DESIGN AND PROTOTYPING

OF MECHANICAL SCISSOR
LIFT

Group Members
Mintesinot Tadesse
Philipos Teshager
Natnael Jigksa
Yabkal Solomon
Sagni Bazine
METAL FABRICATON INDUSTRY Nathan Eskinder
Biruk Worku
Betelehem Ababu
Nati Abebe
Natnael Haile
 EXECUTIVE SUMMARY
Scissor lift is a multifunctional, efficient, and economical material handling system widely used
in industry. This paper has provided design methodology of scissor lift. Material selection is the
main consideration in designing any component as it determines the strength and fatigue life of
the system. Comparison of various materials and their simulation is given. Solid modeling is
carried out using various 3D softwares like SolidWorks and CATIA. The highest and the lowest
position of the scissor lift are set as specification and worked through design. The working
principle and different types of the machine are discussed. Anticipated mechanical failures that
may occur during operation and their methods of elimination are provided in order to improve
productivity. Design calculation is carried out by using concept of free body diagram and
standard formulas. The analysis is carried out with the help of shear force diagram and bending
moment diagram. Material selection plays a key role in designing a machine and also impact on
several factors such as durability, reliability, strength, resistance which finally give rise to
increase the life of scissor lift. Modeling is carried out using different softwares and analysis of
the system is completed using different softwares..

i
 ACKNOWLEDGMENT
We would like to express our deepest gratitude to Jimma University Jimma Institute of
Technology (JiT), school of Mechanical Engineering Department for giving us the chance to go
and at first hand develop our skill set in our perspective fields.

Next we would like to give our great full thanks to Ethio-engineering Group Metal Fabrication
Industry for giving us the opportunities to practice in the company on apprenticeship program.

We also would like to thank our supervisors design department staffs Mr. Fasil and Mr.
Abubeker who helped us in completing this project. They helped us in each activity by providing
us the necessary information and guidance through the completion of the project.

ii
 CONTENTS
EXECUTIVE SUMMARY ............................................................................................................. i
ACKNOWLEDGMENT................................................................................................................. ii
CONTENTS ................................................................................................................................... iii
LIST OF TABLES .......................................................................................................................... v
LIST OF FIGURES ....................................................................................................................... vi
1. INTRODUCTION ................................................................................................................... 1
1.1 Problem statement ............................................................................................................ 1
1.2 Background of Study........................................................................................................ 1
1.3 Objective .......................................................................................................................... 2
1.3.1 General Objective ..................................................................................................... 2
1.3.2 Specific Objectives ................................................................................................... 2
1.4 Specification ..................................................................................................................... 2
1.5 Scope ................................................................................................................................ 3
1.6 Significance of Study ....................................................................................................... 3
2. LITERATURE REVIEW ........................................................................................................ 4
2.1 Chronology ....................................................................................................................... 4
2.2 Scissor Lift Types............................................................................................................. 4
2.3 Stability of Scissor Lifts ................................................................................................... 5
3. DESIGN FOR SCISSOR LIFT COMPONENTS ................................................................... 8
3.1 Design of scissor legs (links) ........................................................................................... 8
3.1.1 Normal force, Shear force and bending moment .................................................... 10
3.1.2 Normal stress due to Normal force and bending .................................................... 11
3.2 Design of lower base plate ............................................................................................. 13
3.3 Design of Upper base plate ............................................................................................ 13
3.4 Design of bevel gear ....................................................................................................... 16
3.4.1 Force Analysis .............................................................................................................. 17
3.4.2 Bevel-Gear Stresses and Strengths ............................................................................... 18
3.4.3 AGMA Equation Factors .............................................................................................. 19
3.5 Lead screw Design ......................................................................................................... 25
3.6 Design of Supporting Rods ............................................................................................ 27
4. MANUFACTURING PROCEDURES ................................................................................. 29

iii
 4.1 Base Plate and Upper Plate ................................................................................................. 29
4.2 Frame................................................................................................................................... 29
4.3 Lead Screw .......................................................................................................................... 29
4.4 Crank ................................................................................................................................... 29
4.5 Rod ...................................................................................................................................... 29
4.6 Bevel Pinion and Gear......................................................................................................... 30
4.7 Bolts and Nut .................................................................................................................. 30
4.8 Supporting Rods .................................................................................................................. 30
5. COST ESTIMATION............................................................................................................ 31
6. PART AND ASSEMBLY DRAWING ................................................................................. 32
6.1 Base Plate ....................................................................................................................... 32
6.2 Upper Plate ..................................................................................................................... 33
6.3 Frame Linkages .............................................................................................................. 34
6.4 Supporting Rod-1 ........................................................................................................... 35
6.5 Supporting Rod-2 ........................................................................................................... 36
6.6 Supporting Rod-3 ........................................................................................................... 37
6.7 Supporting Rod-4 ........................................................................................................... 38
6.8 Supporting Rod-5 ........................................................................................................... 39
6.9 Lead Screw ..................................................................................................................... 40
6.10 Bevel Pinion ................................................................................................................... 41
6.11 Bevel Gear ...................................................................................................................... 42
6.12 Crank .............................................................................................................................. 43
6.13 Handle ............................................................................................................................ 44
6.14 Handle-Pin 1 ................................................................................................................... 45
6.15 Handle –Pin 2 ................................................................................................................. 46
6.16 Handle-Locker ................................................................................................................ 47
6.17 Bolt ................................................................................................................................. 48
6.18 Nut .................................................................................................................................. 49
6.19 Assembly Drawing ......................................................................................................... 50
REFERENCES ............................................................................................................................. 51

iv
 LIST OF TABLES
Table 1 Length measurement of the link ...................................................................................... 10
Table 2 Normal, shear force and bending moment ....................................................................... 11
Table 3 Normal stress, stress due to bending ................................................................................ 12
Table 4 Result on upper and lower base design ............................................................................ 15
Table 5 Character table ................................................................................................................. 19
Table 6 Reliability Factors ............................................................................................................ 23
Table 7 Calculation result ............................................................................................................. 24
Table 8 Result on lead screw ........................................................................................................ 26

v
 LIST OF FIGURES
Figure 1 Free body diagram of the link .......................................................................................... 9
Figure 2 Force free body diagram ................................................................................................. 10
Figure 3 Free body diagram of upper base ................................................................................... 14
Figure 4 Section view 1 ................................................................................................................ 14
Figure 5 Section view 2 ................................................................................................................ 15
Figure 6 Bevel gear ....................................................................................................................... 16
Figure 7 Section view of bevel gear ............................................................................................. 18
Figure 8 Dynamic factor graph ..................................................................................................... 20
Figure 9 Contact geometry factor for 200 pressure angel straight bevel gears ............................. 22
Figure 10 Bending factor for 200 pressure angle bevel gears ....................................................... 22
Figure 11 Free body diagram of lead screw to lower and raise load ............................................ 26

vi
 1. INTRODUCTION
1.1 Problem statement
The problem to be addressed in this project is that concerning feasibility, availability, operational
ability and maintainability. Generally, the problem observed covers Ethio engineering fabrication
workshop and they are stated as the following.

While building the workshop worker use telescopic forklift to work on higher grounds. Metal
carrier is mounted on the fork and carries works up and down.

1. So it’s not safe and also it’s not the forklift purpose to lift works up and down
2. It also takes time to mount the carrier.
3. It can’t be used in places where the forklift can’t get in.
4. Workers easily cannot be at the right height. It’s not convenient or easy to operate.

1.2 Background of Study

A scissor lift is a type of mobile elevating work platform (MEWP). In comparison to other
forms MEWPs such as booms lifts, scissor lifts can easily be maneuvered in confined spaces. As
a result, scissor lifts are widely used indoor and outdoor in construction, telecommunications,
and other industries. The primary purpose of a scissor lift is to elevate workers with their tools
and materials, while providing a working platform. Unlike boom lifts, the working platform of a
scissor lift cannot be horizontally positioned beyond the base (Burkart et al., 2004). Since the
platform can be raised or lowered to the optimal working height, the physical demands of the
worker can be reduced. The elevated heights of scissor lifts vary, with larger models achieving
heights of 18.3 m (60 ftS) or more (Burkart et al., 2004). Also, scissor lifts can support rated
loads up to 1134 kg (2500 lbs).

Due to an increase in worker productivity, the demand for scissor lifts grew throughout the ‘90s,
with sales of around 20,000 units per year in the mid-‘90s to a peak of 50,000 units in 2000
(Yengst, 2002). Since peak production in 2000, scissor lift sales have fluctuated. The sales are
heavily influenced by the rental equipment industry, which is the number one buyer of aerial
work platforms (Yengst, 2005). The sale of scissor lifts in 2004 was projected to be over 27,000
units (Yengst, 2005). [1]

1
As scissor lifts have become increasingly popular, fatal and non-fatal incidents have occurred.
Based on the Census of Fatal Occupational Injuries (CFOI) data, 78 scissor lift fatalities occurred
between 1992 and 2003 (Pan et al., 2007). Of these fatalities, 74% occurred in the construction
industry. Fatalities associated with scissor lift use have numerous causes such as: falls from lifts,
electrocutions, struck by objects, and scissor lift tip-overs/rollovers (Pan et al., 2007; McCann,
2003). However, scissor lift tip-over/collapse has been the most common event resulting in these
incidents (Pan et al., 2007; Knoll, 2002). Most often, these tip-overs occur while the lift is
elevated to heights in the range of 10-29 feet (Pan et al., 2007). The contributing factors for
scissor lift tip-over include: mechanical failure, lift motion, surface condition, overloading, and
operator misuse to name a few (Pan 2007 et al., 2007; Knoll, 2002).[1] While many of these
incidents could be prevented by adhering to the operator’s manual, training programs, and proper
lift maintenance, further studies are necessary to better understand the instability of scissor lifts
from an engineering control prospective. These studies may also lead to advances in the
educational material and training programs.

1.3 Objective

1.3.1 General Objective

The main objective of this project is to design motor operated scissor lift.

1.3.2 Specific Objectives

 Detail design and analysis of the components of the machine.
 Solid modeling of the machine using CATIA and Solid-work software.
 Components’ cost estimation.

1.4 Specification
The specifications of the design are the following:

 It will be operated using man power of an average 400N force applied

 Bevel pinion and gear will change the axis of rotation through 900
 Power screws are self-locking for safety purposes in order to prevent the platform from
moving down due to its own weight.

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  The attachment points of the scissor mechanism should be fixed to the lower base and
upper platform using welding or screws at one side and on the other side a slot is used to
move the scissor mechanism horizontally.
 The scissor angle should be 1600 at the starting position and it should be not less than 700
when the platform is at its maximum position.

1.5 Scope
The scope of this project is designing and modeling a mechanical scissor lift that can lift up to 1
ton through 3 meters high and it moves horizontally on caster wheel. Design calculations give
dimensions of parts that will be used in solid modeling using CAD softwares
(Solidwork/CatiaV5).

1.6 Significance of Study

 Since its mobile, can be moved any desired place
 It occupies small area or space
 It eliminates the cost for fuel since it works with electricity
 It is operated by the person on it, it has ease of access
 To facilitate the working environment
 To help workers load and unload products from higher heights

Advantage

 Operated by person
 Mobile , can move anywhere

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 2. LITERATURE REVIEW

2.1 Chronology
Since Charles Larson of the United States was granted a patent for the first scissor lift in 1963,
scissor lifts have grown to become the “Swiss Army Knife” of the mobile elevating work
platform (MEWP) field. In his patent description, Larson’s original design relates to “an
extensible lift mechanism for elevating a load” He goes on to say, “this invention relates to such
mechanism including an opposed pair of scissor mechanisms, each of which includes a pair of
scissor arms pivotally connected together, where relative pivotal movement of the arms
accompanies extension of the lift mechanism.” From this simple description, an entire industry
grew and prospered.

Over the following years a number of companies were formed to manufacture scissor lifts, and in
the early 1970’s the first market-ready machines became available. Manufacturers continued to
develop the product, and scissor lifts grew larger, taller, and more robust. As the industry grew,
guidelines for use and manufacture were drawn up and manufacturers added safety features to
protect workers. Companies also began offering a variety of different power sources.[2]

Currently, a standard developed by the International Organization for Standardization (ISO

16368, 2003) defines the design calculations, technical safety requirements, and test methods for
MEWP. Similarly, the American National Standard Institute (ANSI) provides a standard (ANSI
A92.6, 2006) with criteria for design, manufacture, testing, and operation of self-propelled
elevating work platforms. Since the MEWPs are generally considered rigid body structures in
the design calculations of ISO 16368, it is unknown whether these standardized assessments are
adequate in predicting tip-over thresholds. Identified dynamic forces are often treated as static
loads with multiplier factors in the standard’s overturning moment calculations of ISO 16368.
While ISO 16368 has suggested typical forces to be considered, the combined dynamic effects of
these forces are difficult to account for using a static rigid body model.

2.2 Scissor Lift Types

Scissor lifts are available in two types – electric (battery) powered for use primarily indoors on a
firm level slab surface, or engine powered (often called rough terrain scissors) for work outdoors
or use on uneven surfaces. Engine powered machines solve the challenge of moving on terrain
4
where different tires or more powerful engines and outriggers are needed to level the vehicle. In
addition to these machines, there are also dual fuel models that operate on both gasoline power
for outdoors use, and propane for emission-free use indoors.

Electric/mechanical scissor lifts are by far the most popular and most commonly used MEWP on
most construction jobsites or for maintenance in a factory, school or other building because they
are so versatile. On large building projects, it is not uncommon to see hundreds of these
machines hanging ventilation ducts, installing drywall, or doing a myriad of other chores. And
when used for maintenance, the lists of jobs they can complete are as varying as they are
challenging.

With versatility like this, scissor lifts quickly found their way into many industries including
construction, maintenance, and others. Mechanical and HVAC engineers use them to install
overhead ducting and football coaches use them to film games from high above the field.
Arborists use them to trim trees and aircraft workers clean and maintain planes with them.
Construction workers use them for multiple tasks and maintenance personnel find all types of
uses for them around a building or factory. The list goes on.

2.3 Stability of Scissor Lifts

In order to protect workers from accidents regarding the use of MEWPs, standards have been
developed. With respect to scissor lift stability, two standards have been developed. The
International Organization for Standardization (ISO) standard (ISO 16368, 2003) and American
National Standards Institute (ANSI) standard (ANSI/SIA A92.6, 2006) provide design,
manufacturing, testing, and safety requirements for scissor lifts. The physical tests in these
standards are to be performed on a new unit of a particular scissor lift model. For the static tests,
ISO 16368 specifies the scissor lift be subjected to a combination of loads and forces while at its
most unfavorable position. Loads and forces to be considered include: rated load, wind forces,
manual forces, and other forces determined by the manufacturer.[3] ANSI A92.6 requires
manufacturers to perform a horizontal load test, vertical load test, and a static load test on sloped
ground.

With regard to dynamic tests, both standards specify a curb impact test and a depression test.
The curb impact test involves driving the scissor lift into a standardized curb at maximum speed.

5
Similarly, the depression test requires the scissor lift to be driven into a standardized square
pothole at maximum speed. For all test conditions, the scissor lift is considered stable if tip-
over/rollover does not occur.

In addition to physical tests, ISO16368 requires manufacturers to perform stability

calculations. The same loads and forces considered in the physical tests are analyzed in the static
stability calculations. In order to account for dynamic effects, forces produced by
acceleration/deceleration for the curb impact test are treated as a dynamic multiplier factor. The
standard also specifies that tolerances in component manufacture, clearances in joints and elastic
deformations are considered in the stability calculations.[1] However, the method in which these
variables are accounted for is not specifically defined. A method for predicting the tip-over speed
in a curb impact is provided in ISO 16368. This calculation is based on the conservation of
energy is defined by the following:

Where,

· m is mass of the lift

· v is the speed of lift

· g is gravitational constant

· ∆z is the change in height of lift’s center of gravity position

If the potential energy (P.E.) after impact is greater than the kinetic energy (K.E.) prior to
impact, then tip-over will occur. Using this method, only the gravitational potential energy is
considered. In reality, the scissor lift exhibits some flexibility from clearances in joints and
elasticity of the frame members, which could affect the tip-over speed threshold.

While these standards are quite extensive in their test methods, additional hazardous scenarios
may lead to tip-over/rollover. The ground surface under the lift’s tires may soften, resulting in
the tilting of the lift. Human interactions with the lift could produce instabilities but physically

6
testing these conditions would be too dangerous. If not properly maintained, the bearings and
joints of a scissor lift could wear. It is unknown whether the increased flexibility from this wear
could affect the lift’s stability. The use of dynamic simulation model may lead to a better
understanding of scissor lift stability.

7
 3. DESIGN FOR SCISSOR LIFT COMPONENTS
Scissor lift be made up of base platform, upper platform, lead screw, bevel gear, ratchet & pawl,
bolt, nut, links and pins. There is no outline strategy accessible for planning these parts. On the
basis of specific assumptions, the design for each of the components has been described as
follows.

In this section, execution of the outline taking into account the measurements of different
numerical relations is produced. Here I have calculated normal force, shear force, bending
moment and buckling load for how scissor lift link responded for the applied load of 300kg.

3.1 Design of scissor legs (links)

In scissor lift these legs are the vertical individuals that permit the platform to change height.
Legs are made by Structural steel with the same scissor join height. When operator gives the
movement to the lift, Movable ends of the lift will elevate the table to the desired height, making
an “X” design with the legs. So that it provides the necessary support for the base platform.

If length of the legs increases, the pantograph contracts, height decrease. Similarly, if the length
decreases while height increases. This is depending on the angle of the link.

Specification

At minimum height (600mm/0.6m) and at maximum height (3000mm/3m)

We set total of 8 links

 The length between the attached links at minimum height is set to be 1.8meter (1800mm)
 The minimum height is 600mm
 length –L
 height- h
 link length-s

 angle between -ᵦ

8
 Figure 1 Free body diagram of the link

Using trigonometric we can find the link length and the angle at minimum and maximum height

𝐿 ⁄ ℎ⁄ ℎ⁄
Cos (ᵦ) =𝑠 2 , Sin (ᵦ) = 𝑠 4 and tan(ᵦ) = 𝐿⁄
4
⁄2 ⁄2 2

ℎ 𝐿 𝑠
( )2 + ( )2 = ( )2
4 2 2

 at minimum height

ℎ𝑚𝑖𝑛 2 𝐿 2
𝑠 = 2√ ( ) + ( ) =1825mm
4 2

ℎ𝑚𝑖𝑛⁄
ᵦ = 𝑡𝑎𝑛 −1
( 𝐿 4) = 10o
⁄2

 at maximum height

ᵦ at max height

ℎ𝑚𝑎𝑥⁄
4
ᵦ = sin−1 𝑠⁄ = 55.2 o
2

9
𝐿 = 𝑠𝑐𝑜𝑠ᵦ = 1039.5𝑚𝑚

Table 1 Length measurement of the link

Angle(ᵦ) Length(L) Height(h) link length(s)

Degree mm mm mm

10 1800 600 1825

15 1762.815 944.69 1825
20 1714.94 1248.37 1825
25 1654.011 1542.56 1825
30 1580.496 1825 1825
35 1494.95 2093.56 1825
40 1398.033 2346.17 1825
45 1290.475 2580.93 1825
50 1173.089 2796.06 1825
55 1046.781 2989.9 1825
60 912.5803 3160.9 1825

3.1.1 Normal
force, Shear force and
bending moment
Applied Load (W) = 300kg

Force (F) =
300*9.81=2943N

where F=force applied

Figure 2 Force free body diagram

10
Q=shear force

N= normal force

N=Fsin ᵦ/4

Q=Fcos ᵦ/4 since the applied force divided to the four links equally support the upper base

M=Q*s/2

Table 2 Normal, shear force and bending moment

Angle normal force(N) shear force(Q) bending moment(M)

Degree Newton(N) Newton(N) Newton meter(Nm)

0 0 735.75 671.3719
10 127.7262 724.5666 661.167
15 190.4121 710.6609 648.4781
20 251.6265 691.3107 630.821
25 310.928 666.8102 608.4643
30 367.875 637.1595 581.408
35 422.0262 602.6528 549.9207
40 472.8665 563.5845 514.2709
45 520.1753 520.1753 474.6599
50 563.5845 472.8665 431.4907
55 602.6528 422.0262 385.0989
60 637.1595 367.875 335.6859

3.1.2 Normal stress due to Normal force and bending

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Thickness (width/b) of the metal plate = 20mm

Height=80mm

Length of link=1825mm

Stress area = L*w=1.825m*0.02m=0.0365m2

Normal stress due to normal force, σN = (ᵦ) /𝑨s

Normal stress due to bending, σM = 𝑴 (ᵦ) /Zx

𝑏ℎ3
Zx = 𝐼𝑥/ |𝑌𝑚𝑎𝑥| , 𝐈𝐱 = =8.53*10-7m
12

𝑌𝑚𝑎𝑥=40mm

Zx= 2.13*10-5

Table 3 Normal stress, stress due to bending

Angle Normal stress (σN) Due to bending( σM) Σϵx = σN+ σM

Degree Mpa Mpa Mpa
0 0 31.470557 31.470557
10 0.003499348 30.992204 30.995704
15 0.00521677 30.397411 30.402627
20 0.006893877 29.569735 29.576629
25 0.008518574 28.521765 28.530284
30 0.01007877 27.253502 27.263581
35 0.01156236 25.777533 25.789095
40 0.01295525 24.106446 24.119402
45 0.01425138 22.249684 22.263935
50 0.01544067 20.226127 20.241567
55 0.01651104 18.051511 18.068022
60 0.01745642 15.735278 15.752735

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 3.2 Design of lower base plate
Usually, in scissor lift the base plate is mounted to the floor. It is constructed using structural
steel. It gives the proper balance to the structure additionally it should be rigidly supported from
underneath to support the point loading created by the two scissor leg roller and the two scissor
leg hinges. The base plate has attached by four wheel.

Length (l) = 2000 mm

width (b) = 1000 mm

Thickness (t) = 6 mm

3.3 Design of Upper base plate

The upper plate in a scissor lift is utilized to put the load and exchange it to the lift legs. The
outlining of the upper plate is attempted comparative as the base plate. It is likewise comprised
of structural steel material. Additional setup of this upper plate gives operator comfortable and
security.

Length (l) = 2000 mm

Width (b) = 1000 mm

Thickness (t) = 6 mm

It is required to design a platform which should serve under heavy load application and
withstand high stresses. Structural steel has high compressive and tensile strength, good stability
and reliability. Furthermore, it is widely used in industries for manufacturing structural shape
steel members, such as c- beam, I- beam, hollow structural section (Rectangular, square and
pipe). So that the above mentioned and many other purpose this material should be suitable for
our scissor lift.

13
 Figure 3 Free body diagram of upper base

RA=W/2=RB=1471.5

The moment and the shear will be

Figure 4 Section view 1

𝑆 = 𝑅𝐴

𝑀 = 𝑅𝐴 ∗ 𝑥

14
 Figure 5 Section view 2

𝑆 = −𝑊/2

𝑊𝑥
𝑀= − 𝑊(𝑥 − 1)
2

Table 4 Result on upper and lower base design

Input Formula Output

Length (l) = 2 m 𝐴=𝑙∗𝑏 2m2

Width (b) = 1m 𝐴𝑥 = 𝑙 ∗ 𝑡 0.012m2

Thickness (t) = 0.006 m

N(60)= 637.1595 𝑁ᵦ 53,146.6N/m2

Normal stress σ(ᵦ) =
𝐴𝑥

W=2943 𝑆 = 𝑅𝐴 1471.3N

RA=1471.5, x=1 𝑀 = 𝑅𝐴 ∗ 𝑥 1471.3Nm

X=2 𝑆 = −𝑊/2 -1471.3N

𝑊𝑥 0
𝑀= − 𝑊(𝑥 − 1)
2

15
Maximum 𝑀 20.43MPa
σm =
moment=1471.3Nm 𝑧𝑥
𝑍𝑥 = 𝐼𝑥/𝑦𝑚𝑎𝑥 7.2*10-5m3

𝑙𝑡 3 2.16*10-7m4
𝐼𝑥 =
12

For Structural steel σx = σn + σm 20.48MPa

𝜎𝑦=250MPa

Factor of Safety =4

3.4 Design of bevel gear

Bevel gears, shown in Fig…have teeth formed on conical surfaces and are used mostly for
transmitting motion between intersecting shafts. The figure actually illustrates straight-tooth
bevel gears. Spiral bevel gears are cut so the tooth is no longer straight, but forms a circular arc.
Hypoid gears are quite similar to spiral bevel gears except that the shafts are offset and
nonintersecting.

Figure 6 Bevel gear

16
Straight bevel gears are usually used for pitch-line velocities up to 1000 ft/min (5 m/s) when the
noise level is not an important consideration. They are available in many stock sizes and are less
expensive to produce than other bevel gears, especially in small quantities.

3.4.1 Force Analysis

In determining shaft and bearing loads for bevel-gear applications, the usual practice is to use the
tangential or transmitted load that would occur if all the forces were concentrated at the midpoint
of the tooth. While the actual resultant occurs somewhere between the midpoint and the large
end of the tooth, there is only a small error in making this assumption. For the transmitted load,

this gives
Where, Wt = transmitted load, kN
H = power, kW
d = gear diameter, mm
n = speed, rev/min
The forces acting at the center of the tooth are shown in Fig…The resultant force W has three
components: a tangential force Wt, a radial force Wr, and an axial force Wa. From the
trigonometry of the figure,

17
 Figure 7 Section view of bevel gear

3.4.2 Bevel-Gear Stresses and Strengths

Fundamental Contact Stress Equation

Permissible Contact Stress Number (Strength) Equation

Bending Stress

18
Permissible Bending Stress Equation

3.4.3 AGMA Equation Factors

Overload Factor (KA)
The overload factor makes allowance for any externally applied loads in excess of the nominal
transmitted load. It can be found from the Table …, from Appendix A of 2003-B97,
Table… Overload Factors, KA
Table 5 Character table

Safety Factors SH and SF

The factors of safety SH and SF s defined in 2003-B97 are adjustments to strength, not load, and
consequently cannot be used as is to assess (by comparison) whether the threat is from wear
fatigue or bending fatigue. Since Wt is the same for the pinion and gear, the comparison of
√SH to SF allows direct comparison.

Dynamic Factor KV
In 2003-C87 AGMA changed the definition of Kv to its reciprocal but used the same symbol.
Other standards have yet to follow this move. The dynamic factor Kv makes allowance for the
effect of gear-tooth quality related to speed and load, and the increase in stress that follows.
AGMA uses a transmission accuracy number Qv to describe the precision with which tooth
profiles are spaced along the pitch circle.

19
 Figure 8 Dynamic factor graph

Size Factor for Pitting Resistance, Zx

Size Factor for Bending, Yx

20
Load-Distribution Factor, KHβ

Crowning Factor for Pitting, Zxc

Lengthwise Curvature Factor for Bending Strength, Yβ

For straight bevel gears,

Pitting Resistance Geometry Factor, ZI

The geometry factor ZI for straight-bevel gears with a 200 pressure angle and 900 shaft angle is
shown on the fig.. below. Enter the figure ordinate with the number of pinion teeth, move to the
number of gear-teeth contour, and read from the abscissa.

Bending Strength Geometry Factor, YJ

Figure…. shows the geometry factor J for straight-bevel gears with a 200 pressure angle and 900
shaft angle.

21
 Figure 9 Contact geometry factor for 200 pressure angel straight bevel gears

Figure 10 Bending factor for 200 pressure angle bevel gears

Stress-Cycle Factor for Pitting Resistance, ZNT

22
Stress-Cycle Factor for Bending Strength, YNT

Hardness-Ratio Factor, Zw

Temperature Factor, Kϴ

Reliability Factors ZZ and YZ

Table 6 Reliability Factors

Elastic Coefficient for Pitting Resistance, ZE

Allowable Contact Stress

23
Allowable Bending Stress Numbers

Table 7 Calculation result

Pinion Speed (rpm) 100

Gear/Speed Ratio - mG 2.5
Power (KW) 0.4
Module – m 3
Number of Teeth - Np 20
Pinion Pitch Diameter - Dp 60
Pressure Angle - Φ 20
Pitch Cone Angle - Ґ = tan^-1(NP/NG) 21.8
Face Width - b (mm) 20
Pitch Line Velocity - Vt = πdn/60 (m/s) 0.5024
Transmitted Load - Wt = 60000H/(πdn) (KN) 1.2738854
Axial Load - Wa = 0.185014
Radial Load - Wr = 0.185014
Overload Factor - KA 1
Dynamic Factor - Kv = ((A+ √200V)/A)^B, where A=50+56(1-B),
B=(0.25(12-Qv))^(2/3) and Qv=6
B=(0.25(12-Qv))^(2/3) 1.3103707
A=50+56(1-B) 32.619241
Kv= ((A+ √200V)/A)^B 1.4206784
Size Factor for Pitting Resistance - Zx 0.5359
Size Factor for bending - Yx 0.511717
Load Distribution Factor - KH = Kmb + 5.6(10^-6)b^2
Km = 1, for both straddle-mounted
KH = Kmb + 5.6(10^-6)b^2 1.00224
Crowning Factor for Pitting - Zxc 1.5
Lengthwise Curvature Factor for Bending Strength - YB 1
Pitting Resistance Geometry Factor - ZI 0.086
Bending Strength Geometry Factor - YJ - Pinion 0.312
Stress-Cycle Factor for Pitting Resistance - ZNT = 3.4822(nL^-0.0602)
nL - number of load cycles = 10^8 100000000
ZNT = 3.4822(nL^-0.0602) 1.1488246
Stress-Cycle Factor for Bending Strength - YNT = 1.6831(nL^(- 0.5552773
0.0323))
Hardness-Ratio Factor - Zw = 1 + B1(mG-1)
B1 = 0.00898(HBP/HBG)-0.00829
Brinell Hardness Number - HBP 300

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 Brinell Hardness Number - HBG 250
B1 = 0.00898(HBP/HBG)-0.00829 0.002486
Zw 1.003729
Temperature Factor - KT 1
Reliability Factors - Zz and Yz
Zz 1.22
Yz 1.5
Elastic Coefficient for Pitting Resistance - ZE 190
Allowable Contact Stress - (σ)Hlim = 2.35HBP + 162.89 Mpa 867.89
Allowable Bending Stress - (σ)Flim = 0.3HBP + 14.48 Mpa 104.48
Bending Stress - σF (Mpa) 49.581751
Permissble Bending Stress - σFP (Mpa) 19.338457
Contact Stress Number - σH (Mpa) 714.16767
Permissble Contact Stress - σHP (Mpa) 580.1304

Gear Number of Teeth - Ng 50

Pitch Circle Diameter - Dg (mm) 150
Pitch Cone Angle - Ґ = tan^-1(NG/NP) 68.2
Stress-Cycle Factor for Pitting Resistance - ZNT = 3.4822((nL/mG)^-
0.0602)
nL - number of load cycles = 10^8 100000000
ZNT = 3.4822((nL/mG)^-0.0602) 1.2139749
Stress-Cycle Factor for Bending Strength - YNT = 1.6831(nL^(- 0.9562322
0.0323))
Bending Strength Geometry Factor - YJ - Gear 0.205
Allowable Contact Stress - (σ)Hlim = 2.35HBG + 162.89 Mpa 750.39
Allowable Bending Stress - (σ)Flim = 0.3HBG + 14.48 Mpa 89.48
Bending Stress - σF (Mpa) 75.461006
Permissble Bending Stress - σFP (Mpa) 24.052749
Contact Stress Number - σH (Mpa) 451.6793
Permissble Contact Stress - σHP (Mpa) 530.03429

3.5 Lead screw Design

Lead screw is an important part in a scissor lift that takes up the operator or considerable load to
be lifted or brought down by lift. A lead screw is a component that converts rotational movement
to straight (linear) movement.

The most widely recognized frame comprises of a cylindrical shaped shaft with helical grooves
or edges called threads around the outside. The fasten goes through a gap another object or

25
medium, with threads within the gap that mesh with the screw's threads. At the point. When the
shaft of the screw is turned with respect to the stationary threads, the screw moves along its pivot
in respect to the medium encompassing it.

There is a large contact range among male and female threads in lead screws and this outcomes
vast frictional loss amid the operation. Because of these frictional misfortunes, lead screws are
not exceptionally proficient but generally self-locking. In self-locking lead screws, the load can't
bring down itself without an outside exertion. Because of this feature it is generally used to hold
loads. So that in our scissor lift subsequent to lifting required stature assume in the event that we
discharge the hand from handle our framework effectively won't permit to move downwards.

Figure 11 Free body diagram of lead screw to lower and raise load

Force required to rising the load P = W× tan (α + ϕ) = w [tan∝+ 𝑡𝑎𝑛 𝜙)/ 1−𝑡𝑎𝑛𝛼 𝑡𝑎𝑛𝜙]

Force required to lower the load P = W× tan (α - ϕ) = w [tan∝− 𝑡𝑎𝑛 𝜙) /1+𝑡𝑎𝑛𝛼 𝑡𝑎𝑛𝜙]

Table 8 Result on lead screw

Major Diameter (mm) 64

Pitch (mm) 20

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Minor Diameter 44
Pitch Diameter (mm) 54
Lead (mm) - single start 20
Thread Depth (mm) 10
Thread Width (mm) 10
Comperssive Axial Force (KN) 0.955
Coefficient of Friction - f 0.15
Torque required for Raise the Load - Tr (N.m) 5.485504863
Torque required for Lowering the Load - Tl 0.811982441
(N.m)
Shear Stress - τ (Mpa) 0.328132245
Axial Nominal Normal Stress - σ (Mpa) -0.62838869
Bearing Stress - σB (Mpa) -0.21402453
Thread-Root Bending Stress - σb (Mpa) 0.787999421
Σx 0.787999421
Σy -0.62838869
Σz 0
Τxy 0
Τyz 0.328132245
Τzx 0
Von Mises Stress at the root of the thread 2.705197712
(Mpa)
Principal Stresses, σ1 0.140106058
Principal Stresses, σ2 -0.76849475
Maximum Shear Stress at the root of the thread 0.778247086
(Mpa)

3.6 Design of Supporting Rods

Pin used to connect the links which enables them to move and transmit power. There are a total
of 16 pin used this design.

The material selected for the pin is carbon steel

Yield strength=310MPa

Ꞇy=σy/2=160MPa

Factor of safty=3
Ꞇall= Ꞇy/fs=53.3MPa

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W=F/2=1471.5N
Shear Stress due to maximum applied load force
𝑊
Ꞇall = 𝜋𝑑2
4

d= 6mm
M15 pin selected.

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 4. MANUFACTURING PROCEDURES
4.1 Base Plate and Upper Plate
The most common way that steel plates are manufactured is through hot rolling, where steel
slabs are heated until they are more malleable. The steel is then run through a series of rollers
that flatten and thin them out to the desired thickness. When making these plates, it’s common to
start with multiple layers of steel that are slowly compressed into one plate. The plate is then cut
to the required dimensions for the scissors lift. On a bending machine these rolled plates are then
bent with specified dimensions stated on design .finally slots, drills, holes and surface finishes
are completed with the given dimensions

4.2 Frame
Metal sheet is rolled to the correct thinness and the final shape is stamp cut or milled to the
necessary size and shape. Metal frames are plated only after they are produced so it takes less
time to start producing metal frames than it does acetate frames.

4.3 Lead Screw

Manufacturing a lead screw via the thread rolling method is actually quite simple in principle: A
metal shaft is placed in the middle between two tools that have a certain thread profile. These
tools rotate at the same time and the thread is rolled into the surface of the raw material through a
process known as cold forming. The thread profile is transferred to the work piece through
compressive stress and rotation, and is then ready to be used in an application.

4.4 Crank
A mold is prepared with desired shape.

4.5 Rod
Pig iron is collected and metal scrub added in to the melting furnace till they melt this molten
iron is then poured in to continuous casting machine which then passes through bar mill to get
the desirable rod shapes for rod 1, rod 2, rod 3 and rod 4 respectively. Finally threads, drills,
tapper turning and surface finishes are completed on lathe machine with the given dimension.

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 4.6 Bevel Pinion and Gear
Bevel pinion and gear are to be selected with appropriate parameters for the project.

4.7 Bolts and Nut

Bolts and nuts are to be selected.

4.8 Supporting Rods

Supporting rods are manufactured by tapper turning on a lathe machine with the desired
dimensions.

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 5. COST ESTIMATION
Part Number Part Name Quantity Estimated Cost Total Estimated
per Part (Birr) Cost (Birr)
1 Metal Plate 6 1500 9000
2 Pin 2 25 50
3 Fasteners – bolt & 46 20 920
nuts and rivets
4 Lead Screw 1 2600 2600
5 Connecting 8 250 2000
metal(link)
6 linking rod 8 280 2240
7 Bevel Gears 2 3000 6000
8 Caster Wheels 4 2000 8000
9 Lubricant 1 300 300
10 Key 2 60 120
11 Handle 1 1500 1500
TOTAL 81 11,535 32,750

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 6. PART AND ASSEMBLY DRAWING

6.1 Base Plate

32
6.2 Upper Plate

33
6.3 Frame Linkages

34
6.4 Supporting Rod-1

35
6.5 Supporting Rod-2

36
6.6 Supporting Rod-3

37
6.7 Supporting Rod-4

38
6.8 Supporting Rod-5

39
6.9 Lead Screw

40
6.10 Bevel Pinion

41
6.11 Bevel Gear

42
6.12 Crank

43
6.13 Handle

44
6.14 Handle-Pin 1

45
6.15 Handle –Pin 2

46
6.16 Handle-Locker

47
6.17 Bolt

48
6.18 Nut

49
6.19 Assembly Drawing

50
 REFERENCES

[1] J. J. Hartsell, “The development of a dynamic scissor lift model,” 2010.

[2] Toyota, “The Evolution of Scissor Lifts Continues,” 2016.

[3] I. Standard and T. S. Preview, “INTERNATIONAL STANDARD iTeh STANDARD

PREVIEW iTeh STANDARD PREVIEW,” vol. 2003, 2003.

STRENGTH ANALYSIS OF SCISSOR LIFT DEVELOPED FOR HOUSEHOLD

APPLICATIONS, Gnanabharathi Ganesan

Georgy Olenin, Design of hydraulic scissors lifting platform

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