb and
Worm drives are used as the tuning mechanism for many musical instruments, including
guitars, double-basses, mandolins and bouzoukis, although not banjos, which use planetary
gears or friction pegs. A worm drive tuning device is called a machine head.
Plastic worm drives are often used on small battery-operated electric motors, to provide an
output with a lower angular velocity (fewer revolutions per minute) than that of the motor,
which operates best at a fairly high speed. This motor-worm-gear drive system is often
A worm drive is used on jubilee-type hose clamps or jubilee clamps; the tightening screw
has a worm thread which engages with the slots on the clamp band.
WORM GEAR
Many worm gears have an interesting property that no other gear set has: the worm
can easily turn the gear, but the gear cannot turn the worm. This is because the angle on the
worm is so shallow that when the gear tries to spin it, the friction between the gear and the
the locking feature can act as a brake for the conveyor when the motor is not turning. One
other very interesting usage of worm gears is in the Torsen differential, which is used on
another gear or device. A gear is different from a pulley in that a gear is a round wheel
which has linkages ("teeth" or "cogs") that mesh with other gear teeth, allowing force to be
geared devices can transmit forces at different speeds, torques, or in a different direction,
from the power source. Gears are a very useful simple machine. The most common
situation is for a gear to mesh with another gear, but a gear can mesh with any device
having compatible teeth, such as other rotational gears, or linear moving racks. A gear's
most important feature is that gears of unequal sizes (diameters) can be combined to
produce a mechanical advantage, so that the rotational speed and torque of the second gear
are different from that of the first. In the context of a particular machine, the term "gear"
also refers to one particular arrangement of gears among other arrangements (such as "first
gear"). Such arrangements are often given as a ratio, using the number of teeth or gear
diameter as units. The term "gear" is also used in non-geared devices which perform
equivalent tasks:
"...broadly speaking, a gear refers to a ratio of engine shaft speed to driveshaft
speed. Although CVTs change this ratio without using a set of planetary gears, they
are still described as having low and high "gears" for the sake of convention."[1]
General
The smaller gear in a pair is often called the pinion; the larger, either the gear, or the
wheel.
Mechanical advantage
The interlocking of the teeth in a pair of meshing gears means that their circumferences
necessarily move at the same rate of linear motion (eg., metres per second, or feet per
minute). Since rotational speed (eg. measured in revolutions per second, revolutions per
its radius, we see that the larger the radius of a gear, the slower will be its rotational speed,
when meshed with a gear of given size and speed. The same conclusion can also be
reached by a different analytical process: counting teeth. Since the teeth of two meshing
gears are locked in a one to one correspondence, when all of the teeth of the smaller gear
have passed the point where the gears meet -- ie., when the smaller gear has made one
revolution -- not all of the teeth of the larger gear will have passed that point -- the larger
gear will have made less than one revolution. The smaller gear makes more revolutions in
a given period of time; it turns faster. The speed ratio is simply the reciprocal ratio of the
on a tooth of the other gear. Consider two teeth in contact at a point on the line joining the
shaft axes of the two gears. In general, the force will have both a radial and a
sideways push on the shaft and does not contribute to turning. The circumferential
component causes turning. The torque is equal to the circumferential component of the
force times radius. Thus we see that the larger gear experiences greater torque; the smaller
gear less. The torque ratio is equal to the ratio of the radii. This is exactly the inverse of the
case with the velocity ratio. Higher torque implies lower velocity and vice versa. The fact
that the torque ratio is the inverse of the velocity ratio could also be inferred from the law
of conservation of energy. Here we have been neglecting the effect of friction on the torque
ratio. The velocity ratio is truly given by the tooth or size ratio, but friction will cause the
torque ratio to be actually somewhat less than the inverse of the velocity ratio.
In the above discussion we have made mention of the gear "radius". Since a gear is not a
proper circle but a roughened circle, it does not have a radius. However, in a pair of
meshing gears, each may be considered to have an effective radius, called the pitch radius,
the pitch radii being such that smooth wheels of those radii would produce the same
velocity ratio that the gears actually produce. The pitch radius can be considered sort of an
"average" radius of the gear, somewhere between the outside radius of the gear and the
The issue of pitch radius brings up the fact that the point on a gear tooth where it makes
contact with a tooth on the mating gear varies during the time the pair of teeth are engaged;
also the direction of force may vary. As a result, the velocity ratio (and torque ratio) is not,
actually, in general, constant, if one considers the situation in detail, over the course of the
period of engagement of a single pair of teeth. The velocity and torque ratios given at the
beginning of this section are valid only "in bulk" -- as long-term averages; the values at
It is in fact possible to choose tooth shapes that will result in the velocity ratio also being
absolutely constant -- in the short term as well as the long term. In good quality gears this
is usually done, since velocity ratio fluctuatons cause undue vibration, and put additional
stress on the teeth, which can cause tooth breakage under heavy loads at high speed.
Constant velocity ratio may also be desirable for precision in instrumentation gearing,
clocks and watches. The involute tooth shape is one that results in a constant velocity ratio,
The definite velocity ratio which results from having teeth gives gears an advantage over
other drives (such as traction drives and V-belts) in precision machines such as watches
that depend upon an exact velocity ratio. In cases where driver and follower are in close
proximity gears also have an advantage over other drives in the reduced number of parts
required; the downside is that gears are more expensive to manufacture and their
The automobile transmission allows selection between gears to give various mechanical
advantages.
Spur gears
Spur gears are the simplest, and probably most common, type of gear. Their general form
is a cylinder or disk (a disk is just a short cylinder). The teeth project radially, and with
these "straight-cut gears", the leading edges of the teeth are aligned parallel to the axis of
rotation. These gears can only mesh correctly if they are fitted to parallel axles.[2]
Helical gears
Unlike most gears, an internal gear (shown here) does not cause direction reversal.
Helical gears offer a refinement over spur gears. The leading edges of the teeth are not
parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this angling
causes the tooth shape to be a segment of a helix. The angled teeth engage more gradually
than do spur gear teeth. This causes helical gears to run more smoothly and quietly than
spur gears. Helical gears also offer the possibility of using non-parallel shafts. A pair of
helical gears can be meshed in two ways: with shafts oriented at either the sum or the
difference of the helix angles of the gears. These configurations are referred to as parallel
or crossed, respectively. The parallel configuration is the more mechanically sound. In it,
the helices of a pair of meshing teeth meet at a common tangent, and the contact between
the tooth surfaces will, generally, be a curve extending some distance across their face
widths. In the crossed configuration, the helices do not meet tangentially, and only point
contact is achieved between tooth surfaces. Because of the small area of contact, crossed
Quite commonly, helical gears come in pairs where the helix angle of one is the negative
of the helix angle of the other; such a pair might also be referred to as having a right
handed helix and a left handed helix of equal angles. If such a pair is meshed in the
'parallel' mode, the two equal but opposite angles add to zero: the angle between shafts is
zero -- that is, the shafts are parallel. If the pair is meshed in the 'crossed' mode, the angle
between shafts will be twice the absolute value of either helix angle.
Note that 'parallel' helical gears need not have parallel shafts -- this only occurs if their
helix angles are equal but opposite. The 'parallel' in 'parallel helical gears' must refer, if
anything, to the (quasi) parallelism of the teeth, not to the shaft orientation.
As mentioned at the start of this section, helical gears operate more smoothly than do spur
gears. With parallel helical gears, each pair of teeth first make contact at a single point at
one side of the gear wheel; a moving curve of contact then grows gradually across the
tooth face. It may span the entire width of the tooth for a time. Finally, it recedes until the
teeth break contact at a single point on the opposite side of the wheel. Thus force is taken
up and released gradually. With spur gears, the situation is quite different. When a pair of
teeth meet, they immediately make line contact across their entire width. This causes
impact stress and noise. Spur gears make a characteristic whine at high speeds and can not
take as much torque as helical gears because their teeth are receiving impact blows.
Whereas spur gears are used for low speed applications and those situations where noise
control is not a problem, the use of helical gears is indicated when the application involves
high speeds, large power transmission, or where noise abatement is important. The speed is
considered to be high when the pitch line velocity (that is, the circumferential velocity)
exceeds 5000 ft/min.[3] A disadvantage of helical gears is a resultant thrust along the axis
of the gear, which needs to be accommodated by appropriate thrust bearings, and a greater
degree of sliding friction between the meshing teeth, often addressed with specific
Double helical gears, invented by André Citroën and also known as herringbone gears,
overcome the problem of axial thrust presented by 'single' helical gears by having teeth that
set in a 'V' shape. Each gear in a double helical gear can be thought of as two standard, but
mirror image, helical gears stacked. This cancels out the thrust since each half of the gear
thrusts in the opposite direction. They can be directly interchanged with spur gears without
Where the oppositely angled teeth meet in the middle of a herringbone gear, the alignment
may be such that tooth tip meets tooth tip, or the alignment may be staggered, so that tooth
tip meets tooth trough. The latter type of alignment results in what is known as a Wuest
the two oppositely-angled courses of teeth. This was necessary to permit the shaving tool
to run out of the groove. The development of the Sykes gear shaper now makes it possible
Bevel gears
Bevel gears are essentially conically shaped, although the actual gear does not extend all
the way to the vertex (tip) of the cone that bounds it. With two bevel gears in mesh, the
vertices of their two cones lie on a single point, and the shaft axes also intersect at that
point. The angle between the shafts can be anything except zero or 180 degrees. Bevel
gears with equal numbers of teeth and shaft axes at 90 degrees are called miter gears.
The teeth of a bevel gear may be straight-cut as with spur gears, or they may be cut in a
variety of other shapes. 'Spiral bevel gears' have teeth that are both curved along their (the
tooth's) length; and set at an angle, analogously to the way helical gear teeth are set at an
angle compared to spur gear teeth. 'Zero bevel gears' have teeth which are curved along
their length, but not angled. Spiral bevel gears have the same advantages and
Straight bevel gears are generally used only at speeds below 5 m/s (1000 ft/min), or, for
A crown gear or contrate gear is a particular form of bevel gear whose teeth project at right
angles to the plane of the wheel; in their orientation the teeth resemble the points on a
crown. A crown gear can only mesh accurately with another bevel gear, although crown
gears are sometimes seen meshing with spur gears. A crown gear is also sometimes
Hypoid gears
Hypoid gears resemble spiral bevel gears, except that the shaft axes are offset, not
intersecting. The pitch surfaces appear conical but, to compensate for the offset shaft, are
in fact hyperboloids of revolution. Hypoid gears are almost always designed to operate
with shafts at 90 degrees. Depending on which side the shaft is offset to, relative to the
angling of the teeth, contact between hypoid gear teeth may be even smoother and more
gradual than with spiral bevel gear teeth. Also, the pinion can be designed with fewer teeth
than a spiral bevel pinion, with the result that gear ratios of 60:1 and higher are "entirely
A worm is a gear that resembles a screw. It is a species of helical gear, but its helix angle is
usually somewhat large(ie., somewhat close to 90 degrees) and its body is usually fairly
long in the axial direction; and it is these attributes which give it its screw like qualities. A
worm is usually meshed with an ordinary looking, disk-shaped gear, which is called the
"gear", the "wheel", the "worm gear", or the "worm wheel". The prime feature of a worm-
and-gear set is that it allows the attainment of a high gear ratio with few parts, in a small
space. Helical gears are, in practice, limited to gear ratios of 10:1 and under; worm gear
sets commonly have gear ratios between 10:1 and 100:1, and occasionally 500:1.[6] In
worm-and-gear sets, because the worm's helix angle is large, the sliding action between
teeth is considerable, and the resulting frictional loss causes the efficiency of the drive to
be usually less than 90 percent, sometimes less than 50 percent.so comparing to other gears
The distinction between a worm and a helical gear is made when at least one tooth persists
for a full 360 degree turn around the helix. If this occurs, it is a 'worm'; if not, it is a 'helical
gear'. A worm may have as few as one tooth. If that tooth persists for several turns around
the helix, the worm will appear, superficially, to have more than one tooth, but what one in
fact sees is the same tooth reappearing at intervals along the length of the worm. The usual
screw nomenclature applies: a one-toothed worm is called "single thread" or "single start";
a worm with more than one tooth is called "multiple thread" or "multiple start".
We should note that the helix angle of a worm is not usually specified. Instead, the lead
In a worm-and-gear set, the worm can always drive the gear. However, if the gear attempts
to drive the worm, it may or may not succeed. Particularly if the lead angle is small, the
gear's teeth may simply lock against the worm's teeth, because the force component
circumferential to the worm is not sufficient to overcome friction. Whether this will
if the tangent of the lead angle is greater than the coefficient of friction, the gear will not
lock.[8] Worm-and-gear sets that do lock in the above manner are called "self locking". The
self locking feature can be an advantage, as for instance when it is desired to set the
position of a mechanism by turning the worm and then have the mechanism hold that
If the gear in a worm-and-gear set is an ordinary helical gear only point contact between
teeth will be achieved. If medium to high power transmission is desired, the tooth shape of
the gear is modified to achieve more intimate contact with the worm thread. A noticeable
feature of most such gears is that the tooth tops are concave, so that the gear partly
envelopes the worm. A further development is to make the worm concave (viewed from
the side, perpendicular to its axis) so that it partly envelopes the gear as well; this is called
A right hand helical gear or right hand worm is one in which the teeth twist clockwise as
they recede from an observer looking along the axis. The designations, right hand and left
hand, are the same as in the long established practice for screw threads, both external and
internal. Two external helical gears operating on parallel axes must be of opposite hand.
An internal helical gear and its pinion must be of the same hand.
A left hand helical gear or left hand worm is one in which the teeth twist counterclockwise
A rack is a toothed bar or rod that can be thought of as a sector gear with an infinitely large
radius of curvature. Torque can be converted to linear force by meshing a rack with a
pinion: the pinion turns; the rack moves in a straight line. Such a mechanism is used in
automobiles to convert the rotation of the steering wheel into the left-to-right motion of the
tie rod(s). Racks also feature in the theory of gear geometry, where, for instance, the tooth
shape of an interchangeable set of gears may be specified for the rack (infinite radius), and
the tooth shapes for gears of particular actual radii then derived from that.
BATTERY
Lead-acid batteries, invented in 1859 by French physicist Gaston Planté, are the
oldest type of rechargeable battery. Despite having the second lowest energy-to-weight
ratio (next to the nickel-iron battery) and a correspondingly low energy-to-volume ratio,
their ability to supply high surge currents means that the cells maintain a relatively large
power-to-weight ratio. This, along with their low cost, makes them ideal for use in cars, as
they can provide the high current required by automobile starter motors. They are also used
in vehicles such as forklifts, in which the low energy-to-weight ratio may in fact be
considered a benefit since the battery can be used as a counterweight. Large arrays of lead-
acid cells are used as standby power sources for telecommunications facilities, generating
PLATES
The principle of the lead acid cell can be demonstrated with simple sheet lead plates for the
two electrodes. However such a construction would only produce around an amp for
roughly postcard sized plates, and it would not produce such a current for more than a few
minutes.
Planté realised that a plate construction was required that gave a much larger effective
surface area. Planté's method of producing the plates has been largely unchanged.
A plate consists of a rectangular lead plate alloyed with a little antimony to improve the
mechanical characteristics. The plate is in fact a grid with rectangular holes in it, the lead
forming thin walls to the holes. The holes are filled with a mixture of red lead and 33%
dilute sulphuric acid (Different manufacturers have modified the mixture). The paste is
pressed into the holes in the plates which are slightly tapered on both sides to assist in
retention of the paste. This paste remains porous and allows the acid to react with the lead
inside the plate increasing the surface area many fold. At this stage the positive and
negative plates are identical. Once dry the plates are then stacked together with suitable
separators and inserted in the battery container. An odd number of plates is always used,
with one more negative plate than positive. Each alternate plate is connected together.
After the acid has been added to the cell, the cell is given its first forming charge. The
positive plates gradually turn the chocolate brown colour of Lead Dioxide, and the
negative turn the slate gray of 'spongy' lead. Such a cell is ready to be used.
Many modern manufacturers use pastes in the plates made directly from Lead Dioxide and
Lead, thus avoiding the necessity to form the plates. Once acid is added, the cell is ready
for use.
One of the problems with the plates in a lead-acid battery is that the plates change size as
the battery charges and discharges, the plates increasing in size as the active material
absorbs sulphate from the acid during discharge, and decreasing as they give up the
sulphate during charging. This causes the plates to gradually shed the paste during their
life. It is important that there is plenty of room underneath the plates to catch this shed
material. If this material reaches the plates a shorted cell will occur.
SEPARATORS
Separators are used between the positive and negative plates of a lead acid battery to
prevent short circuit through physical contact, Dendrites (‘treeing’) most and shredded
active material. Separators cause some obstructions for the flow of ions i.e. electricity
between the electrodes. Separators therefore must have the following characteristics:
Pore size must be small enough to restrict the flow of colloid particles but not restrict the
ions.
They are a little larger than the plates to prevent material shorting the plates.
To balance these criteria, the choice of separator shifted from wood to rubber to glass mat
Permeability, porosity, pore size distribution, specific surface area, mechanical design and
strength, Electrical resistance, ionic conductivity, and chemical compatibility with the
electrolyte. In service the separator must have good resistance to acid and oxidation.
BATTERY REACTION:
Moreover, the battery service temperature can be as high as 70 to 80 degrees Celsius. The
Wet cells designed for deep discharge are commonly used in golf carts and other battery
electric vehicles, large backup power supplies for telephone and computer centers and off-
Gel cells are used in back-up power supplies for alarm and smaller computer systems
bicycles and marine applications. Unlike wet cells, gel cells are sealed, so they are less
Absorbed glass mat (AGM) cells are also sealed and used in battery electric vehicles, as
well as applications where there is a fairly high risk of the battery being laid on its side or
Historically, lead-acid batteries were used to supply the filament (heater) voltage (usually
between 2 and 12 volts with 6 V being most common) in vacuum tube (valve) radio
receivers in areas where no mains electricity supply was available. Such radios typically
used two batteries: a lead-acid "A" battery for the filament voltage and a higher voltage (45
V–120 V) "dry" non-rechargeable "B" battery for the plate (anode) voltage. A few sets also
used a third (3 V–9 V with several taps) "dry" non-rechargeable "C" battery for grid
It became popular on motorcycles because its acid is absorbed into the medium which
separates the plates, so it cannot spill, and this medium also lends support to the plates
batteries, and caution should be exercised in charging and discharging them. MF batteries
should not be confuse with AGM (Absorbed Glass Mat) batteries, which also have an
ENVIRONMENTAL CONCERNS
Currently attempts are being made to develop alternatives to the lead-acid battery
the most successful recycling programs in the world, with over 97% of all battery lead
recycled between 1997 and 2001.[2] Effective Lead pollution control system is a necessity
and furnace designs for greater efficiencies. These recycling plants are ecology friendly as
they follow all emission standards for lead smelters, but new methods should be devised or
alternatives developed to the lead-acid battery so that lead pollution can be reduced to an
perform both tasks if the locomotive is equipped with dynamic brakes. Electric motors are
found in household appliances such as fans, refrigerators, washing machines, pool pumps,
means was demonstrated by the British scientist Michael Faraday in 1821 and consisted of
a free-hanging wire dipping into a pool of mercury. A permanent magnet was placed in the
middle of the pool of mercury. When a current was passed through the wire, the wire
rotated around the magnet, showing that the current gave rise to a circular magnetic field
around the wire. This motor is often demonstrated in school physics classes, but brine (salt
water) is sometimes used in place of the toxic mercury. This is the simplest form of a class
of electric motors called homopolar motors. A later refinement is the Barlow's Wheel.
These were demonstration devices, unsuited to practical applications due to limited power.
The first commutator-type direct-current electric motor capable of a practical application
was invented by the British scientist William Sturgeon in 1832. Following Sturgeon's
commercial use was built by the American Thomas Davenport and patented in 1837.
Although several of these motors were built and used to operate equipment such as a
printing press, due to the high cost of primary battery power, the motors were
Sturgeon in the development of DC motors but all encountered the same cost issues with
primary battery power. No electricity distribution had been developed at the time. Like
Sturgeon's motor, there was no practical commercial market for these motors.
The modern DC motor was invented by accident in 1873, when Zénobe Gramme
connected the dynamo he had invented to a second similar unit, driving it as a motor. The
Gramme machine was the first electric motor that was successful in the industry.
In 1888 Nikola Tesla invented the first practicable AC motor and with it the polyphase
power transmission system. Tesla continued his work on the AC motor in the years to
The classic division of electric motors has been that of DC types vs AC types. This is more
a de facto convention, rather than a rigid distinction. For example, many classic DC motors
The ongoing trend toward electronic control further muddles the distinction, as modern
drivers have moved the commutator out of the motor shell. For this new breed of motor,
driver circuits are relied upon to generate sinusoidal AC drive currents, or some
approximation of. The two best examples are: the brushless DC motor, and the stepping
synchronous types, the rotor rotates in synchrony with the oscillating field or current (eg.
most ubiquitous example being the common AC induction motor which must slip in order
to generate torque.
DC motors
are Michael Faraday's homopolar motor (which is uncommon), and the ball bearing motor,
which is (so far) a novelty. By far the most common DC motor types are the brushed and
brushless types, which use internal and external commutation respectively to create an
oscillating AC current from the DC source -- so they are not purely DC machines in a strict
sense.
BRUSHED DC MOTORS
The classic DC motor design generates an oscillating current in a wound rotor with a split
ring commutator, and either a wound or permanent magnet stator. A rotor consists of a coil
BRUSHLESS DC MOTORS
Many of the limitations of the classic commutator DC motor are due to the need for
brushes to press against the commutator. This creates friction. At higher speeds, brushes
have increasing difficulty in maintaining contact. Brushes may bounce off the irregularities
in the commutator surface, creating sparks. This limits the maximum speed of the machine.
The current density per unit area of the brushes limits the output of the motor. The
imperfect electric contact also causes electrical noise. Brushes eventually wear out and
require replacement, and the commutator itself is subject to wear and maintenance. The
of many parts.
These problems are eliminated in the brushless motor. In this motor, the mechanical
switch synchronised to the rotor's position. Brushless motors are typically 85-90%
Midway between ordinary DC motors and stepper motors lies the realm of the brushless
DC motor. Built in a fashion very similar to stepper motors, these often use a permanent
magnet external rotor, three phases of driving coils, one or more Hall effect sensors to
sense the position of the rotor, and the associated drive electronics. The coils are activated,
one phase after the other, by the drive electronics as cued by the signals from the Hall
effect sensors. In effect, they act as three-phase synchronous motors containing their own
utilize EMF feedback through the main phase connections instead of Hall effect sensors to
determine position and velocity. These motors are used extensively in electric radio-
controlled vehicles, and referred to by modelists as outrunner motors (since the magnets
Brushless DC motors are commonly used where precise speed control is necessary,
computer disk drives or in video cassette recorders the spindles within CD, CD-ROM (etc.)
drives, and mechanisms within office products such as fans, laser printers and
photocopiers.
They have several advantages over conventional motors:
running much cooler than the equivalent AC motors. This cool operation leads to
Commutation also tends to cause a great deal of electrical and RF noise; without a
The same Hall effect sensors that provide the commutation can also provide
applications. In fans, the tachometer signal can be used to derive a "fan OK" signal.
making them better suited to environments with volatile chemicals and fuels.
They are also very quiet motors which is an advantage if being used in
Modern DC brushless motors range in power from a fraction of a watt to many kilowatts.
Larger brushless motors up to about 100 kW rating are used in electric vehicles. They also
Nothing in the design of any of the motors described above requires that the iron
(steel) portions of the rotor actually rotate; torque is exerted only on the windings of the
electromagnets. Taking advantage of this fact is the coreless DC motor, a specialized form
of a brush or brushless DC motor. Optimized for rapid acceleration, these motors have a
rotor that is constructed without any iron core. The rotor can take the form of a winding-
filled cylinder inside the stator magnets, a basket surrounding the stator magnets, or a flat
pancake (possibly formed on a printed wiring board) running between upper and lower
stator magnets. The windings are typically stabilized by being impregnated with epoxy
resins.
Because the rotor is much lighter in weight (mass) than a conventional rotor formed
from copper windings on steel laminations, the rotor can accelerate much more rapidly,
often achieving a mechanical time constant under 1 ms. This is especially true if the
windings use aluminum rather than the heavier copper. But because there is no metal mass
in the rotor to act as a heat sink, even small coreless motors must often be cooled by forced
air.
These motors were commonly used to drive the capstan(s) of magnetic tape drives
and are still widely used in high-performance servo-controlled systems, like radio-
devices, etc.
UNIVERSAL MOTORS
A variant of the wound field DC motor is the universal motor. The name derives
from the fact that it may use AC or DC supply current, although in practice they are nearly
always used with AC supplies. The principle is that in a wound field DC motor the current
in both the field and the armature (and hence the resultant magnetic fields) will alternate
(reverse polarity) at the same time, and hence the mechanical force generated is always in
the same direction. In practice, the motor must be specially designed to cope with the AC
current (impedance must be taken into account, as must the pulsating force), and the
resultant motor is generally less efficient than an equivalent pure DC motor. Operating at
normal power line frequencies, the maximum output of universal motors is limited and
motors exceeding one kilowatt are rare. But universal motors also form the basis of the
traditional railway traction motor in electric railways. In this application, to keep their
electrical efficiency high, they were operated from very low frequency AC supplies, with
25 Hz and 16 2/3 hertz operation being common. Because they are universal motors,
locomotives using this design were also commonly capable of operating from a third rail
powered by DC.
The advantage of the universal motor is that AC supplies may be used on motors
which have the typical characteristics of DC motors, specifically high starting torque and
very compact design if high running speeds are used. The negative aspect is the
maintenance and short life problems caused by the commutator. As a result such motors
are usually used in AC devices such as food mixers and power tools which are used only
accomplished using a thyristor circuit, while stepped speed control can be accomplished
using multiple taps on the field coil. Household blenders that advertise many speeds
frequently combine a field coil with several taps and a diode that can be inserted in series
with the motor (causing the motor to run on half-wave rectified AC).
Universal motors can rotate at relatively high revolutions per minute (rpm). This makes
them useful for appliances such as blenders, vacuum cleaners, and hair dryers where high-
speed operation is desired. Many vacuum cleaner and weed trimmer motors exceed 10,000
rpm, Dremel and other similar miniature grinders will often exceed 30,000 rpm. Motor
damage may occur due to overspeed (rpm in excess of design specifications) if the unit is
operated with no significant load. On larger motors, sudden loss of load is to be avoided,
and the possibility of such an occurrence is incorporated into the motor's protection and
control schemes. Often, a small fan blade attached to the armature acts as an artificial load
to limit the motor speed to a safe value, as well as provide cooling airflow to the armature
With the very low cost of semiconductor rectifiers, some applications that would have
previously used a universal motor now use a pure DC motor, sometimes with a permanent
magnet field.
A typical DC motor.
The stator
WORM DRIVE
A worm drive is a gear arrangement in which a worm (which is a gear in the form
of a screw) meshes with a worm gear (which is similar in appearance to a spur gear, and is
also called a worm wheel). The terminology is often confused by imprecise use of the term
worm gear to refer to the worm, the worm gear, or the worm drive as a unit.
Like other gear arrangements, a worm drive can reduce rotational speed or allow
higher torque to be transmitted. The image shows a section of a gear box with a bronze
worm gear being driven by a worm. A worm is an example of a screw, one of the six
simple machines.
Explanation
A gearbox designed using a worm and worm-wheel will be considerably smaller than one
made from plain spur gears and has its drive axes at 90° to each other. With a single start
worm, for each 360° turn of the worm, the worm-gear advances only one tooth of the gear.
Therefore, regardless of the worm's size (sensible engineering limits notwithstanding), the
gear ratio is the "size of the worm gear - to - 1". Given a single start worm, a 20 tooth
worm gear will reduce the speed by the ratio of 20:1. With spur gears, a gear of 12 teeth
(the smallest size permissible, if designed to good engineering practices) would have to be
matched with a 240 tooth gear to achieve the same ratio of 20:1. Therefore, if the
diametrical pitch (DP) of each gear was the same, then, in terms of the physical size of the
240 tooth gear to that of the 20 tooth gear, the worm arrangement is considerably smaller
in volume.
A double bass features worm gears as tuning mechanisms
Direction of transmission
Unlike ordinary gear trains, the direction of transmission (input shaft vs output shaft) is not
reversible, due to the greater friction involved between the worm and worm-wheel, when a
single start (one spiral) worm is used. This can be an advantage when it is desired to
eliminate any possibility of the output driving the input. If a multistart worm (multiple
spirals) then the ratio reduces accordingly and the braking effect of a worm and worm-gear
may need to be discounted as the gear may be able to drive the worm.
Worm gear configurations in which the gear can not drive the worm are said to be self-
locking. Whether a worm and gear will be self-locking depends on the lead angle, the
pressure angle, and the coefficient of friction; however, it is approximately correct to say
that a worm and gear will be self-locking if the tangent of the lead angle is less than the
coefficient of friction.
An enveloping (hourglass) worm has one or more teeth and increases in diameter from its
TURNING
Turning is the process used to produce cylindrical components in a lathe. It can be done
When turning, a piece of material (wood, metal, etc.) is rotated and a cutting tool is
traversed along 2 axes of motion to produce precise diameters and depths. Turning can be
either on the outside of the cylinder or on the inside (also known as boring) to produce
Turning can be performed manually on what are known as conventional machines with
center lathes which are not computerized. In this case, they require constant supervision.
Alternatively, they may be done using automatic lathes (auto lathes) operated by skilled
tradesmen called machinists (or fitter and turners). Modern practice is moving towards the
Facing is a related term. It involves moving the cutting tool across the face (or end) of the
workpiece and is performed by the operation of the topslide, as distinct from the
longitudinal feed (turning). It is commonly associated with the use of a lathe although it
The bits of waste metal from turning operations are known as chips. In some locales they
may be known as turnings or swarf although swarf is generally applied to the waste from
grinders.
DRILLING
DRILL
A drill (from Dutch Drillen) is a tool with a rotating drill bit used for drilling holes
The drill bit is gripped by a chuck at one end of the drill, and is pressed against the
target material and rotated. The tip of the drill bit does the work of cutting into the target
material, slicing off thin shavings (twist drills or auger bits) or grinding off small particles
(oil drilling).
Taps and dies are cutting tools used to create screw threads in solid substances
including, but not limited to, metal, wood, and plastic. A tap is used to cut the female
portion of the mating pair (e.g. a nut). A die is used to cut the male portion of the mating
pair (e.g. a bolt). Other than pipes, it is more common to create the hole into which a bolt is
screwed than to create the item that is screwed into a hole. Thus, taps are often more
commonly available. The process of cutting the threads in a hole is called "tapping" the
hole.
The die cuts a thread on a preformed cylindrical rod, which creates a male threaded
thermoplastics, by causing coalescence. This is often done by melting the workpieces and
adding a filler material to form a pool of molten material (the weld puddle) that cools to
become a strong joint, with pressure sometimes used in conjunction with heat, or by itself,
to produce the weld. This is in contrast with soldering and brazing, which involve melting
ARC WELDING
Many different energy sources can be used for welding, including a gas flame, an
electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial
process, welding can be done in many different environments, including open air,
underwater and in space. Regardless of location, however, welding remains dangerous, and
precautions must be taken to avoid burns, electric shock, poisonous fumes, and
WELDING PROCESSES
These processes use a welding power supply to create and maintain an electric arc
between an electrode and the base material to melt metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes. The welding region is sometimes protected by some type of inert or semi-inert
gas, known as a shielding gas, and filler material is sometimes used as well.
ADVANTAGES
Light Weight
over come Practical difficulties and carrying out the work with the suggestions and
guidance of our staff and the positive help of our well wishes.
The motorized car Jack is fabricated and tested. It is working satisfactory. More-
sophisticated screw mechanisms may use a recirculation-ball nut to minimize friction and
prolong the life of the screw threads, but such jackscrews are usually not self-locking.
We are immensely pleased to have the satisfaction of carrying out of useful project
at this stage of the course we have actually become a fall-fledged technician by the
Motorized Car Jack. It was more useful for our further study or for our job and we get the
self confidence and also creative things for taking up any bold step in the course of our
professional career.
SCOPE FOR FURTHER WORK
If High reduction gear box is fitted. More weight can be lifted easily. Reduce the
motor weight is very usefull for handle old people and ladies , To Improve the battery
amps, motor can easily drive the lead screw with out heat and struggle.
BIBLIOGRAPHY
WEBSITE REFERENCES
www.google.com
www.mechanicalengineering.com
www.alipaba.com
www.howstuffworks.com
PHOTOGRAPHS