CHAPTER 1

1. INTRODUCTION

Car jack is a device used to lift up the cars while changing the tires during an
emergency. Car jacks are available at the market has some disadvantages such as
requiring more energy to operate, are not suitable for women and cannot be used
on the uneven surface. The purpose of this project is to modify the design of the
existing car jack in terms of its functionality and also human factors
considerations. The day to day usage of cars is keeping on increasing as the world
moves on to a hectic stage. One big problem everyone faces is a flat tire on a
voyage to any destination. If the tire gets punctured the driver has to undergo a lot
of pressure and rigorous mechanical work to lift the car using a screw jack. Then
the changing of a tire is a job that can be done systematically and relatively easy.

Fig 1.1 Scissor

jack

1
1.1.1 GENERAL OBJECTIVE

Our research survey in this regard revealed that in several automobile

garages, revealed the facts that mostly some difficult methods were adopted in
lifting the vehicles for reconditioning, repair and maintenance. This fabricated
model has mainly concentrated on this difficulty, and hence a suitable device has
been designed, such that the vehicle and heavy objects can be lifted from floor land
without the application of impact force. The fabrication part of it has been
considered with almost case for its simplicity and economy, such that this can be
accommodated as one of its essential tools on automobile garages. The object
lifting jack has been developed to cater to the needs of small and medium
automobile garages, which are normally man powered with minimum skilled labor.
In most of the garages the vehicles are lifted by using screw jack.

This needs high man power and skilled labor. In order to avoid all such
disadvantages, the automated motorized object lifting jack has been designed in
such a way that it can be used to lift the vehicle very smoothly without any impact
force. The operation is made simple so that even unskilled labor can use it with
ease. The dc motor is coupled with the lead screw by gear arrangement; the lead
screw rotation depends upon the rotation of dc motor. This is an era of automation
where it is broadly defined as replacement of manual effort by mechanical power
in all degrees of automation. The operation remains to be an essential part of the
system although with changing demands on physical input, the degree of
mechanization is increased.

2
1.1.2 SPECIFIC OBJECTIVE

This research paper analyzes the modification of the existing motor screw
jack by incorporating an electric motor in the screw in order to make load lifting
easier. In this modified design, the power screw is rotated by connecting motor
through universal coupling, plugged to the automobile 12V battery source to
generate power for the prime mover (motor), which transmits its rotating speed to
the power screw to be rotated with required speed reduction and increased torque
to drive the power screw. The significance and purpose of this work is to modify
the existing car jack in order to make the operation easier, safer and more reliable
in order to reduce health risks especially back ache problems associated with doing
work in a bent or squatting position for a long period of time. The modified car
jack is easy to use by women or whoever had problem with the vehicle tires along
the road. The designed motorized jack will also save time and requires less human
energy to operate.

1.2 PROBLEM DIFINITION

Available car jacks, however, are typically manually operated and therefore
require substantial laborious physical effort on the part of the user. Such jacks
present difficulties for the elderly and handicapped. It further requires the operator
to remain in prolonged bent or squatting position to operate the jack. Doing work
in a bent or squatting position for a period of time is not ergonomic to human body.
It will give back ache problem in due of time.

1. Require manual work

2. Delay in time
3. No self locking

3
1.3 BACKGROUND OF STUDY
Before working on project it was necessary to understand the details about
any inventions or innovations or development in following products and
technology or mechanism that can be used. The following patents are studied:
1. Research by Edward M.LONNON.
2. Research by FARHAD RAZZAGHI.
3. Research by Emil MICKAEL.
4. Research by Leo F. Carder.
1.3.1.Research by Leo F. Carder
Patent number: US7988131B1
Date of Patent: Aug 2, 2012
Name of patent: Electric scissor jack apparatus
The electric scissor jack apparatus uses electrical power to elevate an
automobile with a cigar lighter plug of an auto to power the high torque electric
motor of the apparatus shown in Fig 1. The motor is in communication with the
scissor jack via the gear reduction member so that maximum torque is applied to
the scissor jack shown in Fig 2. Of significant importance is that the fail-safe
coupling between the gear reduction drive and the scissor jack ensures against
excessive or premature wear, failure, and danger to an operator. By avoiding any
jack encasement, the apparatus provides for inexpensive multiple jack size
utilization in that various sizes of scissor jacks are optionally fitted to the coupling
housing of the gear reduction member.
Under working condition the jack will lift a vehicle chassis in contact with
the top plate when the power screw is rotated through its connecting gear with the
pinion when electrical power applied to the wiper motor when plugged to the 12V
battery in car. Motor transmits its rotating speed to the pinion gear meshing with

4
the bigger gear connected to the power screw to be rotated with required speed
reduction and increased torque to drive the power screw.
The power screw rotates within the threaded bore of side member in the
clockwise direction that will cause the links to be drawn along the threaded portion
towards each other during load-raising process and vice versa. Initially the jack
will first be placed below the chassis to be lifted such that at least a small clearance
space will exist between the top plate and the vehicle chassis to be raised. Then
after power screw will be turned so that the top plate makes contact with the car
chassis and the clearance space is eliminated. As contact is made, load of car will
be increasingly shifted to the top plate and cause forces to be developed in and
transmitted through links and side member. The force transmitted through the side
member will be transferred on threads of screw. A switching circuit connected to
the motor is used to regulate the lifting and lowering process. Our survey in the
regard in several automobile garages, revealed the facts that mostly some difficult
methods were adopted in lifting the vehicles for reconditioning.
5
Now the research paper has mainly concentrated on this difficulty, and hence a
suitable device has been designed, such that the vehicle can be lifted from the floor
land without application of any impact force. The fabrication part of it has been
considered with almost case for its simplicity and economy, such that this can be
accommodated as one of the essential tools on automobile garages .The motorized
screw jack has been developed to cater to the needs of small and medium
automobile garages, which are normally man powered with minimum skilled labor.
In most of the garages the vehicles are lifted by using screw jack. This needs high
man power and skilled labor. In order to avoid all such disadvantages, the
motorized jack has been designed in such a way that it can be used to lift the
vehicle very smoothly without any impact force. The operation is made simple so
5
that even unskilled labor can use it with ease. The D.C. motor is coupled with the
screw jack by gear arrangement. The screw jack shaft’s rotation depends upon the
rotation of D.C motor. This is a simple type of automation project. This is an era of
automation where it is broadly defined as replacement of manual effort by
mechanical power in all degrees of automation. The operation remains to be an
essential part of the system although with changing demands on physical input, the
degree of mechanization is increased.

6
1.4 SCOPE

6
 In operation, the jack will lift a load in contact with the load platform when
the power screw is rotated through its connecting gear with the pinion gear when
electrical power flows through the cigarette lighter receptacle connected to the
motor, plugged to the automobile 12V battery source to generate power for the
prime mover (motor),which transmits its rotating speed to the pinion gear meshing
with the bigger gear connected to the power screw to be rotated with required
speed reduction and increased torque to drive the power screw. The power screw
rotates within the threaded bore of its connecting members (11 and 16) in the
clockwise direction that will cause the connecting members to be drawn along the
threaded portion towards each other during a typical load-raising process. During
the typical load-raising process, the jack will first be positioned beneath the load to
be lifted such that at least a small clearance space will exist between the load
platform and the object to be raised. Next, power screw will be turned so that the
load platform makes contact with the object and the clearance space is eliminated.
As contact is made, load from the object will be increasingly shifted to the load
platform and cause forces to be developed in and transmitted through lifting
members and connecting members. The force transmitted through the connecting
members will be transferred at the threaded bore to the lead Acme threads, there
within. A switch button connected to the motor is used to regulate the lifting and
lowering process.

7
 7
CHAPTER 2

2. LITERATURE REVIEW

Screw type mechanical jacks were very common for jeeps and trucks of World
War II vintage. For example, the World War II jeeps (WILLYS MB and Ford
GPW) were issued the "Jack, Automobile, Screw type, Capacity 1 1/2 ton",
Ordnance part number 41-J-66. This jacks, and similar jacks for trucks, were
activated by using the lug wrench as a handle for the jack's ratchet action to of the
jack. The 41-J-66 jack was carried in the jeep's tool compartment. Screw type
jack's continued in use for small capacity requirements due to low cost of
production raise or lower it.
A control tab is marked up/down and its position determines the direction of
movement and almost no maintenance. The virtues of using a screw as a machine,
essentially an inclined plane wound round a cylinder, was first demonstrated by
Archimedes in 200BC with his device used for pumping water. There is evidence
of the use of screws in the Ancient Roman world but it was the great Leonardo da
Vinci, in the late 1400s, who first demonstrated the use of a screw jack for lifting
loads. Leonardo’s design used a threaded worm gear, supported on bearings, that

8
rotated by the turning of a worm shaft to drive a lifting screw to move the load -
instantly recognizable as the principle we use today.
We can’t be sure of the intended application of his invention, but it seems to
have been relegated to the history books, along with the helicopter and tank, for
almost four centuries. It is not until the late 1800s that we have evidence of the
product being developed further. With the industrial revolution of the late 18th and
19th centuries came the first use of screws in machine tools, via English inventors
such as John Wilkinson and Henry MAUDESLY The most notable inventor in
mechanical engineering from the early 1800s was undoubtedly the mechanical
genius Joseph Whitworth, who recognized the need for precision had become as
important in industry as the provision of power. While he would eventually have
over 50 British patents with titles ranging from knitting machines to rifles, it was
Whitworth’s work on screw cutting machines, accurate measuring instruments and
standards covering the angle and pitch of screw threads that would most influence
our industry today. Whitworth’s tools had become internationally famous for their
precision and quality and dominated the market from the 1850s.
8
Inspired young engineers began to put Whitworth’s machine tools to new uses.
During the early 1880s in Coati cook, a small town near Quebec, a 24-year-old
inventor named Frank Henry Sleeper designed a lifting jack. Like da Vinci’s jack,
it was a technological innovation because it was based on the principle of the ball
bearing for supporting a load and transferred rotary motion, through gearing and a
screw, into linear motion for moving the load. The device was efficient, reliable
and easy to operate. It was used in the construction of bridges, but mostly by the
railroad industry, where it was able to lift locomotives and railway cars.
Local Coati cook industrialist, Arthur OSMORE NORTON, spotted the potential
for Sleeper’s design and in 1886 hired the young man and purchased the patent.
9
The Norton‟ jack was born. Over the coming years the famous “Norton” jacks
were manufactured at plants in Boston, Coati cook and Moline, Illinois.
Meanwhile, in Alleghany County near Pittsburgh in 1883, an enterprising
Mississippi river boat captain named Josiah Barrett had an idea for a ratchet jack
that would pull barges together to form a „tow‟. The idea was based on the
familiar lever and fulcrum principle and he needed someone to manufacture it.
That person was Samuel Duff, proprietor of a local machine shop, together, they
created the Duff Manufacturing Company, which by 1890 had developed new
applications for the original “Barrett Jack” and extended the product line to seven
models in varying capacities. Over the next 30 years the Duff Manufacturing
Company became the largest manufacturer of lifting jacks in the world, developing
many new types of jack for various applications including its own version of the
ball bearing screw jack. It was only natural that in 1928, The Duff Manufacturing
Company Inc. merged with A.O. Norton to create the Duff-Norton Manufacturing
Company.

9
Both companies had offered manually operated screw jacks but the first new
product manufactured under the joint venture was the air motor-operated power

10
jack that appeared in 1929. With the aid of the relatively new portable compressor
technology, users now could move and position loads without manual effort. The
jack, used predominantly in the railway industry, incorporated an air motor
manufactured by The Chicago Pneumatic Tool Company. There was clearly
potential for using this technology for other applications and only 10 years later, in
1940, the first worm gear screw jack, that is instantly recognizable today, was
offered by Duff-Norton, for adjusting the heights of truck loading platforms and
mill tables. With the ability to be used individually or linked mechanically and
driven by either air or electric motors or even manually, the first model had a
lifting capacity of 10 tons with raises of 2” or 4”. Since then the product has
evolved to push, pull, lift, lower and position loads of anything from a few kilos to
hundreds of tones. One of the biggest single screw jacks made to date is a special
Power Jacks E-Series unit that is rated for 350 tones even in earthquake conditions
for the nuclear industry.

11
 CHAPTER 3
MATERIAL AND METHODOLOGY
3.1EXISTED DESIGN
The main components of required for development of this jack are:
a) Original toggle jack with alteration and replacement of Power Screw and Side
members.
b) Power screw.
c) Gear pair.
d) DC wiper motor.
e) Bracket and holder to carry motor.
Table 3.1 includes details of all components required for building the actual model
or prototype of electrically operated toggle jack.

12
 SI.NO Description Quantity
1 Top plate 1
2 Upper link 1
3 Link 4
4 Power screw 1

5 Side member 2
6 Bottom link 1
7 Stabilizer base 1
8 Solid block 2
9 Pin 8
10 M10 bolt 5
11 Pinion and hub 1

12 Wiper motor 1

13 Bracket assembly 1
14 M15 bolt 1
15 Gear and hub 1

16 Bracket assembly holder 1

17 Screw collar 1

Ta
ble 3.1 List
of
component
.

13

12
 Fig 3.1 screw jack

13

14
 Fig 3.2Electrically operated screw jack

Electrical actuation is chosen here because the power obtained through this is
comparatively high. The direction of the rotation of the motor is obtained by the
pulse modulation from the control relay. Thus it is considered to be the most
efficient and easy method to actuate. A scissor lift (jack) or mechanism is a device
used to extend or position a plate formed by mechanical means. The term “scissor”
is used since the folding supports are in crisscross “X” pattern. The extension or
displacement motion is achieved by applying force to one of the supports and thus
the elongation of the crossed pattern occurs. The force applied to extend the scissor
mechanism may be hydraulic, pneumatic or mechanical means.
3.2. PROPOSED DESIGN

Scissor jacks are usually made of materials that are very strong and are suitable
for withstanding heavy loads. The two main materials used for making good
quality jacks are Steel and Aluminum. When selecting the material suitable for the

15
construction of the Scissor jack one has to consider the properties that will enable
it to function with no expected failure and at the same time the weight and ease of
machining the product.

14

Therefore the main areas that can be classified in this case are the strength of the
material, weight, ease and cost of manufacturing. Aluminum is around one-third
the density of steel at 2.72 mg/m cubed compared to steel's 7.85 mg/m cubed. The
light weight and low melting point of aluminum makes it easier and more efficient
to machine than steel. Aluminum’s fatigue performance is half that of steel, which
is an advantage steel has over aluminum in car jack life durability. Therefore Steel
is the most viable material selected for the manufacture of the car scissor jack [7]
Component number 4, 5and 17 will all use the High Strength Low-Alloy Steel
(40Ni2Cr1Mo28 / AISI 4340), material is selected on bases of application.

Table 4.1

Material property

Tensile Strength, 931 MPA 135000psi

16
 Ultimate
Tensile Strength,
834 MPA 121000psi
Yield
Elongation at
Break

20.2 % 20.2 %
Modulus of 205 29700 KSI Typical for
Elasticity GPA steel
Bulk Modulus 140 20300 Typical for steel
GPA KSI
Poisson's 0.29 0.29 Calculated
Ratio
Shear Modulus 80 11600 KSI
GPA

15

We use solar system to operate scissor jack as power source. Solar Power
Systems are complete, fully integrated solar power supplies designed for site
loads requiring 12, 24 or 48 volts DC. Each solar power system provides safe
and reliable power generation without the need and expense of installing utility

17
power. The sealed, maintenance free batteries are designed for deep cycle
operation and extended life in solar applications. The aluminum array support
structures and battery enclosures are strong yet lightweight and corrosion
resistant for harsh marine or severe weather locations. Solar power system is the
one which can be conveniently installed and transported. It also has the perfect
characteristics of self-control, self-protection, needing no attention, compact
structure, elegant outline and convenience for using ETC

Fig 3.2.1 solar system

Solar power systems provide a continuous, reliable power solution that's

easily deployed, cost-effective and requires little maintenance

16

18
How the solar system work

FIG 3.2.2 ENERGY SOURCE

This system connect to scissor jack then the jack will operate. Therefore we can
use alternative energy source in place other type of energy

19
 17

CHAPTER 4

4. RESULT AND DISCUSSION

4.1 EXISTED DESIGN

The design was focused on all the processes of conception, invention,

visualization, calculation, refinement and specification of details that determine
the form of the product. Hence, the said Motorized Screw Jack for Vehicles,
specifically the Scissors type has gone under force analysis so that its
performance criterion will not fail in any sense.
The main physical parameters of the design are determined through the
appropriate calculations and practical considerations with reasonable
assumptions. It was discovered that at the maximum raising height of 28o of the
horizontal Tensile force in the opposite direction are the same. It is also the
same for the minimum raising height of 55.7o. Mild steel is used as the
materials for both the keys and gears due to its high strength, toughness, tooth
hardness and its economic effects.
The compressive spring is used to reduce noise and vibration effect from the
motor. The speed at which the designed power screw will run is 92 rpm, which
means the gear will complete one and a half revolution in one second or
complete one revolution in 0.66 second which is considered safe and reasonable.
20
 4.2 PROPOSED DESIGN

The design study about using solar system energy to lifting load the solar
system is used for energy source. Solar PV modules collect the sun's energy and
convert it into direct current (DC) electricity. The amount of electricity
produced is proportional to the amount and intensity of sunlight. The number of
panels is determined by the home or business's power needs. Typically 2,000 to
4,000 watts (2-4 kilowatts, kW). A DC to AC grid-tied inverter converts the
electricity from DC to alternating current (AC) for use in a home or business.

18

A rule of thumb is 100 square feet of PV module area per kilowatt (kW) of
electricity produced by the PVs. A typical solar electric system for a home will
require approximately 200-400 square feet. The overall result tracks the net
difference as electricity is generated and sent off to the grid and as electricity is
consumed.
4.3 INFERANCE
Using solar system energy to operate scissor jack is has advantage because its
renewable and easy way to conserve other energy resource so by using this we
can lower or upper the position of the load and this solar system is available in
everywhere the sun exist and it is alternative energy source.

21
 19
CHAPTER 5

5. CONCLUSION

22
 5.1 SUMMARY

Scissor Jacks are the ideal product to push, pull, lift, lower and position
loads of anything from a couple of kg to hundreds of tones. The need has long
existed for an improved portable jack for automotive vehicles. It is highly
desirable that a jack become available that can be operated alternatively from
inside the vehicle or from a location of safety off the road on which the vehicle
is located. Such a jack should desirably be light enough and be compact enough
so that it can be stored in an automobile trunk, can be lifted up and carried by
most adults to its position of use, and yet be capable of lifting a wheel of a 400-
500 kg vehicle off the ground. Further, it should be stable and easily
controllable by a switch so that jacking can be done from a position of safety. It
should be easily movable either to a position underneath the axle of the vehicle
or some other reinforced support surface designed to be engaged by a jack.
Thus, the product has been developed considering all the above requirements.
This particular design of the motorized screw jack will prove to be beneficial in
lifting and lowering of loads.
The existing design was modified by introduction of an electric motor in the
power screw, connecting gear with the pinion, the cigarette lighter receptacle
connected to the motor and plugged to the automobile 12V battery source to
generate power for the prime mover (motor), in order to make load lifting easier.
In this modified design, the power screw is rotated through its gear when
electrical power flows through it. The main advantages of the modified design
over the existing design are that the modified designed motorized jack will save
time, be faster and easier to operate and requires less human energy and
additional work to operate. There by effectively curb the problems associated

23
with Ergonomics - which is a fundamental concept of design process. The
limitation of this design is that it is only applicable to vehicles not weighing
above 1000 kg.

20
5.2 LIMITATION

The solar panel is to move place to place and intensity of light will varies so
the accumulation of charge will be affected. In this case we will get to know the
effectiveness & performance of scissor jack on field, when customer
implements it for replacing the tire. The failure analysis is conducted under
following cases.

Case I: Justification for failure analysis :

This analysis is required to be conducted due to its critical application under
emergency, also it is essential due to following reasons:
A. Impact of the problem
 Impact on customer:
1. Affecting safety of customer.
2. Dissatisfaction of customer
Impact on Departmental goal:
1. Quality indicators effected.
2. Increase in warranty cost.

Case II: Diagnosing the problem:

24
 In this case, the actual area where the jack is failed is detected. Practical tests
are conducted for this analysis by physically replacing the jack and results are
calibrated for getting the solution by operating the jack for replacement of tire of
Bolero.

21

5.3FUTURE SCOPE

 The developed automatic car jack can only withstand above 1000kg of

Load.

 The developed automatic car jack must be operated on a flat surface.

• The developed automatic car jack is only a prototype and not readily
functioning as commercial product.

25
 • The design is based on current scissor jack in the market.

• The developed automatic car jack is only for normal person.

• The developed automatic car jack can only work by using the internal car
power (12V)

5.4 REFERANCE

[1]. PATEL NITINCHANDRA R.DALWADISANKETKUMAR, THAKOR

VIJAY, BAMANIYAMANISH. Design of toggle jack considering material
selection of screw – nut combination, International Journal of Innovative
Research in Science, Engineering and Technology, May 2013 (2), PP 1-9.
[2]. Noor M. M., KADIRGAMA K., Rahman M. M., analysis of auto car jack,
National Conference in Mechanical Engineering Research and Postgraduate
Student, Malaysia, 26-27 May 2010 (1), PP 198-203.
[3]. Noor M. M., KADIRGAMA K., Rahman M. M, SANI M. S. M, REJAB M. R.
M. Development of Auto Car Jack Using Internal Car Power, Malaysian Science
and Technology Congress, Malaysia, 16-17 Dec 2008 (1), PP 1-6.
[4]. AKINOWNMI A. S. and Mohammed A., Modification of the Existing Design
of a Car Jack, Scholar link Research Institute Journals, 2012 (4), PP 1-8.

22
[5]. KHURMI R.S., Gupta J.K., Machine Design Book, 4th ed., S. Chand &
company ltd, New Delhi, 3 July 2005, PP 549-583, 602-630.

26
 [6] Bhandari, V.B. (2010),” Design of machine elements”, Tata McGraw-Hill
Education.
[7] KHURMI, R.S. and Gupta, J.K. (2005), “A Textbook of Machine Design”,
Eurasia Publishing House (P.V.T) Ltd.14th Edition, 1230 pp. ISBN: 81 - 219
-2537 – 1.
[8] Bansal, R.K (2012), “Strength of Materials” Revised Edition, LAXMI
PUBLICATION (P) LTD.
[9] Rajput, R.K. (2010), “Strength of Materials” Revised Edition, S. Chand and
Company Limited. 1448 PP ISBN 81-219-2594-0.
[10] SHARIFF, Abdulla (2010),”Hand Book of properties of Engineering
Materials and Design Data for Machine Elements”, DHANPAT RAI & CO. (P)
LTD

27