Café Service lifter

Contents
CHAPTER 1................................................................................................................................................1
INTRODUCTION.......................................................................................................................................1
1.1. The Problem and Its Background.................................................................................................1
1.2. Statement of the Problem.............................................................................................................2
1.3. Advantage and Application..........................................................................................................2
1.4. Working Principle........................................................................................................................3
1.5. Objectives of the study................................................................................................................3
1.5.1. General objective.................................................................................................................3
1.5.2. Specific objective.................................................................................................................3
1.6. Significance of the Study.............................................................................................................3
1.7. Scope and Limitation of the Study...............................................................................................3
Chapter 2.....................................................................................................................................................3
Theoretical Framework and Related Literature...........................................................................................3
CHAPTER 3................................................................................................................................................3
The Research Design and Methodology......................................................................................................3
3.1. Research Design..........................................................................................................................3
3.2. Study area....................................................................................................................................3
3.3. Source of data..............................................................................................................................3
3.3.1. Method of data collection....................................................................................................3
Chapter 4.....................................................................................................................................................3
Design Analysis...........................................................................................................................................3
4.1. Material Selection........................................................................................................................3
4.2. Calculation...................................................................................................................................3
4.3. Force acting on the cylinder.........................................................................................................3
4.3.1. Lowest position....................................................................................................................3
4.3.2. Highest position...................................................................................................................3
4.4. Forces acting on the leg...............................................................................................................3
4.4.1. Lowest position....................................................................................................................3
4.4.2. Diagram...............................................................................................................................3
4.4.3. Force at highest position......................................................................................................3
4.4.4. Diagram...............................................................................................................................3

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4.5. Cylinder Selection.......................................................................................................................3

4.5.1. Hydraulic Cylinder Calculation...........................................................................................3
4.6. Design of Cylinder for Stresses...................................................................................................3
4.6.1. Circumferential or Hoop Stress............................................................................................3
4.6.2. Longitudinal stress...............................................................................................................3
4.7. Circuit Design Analysis of Hydraulic Cylinders..........................................................................3
4.7.1. Design specification.............................................................................................................3
4.7.2. Size of Cylinder Needed......................................................................................................3
4.7.3. Capacity of pump Needed....................................................................................................3
4.8. Design of leaver...........................................................................................................................3
4.9. Danger Notices............................................................................................................................3
4.9.1. Principle Safety Objective...................................................................................................3
4.9.2. Safety Notices......................................................................................................................3
CHAPTER 5................................................................................................................................................3
COST ANALYSIS......................................................................................................................................3
CHAPTER 6................................................................................................................................................3
Summary of Findings, Conclusion and Recommendation...........................................................................3
6.1. Summary of Findings...................................................................................................................3
Conclusion...................................................................................................................................................3
Recommendation.........................................................................................................................................3
References...................................................................................................................................................3
Appendix.....................................................................................................................................................3

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Café Service lifter

CHAPTER 1

INTRODUCTION
1.1. The Problem and Its Background
This CBTP project is intended to solve some problem around the community based on survey
and research methodology to make some useful mechanical machine for our community. Such a
project structure was chosen as the most appropriate and suitable for the chosen topic. It allows
increasing knowledge by applying to the literature and adding an individuality of the author by
making him solve an actual practical problem using own approach and based on our survey and
interview we chose Jimma University cafeteria.

Jimma University cafeteria is found in Jimma University institute of technology and it service
the students for their meal around 4730 students are use in this cafeteria. All of them are from
different back ground, ethics, nation and nationalities. Jimma University, Kitto Furdisa campus
has 325 workers along the managing officers. This worker doing their works by two shifts from
those, 305 are female workers and the left are males. And we would like to help our university
cafeteria workers by designing the simple and safe way of transporting heavy materials including
processed food by using hydraulic cafe service lifter.

The service lifter is an elevator with a system of levers and hydraulic cylinders on which the
metal platform is capable of moving in the vertical plane. This is achieved by using of linked,
folding supports in a crisscross pattern, called scissor mechanism.

The hydraulic lift was chosen as a subject of the thesis because it is a perfect example of
mechanical engineering field. This mechanism combines a result of several main fields of
engineering and at the same time, it is simple and accessible for understanding. The construction
and load distribution represent statics and strength of material subjects, the hydraulic cylinder
and the control unit involves knowledge of hydraulic systems and automation. Material science
is important for selection of a suitable material as well as knowledge of modeling.

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1.2. Statement of the Problem

During our research by using different methods of collecting data such as survey, and interview
we found that there is a huge problem that cause an irritable, unforgettable and very heart
breaking accident happened 2016 and 2017 after we joined this university on two cafeteria
workers during transportation of processed food and Ingredients. Also, there are some problems
in unloading and transporting food Ingredients and daily wage cost; also most of them have no
enough power to transport heavy materials to and from the store.

Based on our survey we found out this problem is caused because of the following factors:

 The way of transporting heavy load equipments

 The surface slippery and its very risky
 Mechanism of moving objects usually they move this heavy loads by carrying
 Using daily wage workers for unloading different integrant products is high
 Most of the workers lack of power to carry the heavy equipments because of their age.

1.3. Advantage and Application

The concept of lift with hydraulic power comes from Pascal’s law which states that “pressure
exerted anywhere in a confined incompressible fluid is transmitted equally in all directions
throughout the fluid such that the pressure ratio remains the same”

Since the emergence in the light of different cultural achievements, the individual tries to
maximize their use to facilitate the work. The rough labor is replaced by technology, for example
lifting mechanisms. Thus, in particular, the café service lifter has been used successfully to
hydraulic and other works on the heights of about 1.2 meter. Also, lifts of this type could also be
applied to other conditions, such as daily loading and unloading work in warehouses. The café
service lifter perfectly meets the needs for certain warehouse facilities, mainly because of the
fact that above the lifting platform it has a lack of any mechanisms. This is complemented by

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access from all four sides, which gives the opportunity to use it for loading of objects on the top
shelves of warehouse racks.

1.4. Working Principle

The hydraulic cylinder gets power from the manually operating pump. The system is very simple
example which demonstrates the operation of a basic hydraulic system. It has two simple
cylinders connected to each other, containing adequate quantity of hydraulic fluid in it. One of
cylinder is larger in size when compared to the other. Both the cylinders have pistons in them,
but in strict “hydraulic” terminology, the larger piston is called as a “ram” and small one a
“plunger”. As seen from the figure a small force “P” applied on the plunger, in downward
direction, presses the hydraulic fluid in below it. The pressure transmitted equally in all
directions and raises the “ram” (Pascal’s law). The heavier load placed on the ram is lifted up as
shown figure

Figure 1: Pascal’s law

The force applied on the plunger may small when compared to the weight placed on the ram.
Also, the area of plunger is small when compared to the area of the ram. But the pressure acting
on the plunger (due to the application of force “F” on the plunger, and the ram is same (Pascal’s
law) which the pressure is acting that makes the difference. The pressure “P” acts on the ram,
which has a larger area. The same pressure “P” acting on the plunger has a small area. Also, the
distance travelled by plunger is more when compared to the distance travelled by ram. This
makes small force applied on the plunger able to lift heavy loads placed on the ram [4].

1.5. Objectives of the study

1.5.1. General objective
The main objective of this project is to solve society problem by designing a café service lifter.

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1.5.2. Specific objective

The goal of the study is to design the cafe lifter to lift up to a height of 1.2 meters and with the
carrying capacity of 100 kilograms. The driving mechanism of the lift must be a hydraulic
cylinder. Calculations of the inner stresses must be done and a 3D model must be created. It is
also necessary to choose the material.

1.6. Significance of the Study

Since this challenge is main and causes many problem which affect workers safety, on this
research we need to benefit safety, quality, human power required and to save time. Also, this
research helps another university if there is the similar problem. Generally, another advantage of
this research is that it may helps as a sample for another researcher and for fourth year students.

1.7. Scope and Limitation of the Study

The study will conduct in Ethiopia, Jimma town of Jimma University Institute of technology in
the campus of kito furdisa. The scope is within the range of our university because it is one of the
higher educational institution in the country which serves many students and employees in the
content.

As everyone us known, everything and everyone has its own limitation, and also this big
institution has café service limitation. When we say this workers of cafeteria face many problems
during transporting heavy materials including processed food transportation in the service.

This large institution café needs equivalent services regarding to the problem the workers face in
the cafeteria and also make or available for service in the café in order to overcome problem in
this services.

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Chapter 2

Theoretical Framework and Related Literature

Since the emergence in the light of different cultural achievements, the individual tries to
maximize their use to facilitate the work. Only a century ago, the society did not have the
opportunity even to dream about what is already openly available at present. The rough labor is
replaced by technology, for example lifting mechanisms.

People use a huge number of different lifts. The aim is also different some are used in some
situations while others are for a totally different environment. For example, there is an electro-
hydraulic scissors elevator quite a small device allowing lifting hundreds of kilograms of freight
on a height of tens of meters. Thus, in particular, the hydraulic scissor hydraulic lift has been
used successfully to electrical and other works on the heights of about 2-3 floors. Also, it allows
making work at a greater height than tens of meters [5].

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CHAPTER 3

The Research Design and Methodology

3.1. Research Design
In order to increase the reliability of our study we follow a descriptive survey design (mixed way
of collecting the data). We use both of interviews and questioners method for Jimma university
cafeteria workers and interviews for the managers of cafeteria.

3.2. Study area

We undergo our research in Jimma University. Specifically in Jimma Institute of Technology
(JIT)

3.3. Source of data

The participants of this research are thus:

 Students of Mechanical Engineering, Group One, Subgroup E

 The Jimma university cafeteria manager and workers.
 The Mechanical Engineering department and
 Our advisers (Delesa Kajela and Amanuel Tesfaye)

3.3.1. Method of data collection

The method of gathering the needed information that we use is both of questioners and interview
method.

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Chapter 4

Design Analysis
4.1. Material Selection
Depending on a component and tasks that this component performs the selection of a certain
material is founded. Different parts of the mechanism take different load and stress because they
carry out different functions. It is important to use an individual approach to select a material for
every part. It impacts on a total efficiency and benefit received from each detail and best
properties which can give different materials. Thus, it is necessary to allocate the main parts of a
design and to explain features of each of them separately. It is necessary to evaluate the
particular type of forces imposed on components with a view to determining the exact
mechanical properties and necessary material for each equipment. A very brief analysis of each
component follows thus:

 Lifter Arms
 Hydraulic cylinder
 Top plat form
 Base plat form
 Wheels

Lifter Arms: The main interest is made by the legs of the lift, the greatest part of loading is
shared between them and they are a basic element of the assembly. It means that the material of
which they are made has to be capable of maintaining this load. This part is subjected to a
normal force which might cause buckling and shear force which cause bending, which possibly
cause bending deformation or even braking of the part. Then such properties as strength,
hardness, and stiffness are needed. An appropriate material for these purposes is structural steel,
more precisely the S355 steel.

Hydraulic Cylinder: The second basic element of a design is the cylinder. From the technical
point of view, it acts as a bar with pinned ends. It is subjected to direct compressive force which
leads to bending and buckling load in the rod. Also, there exists the internal pressure of the fluid,
which causes circumferential and longitudinal stresses all around the wall thickness. Thereby the

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cylinder must have such properties as strength, toughness, ductility and hardness. An appropriate
material is mild steel.

Top Platform: There are also such components as top plates and base plates. The top plates take
the load caused by a weight of lifting goods. The main needed property here is strength and the
selected material is mild steel. The base plates are subjected to the weight of the load and lifter
mechanism itself cylinder and legs, hence, hardness and stiffness are required. Mild steel is
appropriate.

4.2. Calculation
The calculations of forces, stresses, and reactions of the structure play the most important role in
the design because on the result of these calculations and its correctness depends stability, safety
and successful work of the whole mechanism. The lifting table is a dynamic mechanism, but the
speed of acting is relatively low, so this fact can be neglected and this system can be concerned
as static. Then only two positions are needed to be considered, they are the initial position when
the lift is lowered and just lying on the floor, and the highest position, when the mechanism lifted
a weight on the highest possible distance. In these two positions, the highest reactions and
internal forces are observed. In all the other positions the results will be between the two
mentioned above.

4.3. Force acting on the cylinder

4.3.1. Lowest position
While calculation it is important to understand the behavior of the structure. For this, the
simplified picture is used to focus on the main acting forces. Here is the free body diagram on
Figure 2 [5]

Figure 2: Free body diagram for the initial position

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As it can be seen on Figure 2, A and D are roller supports and B and C are pin supports, point O
is also a pin joint between two legs of the lift. Force W is applied as the weight of the load and it
is acting in the middle of the table, dimension “d” shows it. Also in the other plane which is not
shown, the weight is supposed to be as well in the middle. When the force acting on the middle
or shared over the table, it is transmitted equally to A and B supports. The “Wlegs” is the load
caused by a weight of the legs. It is also acting in the middle, but only in the initial position.
Also, the total incoming forces must be equal to the total out coming, which means that whatever
is happening inside the system the sum of reactions Dy and Cy would be equal to the weight.
Then vertical reactions of D and C are half of the weight of the main load plus the weight of legs.

W + Wlegs
Cy=Dy=
2

EF from Figure 1 is the hydraulic cylinder and here it is acting like a truss. It is subjected a
compression force, that means the cylinder acts with a certain force to the points E and F. On
Figure 3 [5], it can be seen how this force P is decomposed into a Y and X components
according to the axes. And as a result:

Py
sin β= ⇒ Py=Psin β
P

Py
cos β= ⇒ Py=Pcos β
P

Figure 3: Force components at point E

Then the free body diagram is drawn for each leg separately on Figure 4. Fy And Fx are the
components of F force acting on the pin, it is better to decompose it right now because its value
and direction are not known yet.

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Figure 4: Free body diagrams for each of leg separately

Also, it is needed to get the projections of the dimensions of the leg which will be called “L”, the
dimension between E and O is called “a”. The analogous result may be used for projection of
CE, the dimension of which is “( L/2+a)” as shown on Figure 5.

Figure 5: Projections of the leg

Lx
cosα= ⇒ Lx=cosα
L

Ly
sinα= ⇒ Ly=Lsinα
L

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Then, using the diagram on Figure 3 it is needed to consider a balance of forces in Y and X
directions and also the balance of moments created by the action of forces. It is done only for
AC, but there will be an identical result on DB because dimensions are the same.

∑ Fox=0 ⇒ Px−Fx=0 ⇒ Px=Fx

Fx=Pcosβ

W Wlegs
∑ Foy=0 ⇒− + Py−Fy− + Cy=0
2 2

W Wlegs W + Wlegs
⇒− + Py−Fy− + =0
2 2 2

Fy=Psinβ

Rotating around point C, CCW is positive direction:

∑ Mc=0

Wlegs L W L L l L
2 2 2 2 ( ) 2 2 2 ( )
cosα + Lcosα−Psinβ +a cosα + Fy cosα−Pcosβ +a sinα + Fx sinα=0

Wlegs L W L L l L
2 2 2 2 ( ) 2 2 ( )
cosα + Lcosα−Psinβ +a cosα + Psinβ cosα−Pcosβ + a sinα + Pcosβ sinα =0
2

Wlegs L W L L l L
2 2 2 2 ( ) 2 2 ( )
cosα + Lcosα+ P(−sinβ +a cosα+ sinβ cosα−cosβ +a sinα + cosβ sinα)=0
2

Wlegs L W L L l L
2 2 2 2 (( ) )
cosα + Lcosα+ P( sinβ cos α − +a + +cosβsinα − + a + )=0
2 2 2 (( ) )
Wlegs L W
cosα + Lcosα+ P (−a ( sinβcosα +cosβsinα ) )=0
2 2 2

Rule from geometry:

sin β cos α+ cos β sin α =sin ⁡(α + β) (Tammertekniika 2012, page 15).

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P=
Lcos α ( w2 + Wlegs
4 )
a × sin ( α + β )

In this project, there was the following order of actions: first, based on the existing examples and
approximate representation what has to be the elevator, to get the needed measurements and
numbers with which calculations can be done. Then in case if the model does not correspond to
the necessary result it can be changed in an appropriate way.

Figure 6: 3D view of the cafe service lifter

According to the design there are the following measurements:

Length, L=1300 cm=1.3 m

a=0.224 m

Mass of the load, m=100 kg

Weight,W =mgwhere g=9.81m/s²

Weight of load, W =100 x 9.81=981 N

Mass of the legs, Mlegs=10 kgfor four legs

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Weight of legs, Wlegs=10 x 9.81=98.1 N

α =5 ˚

β=13 ˚

P=
1.3 cos 5 ˚ ( 9812 + 98.14 )
0.244 ×sin ( 5 ˚ +13 ˚ )

P=8.846 kN

4.3.2. Highest position

On Figure 6 the free body diagram for the highest position of the lift is shown [5]:

Figure 7: Free body diagrams for the highest position

d=0.650 m

α =66 ˚

AB=0.529 m

∑ Mc=0

W × d+Wlegs ( AB2 )−Dy × AB=0

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Dy=
W . d +Wlegs ( AB2 )
AB

Dy=
0.650W + Wlegs ( 0.529
2 )
0.529

Dy=1.23W +0.5 Wlegs

∑ Foy=0 ⇒ Dy−Cy−Wlegs−W =0

Cy=Dy−Wlegs−W =1.23 W +0.5 Wlegs−Wlegs−W

Cy=0.23 W −0.5Wleg

According to the behavior of the legs: Cy=−By and Dy=− Ay for the free body diagrams of the
legs in the highest position which is shown on Figure below. Calculations are done only for AC,
but there will be an identical result on DB because dimensions are the same.

Figure 8: Free body diagrams of legs in highest position

∑ Fox=0 ⇒ Px−Fx=0 ⇒ Px=Fx

Fx=Pcosβ

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Wlegs
∑ Foy=0 ⇒−Dy+ Py−Fy− −Cy=0
2

Wlegs
Fy=Py−Dy− −Cy
2

Wlegs
Fy=Py – 1.23 W −0.5 Wlegs – – 0.23W +0.5 Wlegs
2
Fy=Py – 1.46 W – 0.5 Wlegs
Fy=PSinβ – 1.46 W – 0.5 Wlegs

Rotating around point C, CCW is positive direction:

∑ Mc=0

Wlegs L L L L L
2 2 2 ( )2 2 2 ( )
cosα + DyLcosα−Psinβ + a cosα+ Fy cosα−Pco sβ +a sinα + Fx sinα=0

Wlegs L L L L
2 2 ( ) (
cosα + ( 1.23W +0.5 Wlegs ) Lcosα−Psinβ +a cosα+ ( Psinβ −1.46 W −0.5Wlegs ) cosα −Pcosβ
2 2 2 ) (
0.5 Wlegs × Lcosα +0.5 WLcosα−P× a ( sinβcosα +cosβsinα ) =0

0.5 Lcosα ( W +Wlegs )−P ×a ( sinβcosα +cosβsinα )=0

Rule from Geometry:

sinβcosα +cosβsinα =sin ( α + β ) (Tammertekniika 2012, page 15).

P=
Lcosα ( W2 + Wlegs
2 )
a × sin(α + β)

The above formula can be used for calculating the force in the cylinder in any position where
reactions Cy and Dy are not the same, it means that any position except initial lowest position,
because in that position dimension between DC is the same dimension as 2.d .

According to the design there are the following measurements:

Length, L=1.3 m

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a=0.082 m

W =981 N

Wlegs=98.1 N

β=72˚ α =66 ˚

P=
1.3 cos 66 ˚ ( 9812 + 98.1
2 )
0.082× sin(66 ˚ +72 ˚)

P=5.2 kN

4.4. Forces acting on the leg

4.4.1. Lowest position
Now all needed forces are known. If P x =F x and P y =F y , then P force equals to the force F in the
pin and as they are acting like counter forces, their values are the same. Then it is necessary to
find normal and shear forces acting on the leg in order to be able to find stresses. For that all the
forces must be projected parallel to the axis of the leg, as shown on Figure 8, using the rules of
geometry and components of the forces as it was done earlier [5].

Figure 9: Forces components parallel to the axis of the leg

C yy W + Wlegs 981+ 98.1

sin 85 ˚= Where Cy=Dy= = =539.55 N
Cy 2 2

C yy=539.55 N ×sin 85 ˚

C yy =537.5 N

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C yx
cos 85 ˚ = ⇒C yx=C y × cos 85 ˚
Cy

C yx=539.55 ×cos 85˚

C yx=47 N

Py'
sin 18 °= ⇒ P'y =Psin 18 ° ⇒P'y =8.846 kn ×sin 18 °
P

P'y =2733.6 N =F ' y

Px '
cos 18 °= ⇒ P'x =Pcos18 ° ⇒⇒ P'x =8.846 kN × cos 18 °
P

P'x =8413 N =F ' x

W
y
2 W W W 539.55
sin 85 °= ⇒ y = sin 85 ° ⇒ y = sin85 °
W 2 2 2 2
2

W
y =268.7 N
2

W
x
2 W W W
cos 85 ° = ⇒ x= cos 85 ° ⇒ x=23.5 N
W 2 2 2
2

Wlegs
y
2 Wlegs Wlegs Wlegs
sin 85 °= ⇒ y= sin 85° ⇒ y=48.86 N
Wlegs 2 2 2
2

Wlegs
x
2 Wlegs Wlegs Wlegs
cos 85 ° = ⇒ x= cos 85 ° ⇒ x=4.3 N
Wlegs 2 2 2
2

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The same things are done for the second leg, where forces are the same but directions are
different. Reaction forces at the points D and B are the same. It is shown on Figure 9 [5].

Figure 10: Forces components parallel to the axis of the second leg

Py ' '
sin 8 °= ⇒ P'y' =Psin8 ° ⇒P'y' =8.846 ×sin 8 °
P

P'y' =1231 N =F ' ' y

Px ' '
cos 8 ° = ⇒ P'x' =Pcos 8 ° ⇒P'x' =8.846 ×cos 8°
P

P'x' =8760 N=F ' ' x

4.4.2. Diagram
Now it is possible to draw a shear force diagram, a normal force diagram, and a moment
diagram. Then corresponding stresses can be calculated. The normal force diagram, shear force
diagram and bending moment diagram for both legs are shown below on Figures 11.

”+” is for tension; ”-” is for compression:

Figure 11 Forces components parallel to the axis of the leg

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To draw normal force diagram, take horizontal force components;

Figure 12 horizontal force components

Figure 13 Normal Force Diagram

To draw shear force diagram and bending momentum diagram, consider vertical force diagram
only

Figure 14 Vertical force diagram

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Figure 15 Shear Body Diagram

Figure 16 Bending momentum diagram

4.4.3. Force at highest position

In the other positions the formula for the force of the cylinder is different, and reaction forces
and internal forces are needed to be revised. The second position is the highest possible point for
the lift. But because of the geometry of the structure, the behavior of the forces is changed,
internal forces are not the same as in the first position, its nature (compression and tension) is
other.

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Café Service lifter

Figure 17 Free body diagram of the first leg in the highest position

We know that;
Dy=1.23W +0.5 Wlegs and Cy=0.23 W −0.5Wleg
Dy=1.23× 981 N +0.5 ×98.1 N=1255.68 N

Dyx=cos 24 ° ×1255.68=1147.1 N

Dyy=1255.68 N × sin 24 °=510.7 N

Cy=0.23 ×981 N +0.5 × 98.1 N =274.68 N

Cyy=274.68 ×sin 24 ° =111.7 N

Cyx=274.68 ×cos 24 °=250.9 N

P'y
sin 42 °= ⇒P'y =Psin 42° =5200 N × sin 42° =3479.5 N
P

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Café Service lifter

P'x '
cos 42° = ⇒ P x =Pcos 42 °=5200 ×cos 42° =3864.4 N
P

W legs
y
2 W W 98.1
sin 24 °= ⇒ legs y= legs sin 24 °= sinn24 ° =20 N
W legs 2 2 2
2

W legs
x
2 W W 98.1
cos 24 ° = ⇒ legs x= legs cos 24 °= cos 24 °=44.8 N
W legs 2 2 2
2

The force of the pin is no longer a counter force for the cylinder, its direction and magnitude is
different now.

' ' W legs

F y =P y −Dyy− y−Cyy
2

F 'y =3479.5 N−510.7 N−20 N −111.7 N =2837.1 N

' ' W legs

F x =P x −Dyx− x−Cyx
2

F 'x =3864.4 N −1147.1 N−44.8 N −250.9 N

F 'x =2421.6 N

F ' =√ F 'x2+ F 'y2

' 2 2
F =√ ( 2421.6 N ) + ( 2837.1 N )

F ' =3730.05 N

4.4.4. Diagram
Now it is possible to draw a shear force diagram, a normal force diagram, and a moment
diagram. Then corresponding stresses can be calculated.

To draw normal force diagram, take horizontal force components;

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Café Service lifter

Figure 18: Normal force diagram

To draw shear force diagram and bending momentum, take vertical force components;

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Café Service lifter

Figure 19: Shear and bending momentum diagram

4.5. Cylinder Selection

The hydraulic cylinder (or the hydraulic actuator) is a mechanical actuator that is used to give a
unidirectional stroke. It has many applications, notably in engineering. The analysis of stresses
induced in a thin cylindrical shell is made on the following assumptions:
1. The effect of curvature of the cylinder wall is neglected.
2. The tensile stresses are uniformly distributed over the section of the walls.
3. The effect of the restraining action of the heads at the end of the pressure vessel is neglected.

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Café Service lifter

When a thin cylindrical shell is subjected to an internal pressure, it is likely to fail in the
following two ways [1]:
1. It may fail along the longitudinal section (i.e. circumferentially) splitting the cylinder into two
troughs, as shown in Fig. 10(a).
2. It may fail across the transverse section (i.e. longitudinally) splitting the cylinder into two
cylindrical shells, as shown in Fig. 10(b).

Figure 20: Failure of a cylindrical shell.

When a thin cylindrical shell is subjected to an internal pressure, it is likely to fail in the
following two ways:

1. It may fail along the longitudinal section (i.e. circumferentially) splitting the cylinder
into two troughs, as shown in Fig. 10(a).
2. It may fail across the transverse section (i.e. longitudinally) splitting the cylinder into
two cylindrical shells, as shown in Fig. 10(b).

Hoop stress is produced as a result of forces applied from inside the cylindrical pipe pushing
against the pipe walls. Hoop stress is the result of forces pushing against the circumferential
cylinder walls. While, longitudinal stress is as a result of forces pushing against the top ends of a
cylinder. These forces are derived using Newton’s first law.
Let d = internal diameter of cylinder
T = thickness of cylinder
P = internal pressure (gauge) in the cylinder
C = circumferential or hoop stress
L = longitudinal stress
L = length of cylinder or pipe

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Pd
Hoop stress δ c=
2t
Pd
Longitudinal stress δ l=
4t
Pd δ C −δ L
Maximum Shear Stress τ max= =
8t 2
Bursting force ( pressure)=PdL

Resisting strength=2<C

Busting force=resisting strength( PdL=2<C)

Note: the maximum stress developed must not exceed the permissible tensile stress (t) of the
material.
Raj put 2010

4.5.1. Hydraulic Cylinder Calculation

Selected cylinder bore diameter from standard cylinder sizes is 30mm and length of cylinder is
309.08mm.

π d2 π ×302 2
A 1= ⇒ A1= =706.5 mm
4 4

Assume thickness of cylinder, t=20 mm. The wall diameter of cylinder, D=d+ t.

D=30+ 20=50 mm

π D 2 3.14 × 502 2
A2= = =1962.5mm
4 4

F
Supplied pressure, P=
A

5200 N
P= 2
=2.65 N / mm2
1962.5 mm

πEI
Buckling load, P E=
L2

Where, length of cylinder L=309.08 mm

Young’s Modulus of mild steal, E=210GN /m2

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Café Service lifter

π d4
Inertia, I =
64

3.14 ×30 4 4 −8 4
I= =39740.6 mm =3.97406× 10 m
64

3.14 ×210 ×10 9 × 3.97406× 10−8 m 4

P E= =274.3 KN
0.309082 m

Buckling stress, δ E

PE
δ E=
A

274.3 KN
δ E= 2
=388.25 KN /m2
0.7065 m

Since the load required P=5.12 N is less than the Buckling load, P E=274.3 kN , the cylinder is
safe in operation.

L
Slenderness ratio, Sr =
K

d
Radius of Gyration, K=
4

0.030
K= =0.0075
4

0.30908
Sr = =41.08
0.0075

4.6. Design of Cylinder for Stresses

4.6.1. Circumferential or Hoop Stress
Consider a thin cylindrical shell subjected to an internal pressure as shown in Fig. 11 (a) and (b).
Tensile stress acting in a direction tangential to the circumference is called circumferential or
hoop stress. In other words, it is a tensile stress on *longitudinal section (or on the cylindrical
walls). [1]

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Café Service lifter

Figure 21 Circumferential or hoop stress.

Pd
Hoop stress, δ c =
2t

5.2 N /mm 2 ×50 mm 2

δ c= =65 N /mm
2× 2mm

4.6.2. Longitudinal stress

Consider a closed thin cylindrical shell subjected to an internal pressure as shown in Fig. 7.3 (a)
and (b). Tensile stress acting in the direction of the axis is called longitudinal stress. In other
words, it is a tensile stress acting on the *transverse or circumferential section Y-Y (or on the
ends of the vessel).

Figure 22: Longitudinal stress.

Pd
δ L=
4t

5.2 N /mm 2 ×50 mm 2

δ L= =32.5 N /mm
4 ×2 mm

Since the Hoop stress is less than the tensile stress of the material of the cylinder, the cylinder
will not burst.

δ c =65 MPa<δ t=355 MPa

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Café Service lifter

Factor of safety,FOS

δt
FOS=
δc

355 MPa
FOS= =5.5
65 MPa

4.7. Circuit Design Analysis of Hydraulic Cylinders

4.7.1. Design specification
Load to be fitted, F=mg

Mass of the load to be lifted; m=100 kg

F=100 kg × 9.81m/ s2=981 N

Piston travel distance (stroke length); L=0.15m/ s

Speed of piston rod assembly; V =0.08 m/s

Due to corrosion resistance and easy heat dissipate and absorb stainless steel is suitable for
utensil

4.7.2. Size of Cylinder Needed

Cylinders can be reasoned:

 Large diameter cylinder

 Operates at low pressure
 Require bigger pump to operate

The cylinder manufacturers follow ISO standards in respect of bore sizes of hydraulic cylinders
(e.g.). The preferred bore size can be30 mm bore diameter cylinder. So, the rod size is 20 mm.

Actual working pressure for extending,

Force
Pext =
Area

981 N
P= 2
=1.4 N /mm2
706.5 mm
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Café Service lifter

Actual working pressure for retraction,

Force
Pret =
Areaofcylinder− Areaof road

π d2
Area of road, Arod =
4

(20 mm)2
Arod =3.14 × =314 mm2
4

981 N
Pret = 2
=2.5 N /mm2
(706.5−314) mm

4.7.3. Capacity of pump Needed

Minimum cylinder speed, V =0.08 m/s

Flow rate,

 Extension flow rate

Q ext =Bore Area× Velocity

Qext =0.0007065mm 2 × 0.08 m/ s

Q ext =0.057l /min

 Retraction flow rate

Minimum retraction speed, V ret =0.18 m/s

Q ret =road Area ×Velocity

Qret =0.000314 mm2 ×0.18 m/s

Q ret =0.057 l/min

 Total flow rate, Qtot =Qext +Qret

Q tot =0.57 l/min+ 0.57 l/min
Qtot =1.14 l/min

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Café Service lifter

Figure 23 Fluid SIM

4.8. Design of leaver

A lever is made up of mild steel and is used to apply load on the plunger. It is attached to the
plunger with the help of pivot.

Assumption;

Take length of lever 50 cm

Lever is made up of mild steel.

Permissible tensile strength of mild steel (σt )=120 N / mm2

Let,

W =¿ Load acting on the ram

F=¿ Effort put on leaver by man

d p= Diameter of the plunger

P= Pressure developed in plunger cylinders

From standard table select inside diameter of plunger cylinder, d p=8 mm

π 2
Where, A p is area of the plunger. A p = d
4

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Café Service lifter

82 2
A p =3.14 × =50.24 mm
4

From the Pascal’s law, P1=P2. Where, P1 is Pressure applied on the ram of cylinder and P2 is
pressure applied by the plunger of the cylinder.

W1 W2
P 1= And P2=
Ar Ap

W1 W 2
=
Ar A p

W1 2 5200 N
W 2 =A p =50.24 mm × =832 N
Ar 314 mm 2

Therefore, load acting on the plunger is 832 N

Bending momentum calculation;

Bending momentum at point A=0

∑ M A =0

832 N × 15 cm−F ×50 cm=0

F=249.5 N

Therefore, effort put on leaver by man is 249.5 N

4.9. Danger Notices

The safety precautions in this manual are classified into the following four levels. Please be
particularly careful when performing operations that have a high degree of danger.

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Café Service lifter

 DANGER: Failure to follow this safety precaution may result in great physical danger to
the operator, or even death.
 CAUTION: Failure to follow this safety precaution may result in great physical danger
to the operator, or severe damage to the Café service lifter.
 WARNING: Failure to follow this safety precaution may result in an injury to the
operator, or damage to the Café service lifter.
 NOTICE: Failure to follow this safety precaution may result in damage to the Café
service lifter.

4.9.1. Principle Safety Objective

 The principle safety objective is to remove the possibility of any hazard or risk to the
health or safety of the lift's operator or service personnel.
 Extreme caution must be exercised while servicing or installing the Café service lifter.
 Accident prevention should become part of standard working, operating and maintenance
procedures, and training should be provided to ensure safety standards are understood.
Part of safety training should include the instructions outlined in this section.
 Always ensure suitable qualified personnel carry out servicing and maintenance tasks.
The operator should understand the limits of their responsibility, and the training should
reinforce the importance of not exceeding them.

4.9.2. Safety Notices

To protect the operator or service personnel from any injuries or accidents during operating the
Café service lifter, please read this section carefully for safe and proper use of the.

 Only qualified personnel should be allowed to operate or service this Café service lifter.
 When abnormal conditions not specified in this instruction manual occur during
operation, stop operation of the Café service lifter and contact the manufacturer.
 Do not stand or sit under the Café service lifter while lifting the loading materials. This
may result in physical danger or death.
 Never modify safety devices.
 If safety devices are not working, a serious accident may occur.
 While lowering the lift, be careful not to put your foot under the tabletop. Serious injury
may occur.

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Café Service lifter

During lifting and lowering the lifter:

 Always watch the lifting materials while operating lift to ensure that there are no
problems taking place while raising or lowering.
 Do not lift the lifting materials exceeding the rated capacity of the lifter.
 Check for oil or foreign material on the lift.
 Only raise lift after verifying that loading material is properly positioned.
 Stop raising lift after it has reached maximum height.
 When the lift raised or lowered, wait 1 or 2 seconds before the next operation is carried
out.
 After the lift is completely lowered, the materials can be loaded or removed from the lift.

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Café Service lifter

CHAPTER 5

COST ANALYSIS

Item Quantity Dimensions Total Cost(Birr)

Arm 4 L=1300 cm 800
Cylinder 1 Bore=30 cm 2400
Top Plate 1 Area , A=140 cm 900
×62 cm

Bottom Arm 3 3×140×9=378 400

Plunger Support 2 19.625 150
Wheel 4 Diameter , D=10 cm 200
Machining and 1200

labor cost
Total Cost 6050

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Café Service lifter

CHAPTER 6

Summary of Findings, Conclusion and Recommendation

6.1. Summary of Findings

The goal of this TCBTP project is to solve our community problem by approaching different
methods. Our project focuses on café service lifter to solve problems regarding to transportation
of processed food and loading and unloading heavy materials. This problem is caused by
different factor such as the way of transporting, surface slippery. But by using this machine we
can safe time, human power and safety of the workers.

This café service lifter works by the principles of Pascal law by using hydraulic cylinder to lift
the plat form up to a height of 1.2 meters and with the carrying capacity of 200 kilograms. The
driving mechanism of the lift must be a hydraulic cylinder.

This is done by collecting data by using survey and interview and this collected data for design.
The design of this café service lifter starts from material selection, force analysis and different
parts on the machine by selecting compatible hydraulic cylinder

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Café Service lifter

Conclusion
Café service lifter is the most important equipment’s in our campus. So it needs special
knowledge to design and manufacturing in our opinion. For these reason, by referring different
books, literatures and different types of resources to improve our knowledge on this project. In
this project the design the following parts designs are include design of lifter Arms, Hydraulic
cylinder, Top plat form, Base plat form, Wheels then we check their strength and they are safe to
lift up to 100 kg. From part designs and calculating safety factor of parts the prepared design
project is safe from the lowest position to highest position and vice versa.

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Café Service lifter

Recommendation
In this design project all parts can be manufactured in any manufacturer workshops that are
found any were. So the manufacturers and users should be following the instruction given below.

1. Do not manufacture the given part without the design analysis

2. After manufacturing the lifting system, we want to recommend the do not use more
100kg
3. We want to recommend the equipment used to transportation must be heat and wear
resistant.
4. Users should have use special type of oil for the cylinder for reducing the heat
generated by moving components.
5. User should have use grease to reduce contact friction between components like in
universal joints.
6. The workers should be wear proper cloth and shoes.
7. Do not use the lift whenever any of the safety devices are not operating properly.

So if the users and manufacturers follow the above given instruction, the manufactured weight
lifter can give safe function for long period of time.

References
[1] R.S khurmi and K.Gupta, “A text book of machine design” Fourteenth edition, 2005.

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Café Service lifter

[2] Beer, “mechanics of material strength” 5th edition

[3] Shigley, “mechanical engineering design”, 8th edition

[4] Internet (Mechanical Engineering website)

[5] Georgy Olenin “Design of hydraulic scissors lifting platform”

Appendix

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