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IN MECHANICAL ENGINEERING
CONTENT
TABLE OF CONTENTS
Chapter
Topic
No
ACKNOWLEDGEMENT
SYNOPSIS
1 INTRODUCTION
2 LITERATURESURVEY
3.1 Fork
3.2 DC motor
3.3 Battery
3.5 RF Remote
3.6 Vehicle
4 ASSEMBLY DIAGRAM
5 WORKING PRINCIPLE
6 MERITS
7 COST ESTIMATION
8 PROJECT COST
SYNOPSIS
SYNOPSIS
INTRODUCTION
CHAPTER - 1
INTRODUCTION
Forklifts are most often used in warehouses, but some are meant to be used
outdoors. The vast majority of rough terrain forklifts operate on gasoline, but some use
diesel or natural gas. Rough terrain forklifts have the highest lifting capacity of all forklifts
and heavy duty tires (like those found on trucks), making it possible to drive them on
uneven surfaces outdoors.
It is important for forklift operators to follow all safety precautions when using a
forklift. Drivers should be careful not to exceed the forklift's weight capacity. Forklift
operators also need to be able to handle forklift's rear wheel steering. Driving a forklift is
similar to driving a car in reverse, meaning that the driver must constantly steer to keep
it moving in a straight line.
The driver must be aware of the forklift's ever-changing center of gravity and
avoid making any quick sharp turns or going too fast. It is advisable that anyone who
operates a forklift be fully trained and licensed.
Forklifts have revolutionized warehouse work. They made it possible for one
person to move thousands of pounds at once. Well-maintained and safely operated
forklifts make lifting and transporting cargo infinitely easier. This is the general
description of a normal forklift truck. To enhances the technology further, this prototype
module is constructed with remote technology, there by the operator can walk along with
the forklift for better visibility &the container can be placed accurately (precision
position). This increases the safety of the operator.
LITERATURE SURVEY
CHAPTER -2
LITERATURE SURVEY
In addition to the possible shortcomings in product design that contribute to forklift roll-
overs, are a litany of behavioral induced systems breakdowns. The mismatching of
factory logistics and work processes can result in increased risks of pedestrian’s being
struck by forklifts. (Collins et al (c), 1999) The practice of using the forklift to gain
access to height is one that requires stringent supervision and is only permissible when
in a fully equipped working platform (MOL, 1999).
A hazard often originates with actions like riding with the material or hitching a
ride standing on the tines of the forklift. This practice doesn’t only show a disregard for
safe work practices of both only the operator and worker, but is indicative of a lack of
safety management at supervisory and managerial level. The causal factors of loads
which fall whilst being handled isn’t restricted to lack of driving training. In fact
verification of the required action with specific load masses is also often under-
represented on the load chart placard on the forklift, therefore deeming many
inadequate.
Assuming the load chart is still attached and legible, there is often a lack of
operator instruction regarding the impact on forklift stability with the requirement to
manoeuvre the load at height. The list of contributing factors to the instance of falling
loads extends above and beyond the lack of information provided in many load charts.
The practice of not properly securing loads and working under a raised load severely
magnifies the scope of the hazard. Additionally inappropriate/modified forklift
attachments and lifting loads without setting the tines to the appropriate width of the
load are also causal factors to the instance of falling objects. (Scott, 1996)
DESCRIPTION OF THE
COMPONENTS
CHAPTER 3
1. Fork
2. DC motor
3. Battery
4. Rope system
5. RF Remote
6. Vehicle
3.1 FORK
A fork is a tool consisting of a carriage with two narrow tines on one end. The forks also
known as blades. It has a heel where it curve upward and an upright shank where they
are attached to the carriage.
It is used to lift heavy weight to up or to hold in a place. Times mean parallel or
branching spikes forming parts of various tools and natural objects. It is used for carry,
push, pull, lift, stack or tier material. They may be made of metal, or other hard, strong
material. Weighed material can be lifted either by spearing it on the tines, or by holding it
on top of the tines.
The forks, also known as blades or tines, are usually made out of steel and can
lift up to a few tons. The mechanical structure of this prototype module is constructed
with square metal bars, this structure looks like a rectangular flat. Forks have
comparatively a fairly short, their tines are usually shorter, flatter, thicker, and more
closely spaced.
Table 3.1
SPECIFICATION OF FORK
S.NO SPECIFICATION VALUE
1 Width 50 mm
3 Thickness 10 mm
3.2 DC MOTOR
An electric motor is a machine which converts electrical energy to mechanical energy.
Its action is based on the principle that when a current-carrying conductor is placed in a
magnetic field, it experiences a magnetic force whose direction is given by Fleming’s left
hand rule. When a motor is in operation, it develops torque. This torque can produce
mechanical rotation. DC motors are also like generators classified into shunt wound or
series wound or compound wound motors. A brushed DC motor is the simplest of all
motor types, and typically consists of the following parts;
3.3 BATTERY
The storage battery or secondary battery is such battery where electrical energy
can be stored as chemical energy and this chemical energy is then converted to
electrical energy as when required. The conversion of electrical energy into chemical
energy by applying external electrical source is known as charging of battery, whereas
conversion of chemical energy into electrical energy for supplying the external load is
known as discharging of secondary battery. During charging of battery, electric current
is passed through it which causes some chemical changes inside the battery. This
chemical changes, absorb energy during their formation.
Table 3.4
SPECIFICATION OF ROPE SYSTEM
S.NO SPECIFICATION VALUE
1 Pitch 300 mm
3.5RF REMOTE
An RF module (short for radio-frequency module) is a (usually) small
electronic device used to transmit and/or receive radio signals between two devices. In
an embedded system it is often desirable to communicate with another device
wirelessly. ... RF modules are typically fabricated using RF CMOS technology. A radio
receiver is the opposite of a radio transmitter. It uses an antenna to
capture radio waves, processes those waves to extract only those waves
that are vibrating at the desired frequency, extracts the audio signals that were added to
those waves, amplifies the audio signals, and finally plays them on a speaker. The RF
module, as the name suggests, operates at Radio Frequency. The corresponding
frequency range varies between 30 kHz & 300 GHz. In this RF system, the digital data
is represented as variations in the amplitude of carrier wave. This kind of modulation is
known as Amplitude Shift Keying (ASK).
Most A/V equipment is IR based and has an IR sensor on the front panel.
Because RF remote control signals must wind up as IR signals at the IR sensors, an RF
receiver (base station and antenna) accepts RF and converts it to IR. Receivers are
wired to an "IR emitter" (flasher) pasted onto the sensor of each device or to an "IR
blaster" located inside the home theater cabinet. The blaster reflects off the closed
cabinet door, showering IR signals to all the devices at the same time. See IR remote
control, Wi-Fi remote control and RF. This RF module comprises of an RF
Transmitter and an RF Receiver. The transmitter/receiver (Tx/Rx) pair operates at a
frequency of 434 MHz an RF transmitter receives serial data and transmits it wirelessly
through RF through its antenna connected at pin4. The transmission occurs at the rate
of 1Kbps – 10Kbps.The transmitted data is received by an RF receiver operating at the
same frequency as that of the transmitter.
Table 3.5
SPECIFICATION OF RF REMOTE
S.NO SPECIFICATION VALUE
3.6 VEHICLE
Thin-shell structures are light weight constructions using vehicle elements.
These elements are typically curved. A vehicle is a type of structural element which is
characterized by its geometry, being a three-dimensional solid whose thickness is very
small when compared with other dimensions, and in structural terms, by the stress
resultants calculated in the middle plane displaying components which are both
coplanar and normal to the surface. Essentially, a vehicle can be derived from a plate by
two means: by initially forming the middle surface as a singly or doubly curved surface,
and by applying loads which are coplanar to a plate's plane which generate significant
stresses. The sheet metal and structural material selected for best one of these to
fabricate.
Figure 3.6Vehicle
The structural system of a vehicle is designed to cope with the vertical gravity
loads and lateral loads caused by wind or seismic activity. The structural system
consists only of the members designed to carry the loads, all other members are
referred to as non-structural. These vehicle have a wheel assembly for mobile purpose.
The wheel is a circular component that is intended to rotate on an axial bearing. The
wheel is a device that enables efficient movement of an object across a surface where
there is a force pressing the object to the surface. Wheels, in conjunction with axles,
allow heavy objects to be moved easily facilitating movement or transportation while
supporting a load, or performing Labour in machines. A wheel greatly reduces friction by
facilitating motion by rolling together with the use of axles. In order for wheels to rotate,
a moment needs to be applied to the wheel about its axis, either by way of gravity, or by
the application of another external force or torque. Table 3.6 shows the specification of
Vehicle.
Table 3.6
SPECIFICATION OF VEHICLE
SPECIFICATION VALUE
S.NO
Dimension
1 400 X350 X 150 ht
Structure size
2 25 X 25 X 5 mm thick
Wheel size
4 Ø 100 X 45 width
ASSEMBLY DIAGRAM
CHAPTER 4
ASSEMBLY DIAGRAM
PROPOSED SYSTEM
The proposed system is a new computerized design.
The new ideas are performed very quick and easy way.
It provides our ideas through the drawing.
This is used to implement the project as carefully planned and controlled.
It can considered to be most must give the project will work and be effective.
WORKING PRINCIPLE
CHAPTER 5
WORKING PRINCIPLE
Mast placed in front of the vehicle. It is having the carriage with fork assembly in front of
the vehicle. A motor mounted on top of the vehicle. The motor have a power unit (12 volt
battery) and a key operated control unit, located on base frame of the vehicle. The
carriage slide on the mast. The mast have a columns and are symmetrical so the
column with the mounting fixture for the power unit may be located on either side. The
Power unit consist of motor and hitch plate with the mounting type. The pulley is located
in both columns through run over the round robe between the columns. The robe runs
over from the hitch plate to carriage through the pulley systems. This vehicle fabricate
with square tubes.
This lifting system is powered by electric motor and the thing was indeed
spinning that speed on the centre shaft of the motor. When key switch on the electric
motor the mechanical power induced from the motor shaft. Forward mode of the motor
is switch on; the hitch plate loaded the robe run over the pulley, the fork move upward.
Reverse mode of the motor is switch on; the hitch plate releases the robe run over the
pulley. The pulley system had a tension force to the fork. The fork functions, if that
moves up and downward without vibration with the help of carriage with mast. The robe
(high strength cable) provides tension on the carriages to make sure that both sides go
up at the same speed and provides the lifting power.
Common aspects of the designs:
This system performs lifting operation at same time and speed the up and
downward motion.
This system has a power source from electric motor with robe system
MERITS
CHAPTER 6
MERITS
Suitable for indoor use.
Longer life.
Minimum noise level.
Eco-friendly operation
It can be used in hazardous areas.
Huge advantage of forklift is that they have no fuel cost.
The best electric forklift is that they have zero emission which causes safe and
healthy environment.
That is why they can be called the Green Forklift.
The operation cost is low.
The life of electric forklift is greater than other types.
Maintain better control of material management
Reduce product damages
Reduce manpower
Increase productivity
Suitable to transfer frames
COST ESTIMATION
CHAPTER 7
COST ESTIMATION
Table 7.1
COST ESTIMATION
S. RATE AMOUNT
PART NAME QTY MATERIAL
NO (Rs/-) (Rs/-)
RF Remote
5 1 no - 1000 1000/-
Vehicle
6 1 no Steel 1000 1000/-
TOTAL 6300/-
PROJECT COST
CHAPTER 8
PROJECT COST
A project cost is a detailed, time-phased estimate of all resource costs of our project. It
means the sum total of all funds required to complete this project purchase transaction.
We need to set a total cost for the project purchase which includes all expenses.
Direct costs
Indirect costs
Labour costs
Material costs
A Labour cost may be calculated as a fixed task based amount, or at an hourly rate, or
based on an easily measured quantity of work done. Salaries for our team members for
the hours we work on the brochure of our project.
Total =Rs1000/-
Materials cost is the cost of direct materials which can be easily identified with
the unit of production. The special paper stock for the brochure specific materials, and
purchase equipment for our project.
Overhead costs
Travel Expenses
=6300+1000
=7300
=1460
Table 8.3
TOTAL 8760
CHAPTER 9
Table 9.2 shows the experiment reading of the Project work result.
Table 9.2
EXPERIMENTAL READING
9.3 DISCUSSIONS
It was found that the lifting capacity of the “TWO WHEEL DRIVE FOR FORK
LIFT” ranged from approximately 25 Kilograms. A model was proposed to describe the
response of weight lifting capacity, seen above the Table 10.1.It is more mechanical
efficient for industrial apply compare with other commercial lifting system.
Economic analysis of the system was conducted to determine the long term
feasibility of operating the fork lifting system. Net present worth calculations were
undertaken based on typical usage patterns at weight lifting capacity approximately 25
Kgs. It was found that the total cost of operation (measured by net present worth)
approximately Rs.6000/-.It is below the cost of purchasing and operating a commercial
weight lifting system.
CONCLUSIONS AND
RECOMMENDATIONS
CHAPTER 10
10.1. CONCLUSIONS
The project work “MULTI DIRECTIONAL PORTABLE FORK LIFT” is aimed to
control through wired communication network designed with RF modules. The main
advantage of using this technology is to increase the safety of operator by operating the
forklift from certain distance. This increases the efficiency of the productivity, because
human errors due to the poor visibility can be minimized. The system is designed and
developed successfully, for the demonstration purpose prototype module (mini module)
is constructed & results are found tobe satisfactorily.
After going through these collected data and statistics from various journals as
well as research papers; we came to conclusion that remote controlled fork lift is the
only way to stop such industrial issues like labour cost, hazardous material handling.
Most of all human safety is a major concern’s by using a remote controlled forklift. We
can use our human brain but the hands and legs of a robot, and thereby nullifying the
chances of accident.
Our project is just a prototype, in which we have not used any electronic micro-
controller in itsIC. Ours has a simple electrical heart and a simple mechanical body. As
this is the simplest one, we have got wired remote for manual operating. It can be
modified into any high class application. Considering the project time and all the
necessary steps, we concluded this project is the right one.
This robot can be used as an aid for who are bound to use wheel-chair. Since
just a simple modification in its mechanical arm and movement way, we can convert into
any robot that can perform a special type of work.
10.2. RECOMMENDATIONS
In view of the experience gained by the researcher it is suggested the following
improvements for the research. Thus our project study is numerous improvements that
could be employed to improve the MULTI DIRECTIONAL PORTABLE FORK LIFT.
When multi pulley system is designed for additional frictional pressure drop.