FORKLIFT : NEW PRODUCT

DEVELOPMENT PROGRAM
Mast section selection strategy

Date : 6thth March 2020

❑ Created By – Abhiman Kokate
❑ Checked By – Nikhil N / Makarand P / Anand Tawade / Prasad Ingale
❑ Reviewed By – ####
❑ Approved By – ####

© Copyright 2019 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.
MAST SECTION CJJ & III COMPARISON
CJJ III
Lower section modulus for same bearing size I Sect. Higher section modulus

Factors in section
More Visibility Less Visibility
selection

Good Packaging feasibility Poor Packaging feasibility

Visibility
Import Cost is High Section Modulus No import cost. Sections are Locally available
Packaging feasibility
High Lead time in SCM
Cost Less Lead time in Inventory
Sourcing
Locally available sections are not Suitable Readily Available in local market

CJJ section is not readily available in Local market &

Toyota, Heli, Linde, Jungheinrich needs to import which results in high lead time in SCM Godrej, Voltas
and cost. This makes III as our first choice for Mast.

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 2
 Visibility
VISIBILITY COMPARISON IN PHYSICAL BENCHMARKING
Bearing to
Ground Closed
Capacity Visibility Section Section Carriage Bearing carriage Fork Fork Bearing MFH
Sr. No Variants C/S WxH Mast type Clearance Length Overlap
(Ton) Space Height s Type Type vertical distance Length Height Dia.
(M1) (OAHL)
A to B B to C
1 3WE_Junghenrich 1.6 328 67 X 145 2015 C 2A 3 stage with FFL 320 150 1255 550 79.8 4800 80 2095 412
2 3WE_Godrej 2 296 72 X 140 2460 C 2A 3 stage with FFL 285 120 1205 560 95 6000 95 2555 482
3 3WE_Toyota 2 355 65 X 150 2030 C 2A 3 stage with FFL 380 115 1280 580 108 4700 75 2105 467
4 4WE_Toyota 2 420 65 X 145 2030 C 2A 3 stage with FFL 400 110 1130 580 108 4700 70 2100 465
5 4WE_Godrej 2 355 70 X 140 2040 I 2A 3 stage with FFL 285 120 1205 560 100 4500 100 2140 605
6 4WD_Godrej 3 355 70 X 140 2040 I 3A 3 stage with FFL 285 120 1205 560 100 4500 110 2150 610
7 4WD_Heli 3 350 90 X 160 2100 C 3A 3 stage with FFL 520 - 1160 655 120 4500 135 2235 665
8 4WD_Toyota 3 400 80 X 170 2030 C 3A 3 stage with FFL 450 - 1150 620 117 4300 110 2140 665
9 4WE_Linde 3 500 90 X 160 2170 C 3A 2 Stage without FFL 480 175 1433 640 3000 125 2295 825

• 4WD 3T Godrej and Heli have nearly same visibility with I and C sections.
Visibility Space FORK HEIGHT
Section Height

C
OAHL
B
Inner Rail A

*Study based on physical machine available.

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 3
 Visibility
VISIBILITY IN 4WD BENCHMARK MACHINES

400
355 350

180 680

GODREJ 4WD HELI 4WD TOYOTA 4WD

• Overall width (680 - 700mm) of the mast is limited due to width of the forklift. (Mast to be fitted
between front wheels)
• As shown in sketch, horizontal dimension (160mm) in Godrej is within the range with
competition. (Heli 180mm, Toyota 140mm).
• As overall dimensions in I section does not make significant difference compared to C section
from competition, the main factor affecting the visibility is packaging of components fitted on
mast.

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 4
 Section Modulus
SECTION MODULUS IN C AND I SECTION

Section
Section
Section d h b t s Modulus
Modulus Zy
kg/meter
Zx (cm3)
I-Section 140 100 70 10 20 156 32 30 Godrej-3T

C-Section 140 100 43 13 20 104 14 24 JREW

J-Section 140 100 43 13 20 - - 27.4

C-Section 170 120 43 12 21 157 25 29 Toyota-3T

J-Section 163 122 43 11 22 153 25.5 29.4

• Section modulus of I section and C section are same when we take one size bigger in C
section compared to I.
• This Indicates that we can select I section as there is not much difference in section
modulus.

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 5
 Section Modulus
SECTION MODULUS OF PHYSICAL AVAILABLE MACHINE

Section Modulus Section

I Section d h b t s kg/meter
Zx (cm3) Modulus Zy
4WE GODREJ 140 100 70 10 20 156 32 30

Section Modulus Section

C Section d h b t s kg/meter
Zx (cm3) Modulus Zy
3WE JUNGHENRICH 145 80 40 15 21 108 14 31
3WE GODREJ 150 90 42 10 30 131 21 30
3WE TOYOTA 150 110 40 12 20 110 15 22
4WD HELI 162 120 55 16 21 164 27 32
4WD TOYOTA 170 120 44 12 25 157 25 29
4WE LINDE 160 118 55 15 21 166 28 32

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 6
 Section Modulus
CALCULATIONS
I - Section C - Section
Input Data
RM-I-100 Toyota-3T
▪ I and C sections are compared for
FORKLIFT CAPACITY 3.5T 3.5T equal static load condition and
LOAD kg 3700 3700 stress & defections are compared.
MFH mm 4500 4500 ▪ I and C sections has similar section
LOAD OFFSET FROM MAST BEARING CENTER mm 713 729
TILT CYL. ANGLE degree 17 17
modulus values.
MAST TILT FORWARD ANGLE degree 3 3 ▪ Factor of safety coming from these
Self weight of mast kg 650 650 calculations is within the range and
section details X-X
acceptable. (YS = 415MPa)
d mm 140 170
h mm 100 120
b mm 70 44
t mm 10 12
Modulus of Elasticity € N/mm2 200000 200000 Sample Calculations
CALCULATIONS
Moment of Inertia( I XX) mm4 10941020 13691379
Section Modulus cm3 156 157
Section Weight / m kg/m 30 28
MAST TILT WEIGHT kg 194 194
Max Shear Force kg 3448 3506
Shear Stress ( σs) kg/mm2 0.9 1.0
Maximum Bending Moment (M) kg-mm 1834609 1864593
Bending Stress (σb) kg/mm2 11.74 12
Combined Stress (σcombined ) N/mm2 116 115
FOS 3.6 3.6
Total Deflection at the free end (y) mm 57 46

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 7
 Costing and sourcing
COST OF MAST SECTIONS
Mannstaedt GmbH
Section III - JREW
Forklift JREW
Sr No
Mannstaedt
capacity in
section
ref no Price • Weight : 30 kg/m
no. types FOB Euro/Kg for FOB
ton
Length 2025 mm INR/Kg
Rs/Kg • Rate : 85 Rs/kg
• Mast height : 2m*6 = 12m
1 W05.023 1.5t , 2t 3019 std 2 1.128 90.24 85.00
I • PRICE = 25.3*85*12=RS. 30600/-
Section
2 W60.028 2.5t,3t,3.5t - 1.146 91.68 85.00

2810, std
Section CJJ - Mannstaedt
3 W97.035 1.5t , 2t 1.197 95.76
2 • Weight : 35.7 kg/m
C
4 W97.037 2.5t,3t,3.5t Section 2862 std 4 1.095 87.60 • Rate : 95.44 Rs/kg
• Mast height (J) : 2m*4 = 8m
5 W97.036 3t , 3.5t 2811 std 3 1.094 87.52
• Mast Height (C) : 2m*2=4m
6 W06.026 1.5t , 2t 3351 1.244 99.52
• Import Duty & Misc. = 20%
J
7 W06.027 2t, 2.5t
Section
3384 1.193 95.44 • PRICE = (35.7*95.44*8*1.2)+12000=RS. 44709/-
8 W06.028 3t , 3.5t 3352 1.146 91.68

• Price difference between Mannstaedt

and JREW is around 48%
Assumption :
1. CVT mast with approx. Closed length of 2125 is considered for comparison (MFH = 4500mm).
2. Import Duty & Misc. = 20%

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 8
 Availability
WELDED “J” MAST SECTION
▪ ‘CJJ’ mast is generally preferred over ‘III’ mast looking at its advantages in visibility and its section modulus.
▪ M/s JREW makes ‘J’ section by welding ‘C’ section with a flat rolled plate and due to this reason the section
unsuitable to use in our application.
▪ ‘CJJ’ sections from Hoesch / mannstaedt will be imported from Germany and will be difficult in managing inventory,
Lead time and RMC ( 30 to 35 % more in cost)

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 9
MAST SECTION AVAILABILITY Costing and sourcing

Supplier Name:-
1) JREW Engineering LTD / hoesch profile/ Mannstaedt – data available
2) Liaoning Hongchang – Awaiting reply
3) Anyang Rarlong Machinery Co Ltd – Awaiting reply

I Section d h b t s A (mm2) I (mm4) kg / m

RM-I-125 175 128 80 13.2 23.5 5450 2.41E+07 42.8
RM-I-100 /3440 US-Std 140 101 70 11 19.5 3841 1.09E+07 30.2
RM-I-80 / 3019 std 2 113 77 66 11 18 3223 5.84E+06 25.3

C Section d h b t s A (mm2) I (mm4) kg / m

RM-C-70 103 70 40 8.2 16.6 1902 2.75E+06 14.9
RM-C-90 120 90 38 10 15 2040 3.77E+06 16.0
RM-C-100 140 102 43 13 19 2960 7.18E+06 23.3
2810 Standard 2 121.3 78.7 41 10.8 21.3 2597 4.87E+06 20.4
2811 Standard 3 135.4 89.4 53 12.7 23 3573 8.56E+06 28.1
2862 Standard 4 157.2 108.4 61.2 14 24.4 4504 1.48E+07 35.4
© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 10
MAST SECTION SELECTION

• Following sections are considered for various masts as mentioned in table based on sourcing input
(Sections from Hoesch profiles & JREW engineering are equivalent in required rated capacity of the
forklifts hence at present only sections from JREW considered)
• Below mast sections are considered for Diesel and Electric forklifts across all the variants with
difference in mountings for different forklifts.

TYPE OF SECTION SECTION

CAPACITY WEIGHT STRESS
SECTION MODULUS MODULUS FOS
( Ton ) (kg/m) ( N/mm2 )
(I / C) Zx (cm3) Zy (cm3)
1.5 I - 80 104 26 25.7 115.5 5.4
2 I - 80 104 26 25.7 150 4.2
2.5 I - 100 156 33 31 127.5 4.6
3 I - 100 156 33 31 150 4.1
3.5 I - 100 156 33 31 174 3.6

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 11
 For more information about Tata Technologies and what we can do to help
create better products for your customers, visit: www.tatatechnologies.com

© Copyright 2018 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 12