i|Page

JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

FACULTY O F MECHANICAL ENGINEERING

CBTP PHASE III- ACTION PLAN DEVELOPMENT

TITLE:DESIGN OF PALLET TRUCK

ADVISORS: MEKDES T.& YOHANNIS A.

Submissiondate:12/06/201018

Group-2

i|Page

Group Members ID NO

1. Abule Moges…………………………………....RU 1715/08

2. Mesay Tesfaye………………………………….RU 2123/08

3. Boko Chana………………………………….….RU 1745/08

4. Diribi Dereje…………………………….…….…RU 1820/08

5. Kidanie Tsigie…………………………………….RU 0947/08

6. Elias Assefa ……………………….……………..RU 2361/08

7. Ermiyas Zemene……………….………………....RU 2097/08

8. Tsion Getachew ………….……………………….RU 2434/08

9. Israel Girma…………………..…………………….01335/05

10. DamachalaAsefa………………………………… RU 0480/07

11. Kasahun Tesfaye………………………………….RU 2147/08

ii | P a g e

ACKNOWLEDGEMENT

First of all, we would like to thank Jimma university because, the university always teaches
us to serve our community. In our university’s logo there is a title caled “WE ARE IN THE

COMMUNITY” which has a positive effect on us to search and find problems and to give the

solution in our society. Secondly our deepest and hearty thanks goes to our advisors Mr.

Yohannes and Miss. Mekdes for their directing, supervising and advising for the final

complete work of the project. Thirdly our thanks go to Mechanical Engineering Department

for offering such great opportunity to Mechanical Engineering students which help us in the

dealing with different design concepts.

Lastly we would like to thank our team members for their great contribution and cooperation

in collecting, analyzing different data required for the success of the project.

iii | P a g e

ABSTRACT

In this paper we used machine for small scale industries as well as in domestic purpose. A

pallet truck is a tool used to lift and move pallets. Pallet truck is manually adjusted to allow

lifting and moving of heavier and stacked pallets. This is having a very low initial and

maintenance cost. The main important part of our paper is there are rollers or wheels which

can be move from one place to another and also it is light in weight this paper is very useful

as is reduces human effort also thus overall the paper is having a great advantage thus can be

used in domestic purpose. Our paper can also lift the load up to 100kg.

1|Page

Table of Content

CHAPTER ONE ......................................................................................................................................... 2

INTRODUCTION..........................................................................................................................................2

1.1. problem statement................................................................................................................... 2

1LITERATURE REVIEW ................................................................................................................. 4

CHAPTER
THREE.................................................................................................................................................... 5
3. OBJECTIVE................................................................................................................................... 5

3.1. GENERAL OBJECTIVE ......................................................................................................... 5

CHAPTER
FOUR ..............................................................................................................................................6

4.METHODOLOGY.................................................................................................................................6

4.1. DATA COLLECTING METHOD .............................................................................................................. 6

5.DESIGN ANALYISIS..................................................................................................................... 8

5.1. Design of welding joint........................................................................................................................ 8

Cost estimation of manually operated pallet truck............................................................................ 15

CONCLUSSION..............................................................................................................................................1
5

REFERENCE............................................................................................................................................ 18

ASSEMBLE AND 3D VIEWS ..................................................................................................................... 19

2|Page

CHAPTER ONE

INTRODUCTION

A manually operated pallet truck is a machine used to lift and move pallets. As rack and

pinion begin rotating, metal plate which is used to hold material moves vertically upward and

downward to the required position and height. manually operated pallet truck is adjusted

manually to allow lifting and moving of heavier and stacked pallets. The pallet is generally

moved by pushing or pulling handle to move forward or in reverse and steered by swinging

the handle in the intended direction. A pallet truck is a type of machine, generally equipped

with a handle, rack and pinion that can be used both to lift and lower materials and to move

them horizontally. This machine is mainly used for lifting heavy things and transporting them

to other places. It uses one or more simple machines to create mechanical advantage and thus

move loads beyond the normal capability of a man. Pallet trucks are commonly employed in
the transport industry for the loading and unloading of industrial goods, in the construction

industry for the movement of materials and in the manufacturing industry for the assembling

of heavy equipment

1. 1problem statement

The problems required to be addressed in this mini project are those concerning feasibility

availability, cost, operational ability and maintainability. Generally, problems stated are:

 We have seen carrying of goods manually is tedious.

 Peoples use animals to transport goods which harms animals and this also causes

traffic problems.

 We have seen problems of transporting of goods in kitchen.

1.2 SIGNIFICANT OF THE STUDY

 Applicable in everywhere.

 To save time.

 More works with small human power.

 Cost of the machine to manufacture is less.

1.3 WORKING PRINCIPLE OF PALLET TRUCK

This excellent manually operated pallet truck is operated on the principle of engaging of two

gears. There are two gears in gearing operation, one is pinion and the other is gear.

3|Page

The first is smaller gear while the other is larger gear to increase torque and decrease speed or

vice versa. In our case there are two gears, these are pinion and rack. The pinion has

rotational motion and the rack has translational motion. When we rotate the pinion at the back

of the pallet manually the rack makes up and down motion to raise and lower any subjected

good. Since main purpose is to lower goods, it is easy because the weight of the goods helps

us to rotate the pinion easily. That is why we said “EXCELLENT MANUALLY

OPERATED PALLET TRUCK.”

1.4 Main components of pallettruck

 Gears (rack and pinion)

 Shaft

 Wheel

 Metal plate

 Handle

 Bearing

4|Page

CHAPTER TWO

1 LITERATURE REVIEW

Two-faced pallets are used in connection with power-forked-tiering trucks. These powerforked-tiering
trucks, we call them fork lifts today, not only transport the load but tier

one load on top of the other. The bottom face of the pallet serves as a base for resting

upon the load beneath.”

That’s George Raymond’s grandson, Steve, who’s now president of Raymond Handling

Concepts Corporation in Fremont, California.

So Raymond Senior and his company, which started out as Lyon Iron Works, later

became Raymond Corporation, and was bought by Toyota Industries in 2000, patented

the wooden pallet 75 years ago Friday and, at the same time, patented the hand truck

used to move those pallets around. That was the foundation of a company that now

employs about 1500 people in the small town of Greene and sells its hand trucks all over

the world.

Raymond the grandson says the simplicity of the two inventions will make them hard to

replace, even 75 years later.

When we come to our case, we intended to design the pallet tuck according to our
geographical area and the communities economical level. we use rack and pinion instead

of hydraulic jack for lifting and lowering purpose and also we use radial ball bearing for

rolling case, but most of the time pallet trucks are rolled by plastic roller which is not

suitable for our focused areas.

Pallet truck is a type of machine, generally equipped with a gear and pinion that can be

used both to lift and lower materials and to move them horizontally. It transports them to

other places. It uses one or more simple machines to create mechanical advantage and

thus move loads beyond the normal capability of a man. Pallet truck are commonly

employed in the transport industry for the loading and unloading of freight, in the

construction industry for the movement of material and in the manufacturing industry for

assembling heavy equipment.

5|Page

CHAPTER THREE

3. OBJECTIVE

3.1. GENERAL OBJECTIVE

The general objective is to design manually operated pallet truck.

3.2. Specific objectives

 Primarily, to introduce manually operated pallet truck.

 To modify the labor work into machine based.

 Accessing this truck to all society with cheap cost, easily use and so on.

 To determine working principle of manually operated truck.

 To determine maintenance stratagem of each part of the machine.

6|Page

CHAPTER FOUR

4.METHODOLOGY
Methodology is one of the most important in any project works. Particularly we choice this

project inCBTP in order to solve the community problem and the basic information to design

this machine or multi-purpose manually operated pallet truck is information that we gathered

in CBTP phase I and phase II around Jimma city.

During CBTP phase I and phase II, we observed that the community was facing with

different problems in simple machine like transporting goods and materials. Now, we stand

to solve the main problem of the community to increase the availability of this simple

machine especially, in Jimma town where there is lack of technically operated transporting of

goods and we design simple manual operated machine with high efficiency for the peoples

that need to operate two things at a time. Generally, to design this machine we referred to

design books, website and also previous hydraulic pallet truck machine proposal and study

short come of this proposal and make up grade and easy constructions or design multipurpose machine.

4.1. DATA COLLECTING METHOD

4.1.1. OBSERVATION

We have observed the hydraulic lifting trucks that was created before. Now we modified in to

our case to manually operated pallet truck for our community.

4.1.2. DOCUMENTS

We have referred to CBTP phase III documents done by other students related to our project

4.2. DESIGN CONSIDERATION

 Cost

 Availability

 Corrosion and wear resistance

 Strength and hardness

 manufacturability

 durability and effectiveness

 ease of construction and use

 safe production

 long service life

7|Page

Decision factor

 Parts are easily available

 Simple to build and operate

 Easilymaintain

 Adaptable to variety of situations

 Easily assembled anddisassembled

8|Page

CHAPTER FIVE

5. DESIGN ANALYISIS

At the end of this chapter we will overcome with: -

 Design of welding joint

 Design of shaft

 Design of gear

 Design of bearing

5.1. Design of welding joint

A welded joint is a permanent joint which is obtained

by the fusion of the edges of the two parts to be joined

together, with or without the application of pressure and filler material.

Advantage of welding

1.The welded structures are usually lighter than riveted structures. This is due to the reason,

that in welding, gussets or other connecting components are not used.

2. The welded joints provide maximum efficiency (may be 100%) which is not possible in

case of riveted joint

3. Alterations and additions can be easily made in the existing structures.

4. As the welded structure is smooth in appearance, therefore it looks pleasing.

5. In welded connections, the tension members are not weakened as in the case of riveted

joints.

6. A welded joint has a great strength. Often a welded joint has the strength of the parent

metal itself.

9|Page

Welding Process

Welding process may be broadly classified in two groups

1 Fusion welding is a welding process that use of heat

2 Forge welding is a welding process that use a combination of heat and pressure

Load p=980N

Eccentricity=800mm

Cross section=0.8*0.03=0.024m2

Size of weld H=3mm

required

1 maximum normal stress

2 maximum shear stress

The joint is subjected to direct shear and bending stress

Throat area of rectangular section

A=t(2b+2d) when t=0.707h=0.707*3=2.12mm

=2.12(2*30+2*800) =3520.86mm2

Direct shear stress

τ=P/A=980/3520.86=0.278N/mm2

bending moment

Mb=P*e=980*1=980000Nmm

Section modulus by considering the weld thickness

Zw=t(bd+d2

/3) =2.12*(30*800+8002

/3) =503384mm3

Bending stress

10 | P a g e

σb=Mb/zw=9.8*105Nmm/503384=1.946N/mm2

maximum nominal stress

σmax=σb/2+0.5(σb

2+4τ2

0.5

=1.946/2+0.5(1.9462+4*0.2782

0.5

=1.984N/mm2

Maximum shear stress

τmax=0.5(σb

2+4τ2

0.5

=0.5(1.9462+4*0.2782
)

0.5

=1.011MPa

5.2. Design shaft

A shaft is rotating machine element which used to transmit power from one place to another.in

order to transfer the power from one shaft to another the various members such as pulley gears

etc., are mounted.

Material used for shafts

The material used for the shafts should have the following properties

1 It should have high strength

2 It should have good machinability

3 It should have low notch sensitivity factor

4 It should have good heat treatment properties

5 It should have high wear resistant properties

The material use for ordinary shaft is carbon steel of grades 40C8, 45C8, 50C4 and 50C 12.

When a shaft of high strength is required, then an alloy steel such as nickel, nickel-chromium

10 | P a g e

or chrome-vanadium steel used.

The material we select for shaft is carbon steel

11 | P a g e

Let take safety factor n=6

Yield stress σy=320Mpa

Reaction force at A and B

ƩFy,=0

RA + RB = 980N
RA = 980 - RB

Bending moment at B

ƩMb=0

RA * 300 = 980*150

RA = 490N

R=490N

Maximum bending moment occur at the center.

Mmax = 980*150=147000Nmm

Allowable stress =σall=σy/n=320/6=80Mpa

now Mmax=π/32*σb*d3

147 = 3.14/32*80*d3

d=30mm

5.3. . Design of gear

Gears are power transmission devices that are commonly used to transmit power from one

shaft to another. It is accomplished by the successive engagement of teeth. Two gears

transmit motion by the direct contact of teethes.

Advantages

1. It transmits exact velocity ratio.

2. It may be used to transmit large power.

3. It may be used for small centre distances of shafts.

12 | P a g e

4. It has high efficiency.

5. It has reliable service.

6. It has compact layout.

Gear materials
The material used for the manufacture of gears depends upon the strength and service

conditions like wear, noise etc. the gears may be manufactured from metallic or nonmetallic

materials.

The material used for designing gear is cast iron, cast steel, carbon steel etc. from these

material we use cast iron.

Cast iron is widely used for manufacture of gears due to 9

 It has good wearing properties

 It has excellent machinability

 Easy to producing complicated shape by casting method

Gear ratio = 10:1

Distance between center = 200mm

Speed = 20rpm

Pressure angle 22.50

Tp= 2Aw/G[(1+1/G(1/G+2) sin2Ф)0.5

-1] , Tp= number teeth pinion

=2/0.15 Tr= number of teeth rack

=13.3 say 14

Tr=G*Tp=140

We know that

L = Dr/2+Dp/2=5.5Dp

200= 5.5Dp

Dp=36.36

we also know that Dp =`mTp

m=Dp/TP=2.597 say 3

Number of teeth on each Tp=Dp/m=36.36/3=12

Tr=G*Tp=120

13 | P a g e

5.4. Design of bearing

Bearing is mechanical device that used for support another machine element and reduce

friction.

 Material used for bearing metal are

 Copper-base alloys

 Lead-base alloys

 Tin –base alloys

 Cadmium-base alloys

From these material we choice copper base alloys because this alloys are harder and stronger

than the white metal (lead base and tin

base alloys) and are used for bearing subjected heavy pressure.

 Bearing material should have the following properties

 It should have low coefficient of friction

 It should be economical in cost

 It should have non corrosive properties

 It should have good wearing qualities

Rolling contact bearings

A rolling the contact bearing surface is rolling instead of sliding as contact

bearings

There are two types rolling contact bearing depending upon the to be carried: -

1.radial ball bearing

2.trust bearing

From we need to use radial ball bearing due to the advantage it have
Advantage of radial ball bearing contact.

 Easy to mount and erect

 Reliability of service

 Accuracy of shaft alignment

 Cleanliness

14 | P a g e

15 | P a g e

Chapter six

Cost estimation of manually operated pallet truck

No Part 0f the pallet quantity Cost per parameter

In birr

Total price

1 Metal sheet 3m2 300 900

2 Bearing 6 100 600

3 Rack 1 250 500

4 Pinion 1 250 100

5 Shaft 30cm 100 24

6 Bolt and nut 8 3 200

7 Hollow rectangular

Metal

6m 200 1200

Total price 2324

16 | P a g e

CONCLUSSION

The study focused on the design of the manually operated pallet machine, the
design of pallet truck was done by using gearing mechanism by the help of bearing

and the fabrication of the machine can be done by using indigenous materials and

devices like metal sheet, shaft, ball bearing rack and pinion. The designed

manually operated carrying and transporting machine for providing a human

operated carrying machine to the people of such places where modern transporting

mechanism is not available. It is very useful for such people who cannot afford the

cost of hydraulic lifting lowering machine. The main objective behind

development of manually operated pallet truck is changing carrying mechanism of

goods from human and animals to machines. On the basis of producing cheap,

easy to operate system which can be easily fabricated by readily available material

and thus we proposed a simplistic design that can deliver efficient carrying

mechanism especially for urban areas. This equipment can be easily operated by

any operator.

Generally, from this study it is evidently clear that the designed manually operated

machine can be better used for the good quality of transportation of goods. This

can be popularized in marketing areas where human labor frequently used for

carrying purpose.

17 | P a g e

RECOMMENDATION

 It is recommended that pallet truck machine has to be advertised to

increase the awareness of the community and motivate peoples to use this

improved machine.

 Government has to play a role to afford the machine for community

who do not have the capable of buying the machine as per individual to

decrease the use of animals for transportation purpose.

 It is highly recommended that the user has to follow proper

operation and maintenance procedures during idle or operation of the

machine.

 Lastly, it is recommended that designer and engineers has to

optimize and improve the technology to more appropriate and advanced

technology.

18 | P a g e

REFERENCE

1. R.S.Khurmi&J.K.Gupta text book of Machine Design 14th edition

2. Shigley’s Mechanical Engineering Design 9

theditons

3. Mechanical Design Handbook

4. http//www.google.com

5. Fundamental of Material science and Engineering, William D. Callister, Jr. Department

Metallurgical Engineering, The University of Utah fifthedition

6. www.siencedirect.com

19 | P a g e

ASSEMBLE AND 3D VIEWS

20 | P a g e

21 | P a g e

22 | P a g e

23 | P a g e

24 | P a g e