Finished

Arba Minch University
Arba Minch Institute of Technology

Department of Mechanical Engineering
A Report on Internship Work At

Anbessa City Buses Service Enterprise
(ACBSE)
By: Daniel Anbelu ID: Ramit/501/08
October 10, 2019 G.C

ARBA MINCH INSTITUTE OF TECHNOLOGY 2019
DECLARATION
This report documentation is belongs to me. I Daniel have been taking my internship
experience in Anbessa city buses service enterprise. My internship program was started on
March 18, 2019 to July 05, 2019 under the guidance of company supervisor Mr. Esuyawkal
and our University advisor Mr. Zinabu. This is to declare that this work is original and belongs
to me.
Page | ii
EXECUTIVE SUMMARY
This report contains the brief history of the Anbessa city busses service enterprise and its main
mission, vision and values. The report also includes the organizational structure and its
workers profile. This report explains my work experience in ACBSE and the challenges that I
have faced while working in the company. It also includes the technical aspect of the
internship and benefits that I have gained in terms of improving my technical skill and
management skill. Generally it covers the overall four month report and the project that I done
with my group members. Finally it includes conclusion and my recommendation.
Page | iii
ACKNOWLEDGMENT
First of all I would like to thank almighty God for helping me in all aspects. Secondly I want
to express my gratitude to my hosting company, Anbessa city bus service enterprise, for
allowing me to take this internship program. I am thankful for all the workers and members of
the Anbessa city bus. I wish to express my sincere appreciation for company‟s supervisor Mr.
Esuyakal and University advisor Mr. Zinabu for their encouragement and guidance. I also
would like to thank Arba Minch University and Mechanical Engineering Department for
giving me this internship opportunity. Finally I would like to thank my family and friends for
their great support.
Page | iv
Table of Contents
DECLARATION ............................................................................................................................ ii
EXECUTIVE SUMMARY ........................................................................................................... iii
ACKNOWLEDGMENT ................................................................................................................iv
List of Tables ..................................................................................................................................ix
CHAPTER ONE .............................................................................................................................. 1
1. INTRODUCTION ....................................................................................................................... 1
1.1 Company background and overviews........................................................................................ 1
1.1.1 Main purpose for the establishment of ACBSE ..................................................................... 2
1.1.2 Vision and mission of ACBSE ............................................................................................... 2
1.1.3 Major values and Principles of the Enterprise ........................................................................ 3
1.2 Organizational structures ........................................................................................................... 3
1.2.1 Major Section of the Enterprise .............................................................................................. 4
1.3 Stuff profile of ACBSE ............................................................................................................. 5
CHAPTER TWO ............................................................................................................................. 7
2. WORK, RESPONSIBILITIES AND ASSIGNMENT ............................................................... 7
2.1 Preventive maintenance shop .................................................................................................... 7
2.2 Engine Overhaul shop ............................................................................................................... 9
2.3 Gear Box overhaul shop .......................................................................................................... 14
2.4 Differential overhaul shop ....................................................................................................... 16
2.5 Tyre repairing shop .................................................................................................................. 18
2.6 Accessory shop ........................................................................................................................ 20
2.7 Electric Shop ........................................................................................................................... 21
2.8 Body workshop ........................................................................................................................ 21
2.9 My responsibilities during the internship ................................................................................ 23
2.10 Assignments during the internship ........................................................................................ 23
Page | v
CHAPTER THREE ....................................................................................................................... 24

3. TECHNICAL ASPECTS OF THE INTERNSHIP ................................................................... 24
3.1 Objective of the internship ...................................................................................................... 24
3.2 Methods and procedures of technical task ............................................................................... 24
3.3 Technical tasks ........................................................................................................................ 25
3.4 Knowledge and Acquaintances Acquired................................................................................ 26
3.4.2 Management skill gained ...................................................................................................... 26
3.4.3 Communication skill ............................................................................................................ 27
3.4.4 Acquaintances Acquired ....................................................................................................... 27
3.5 Problems encountered during the internship period ................................................................ 28
3.6 Contribution ............................................................................................................................. 28
CHAPTER FOUR ......................................................................................................................... 30
4. GEAR BOX LIFTER WITH GEAR DRIVE ............................................................................ 30
4.1 Introduction ............................................................................................................................. 30
4.2 Statement of the problem......................................................................................................... 31
4.3 Objectives of the project .......................................................................................................... 32
4.3.1 General objective .................................................................................................................. 32
4.3.2Specific objective .................................................................................................................. 32
4.4 Literature Review .................................................................................................................... 32
4.5. Methodology........................................................................................................................... 34
4.6 Design analysis ........................................................................................................................ 35
CHAPTER FIVE ........................................................................................................................... 60
CONCLUSION AND RECOMMENDATION ............................................................................ 60
5.1 Conclusion ............................................................................................................................... 60
5.2 Recommendation ..................................................................................................................... 61
Reference ....................................................................................................................................... 61
Appendix ....................................................................................................................................... 64
Page | vi
List of figure
Figure 1.1 when first Bishoftu Articulated buses arrived……………………………………..2
Figure 1.2 ACBSE organizational structure…………………………………………………...4
Figure 1.3 Depot Structure…………………………………………………………………….5
Figure 2.1 Brake shoe………………………………………………………………………….8
Figure 2.2 steering oil pump and steering box…………………………………………………9
Figure 2.3 Engine block and Engine Head……………………………………………………12
Figure 2.4 Timing Box and Engine oil pump …………………………………………….......13
Figure 2.5 Assembled Engine and my work on it……….……………………………………13
Figure 2.6 Gear box with input shaft……………………………………………………….....14
Figure 2.7 Parts of gear box and gear box housing…………………………………………....14
Figure 2.8 Gear assembling and assembled gear box ………………………………………...15
Figure 2.9 Disassembled components of differential………………………………………....17

Figure 2.10 Cushion gum……………………………………………………………………..19
Figure 2.11 Chamber and Recapped tier……………………………………………………...19
Figure2.12 Regulator and four way valves……………………………………………………20
Figure 2.13 Bishoftu bus under body maintenance…………………………………………...22
Figure 3.1 my work on the engine assembling……………………………………………………………………………………29
Figure: 4.1. Gear box lifter …………………………………………………………………...35
Figure: 4.2. Force acting on links at maximum position……………………………………...38
Page | vii
Figure: 4.3. Force acting on links at minimum position………………………………………39
Figure: 4.4. Force acting on power screw at maximum position……………………………...41
Figure: 4.5. Force acting on power screw at minimum position……………………………...42
Figure: 4.6. Terms screw thread……………………………………………………………...46
Figure: 4.7. Acme thread profile……………………………………………………….…….56
Page | viii
List of Tables
Table 1.1 Stuff profile of ABSSE……………………………………………………………5
Table 1.2 Daily income sample of ACBSE…………………………………………………..6
Page | ix
CHAPTER ONE
1. INTRODUCTION
1.1 Company background and overviews
The ACBSE began working after the invasion of fascist Italians regime with the authority of
Ministry of work by gatheinrg the remaining vehicles in the city garage in 1943 G.C. The
company has launched its operation by giving service to Addis Ababa and provinces on 1951
G.C. as a share company and named as “Ethiopian Vehicles Services SC”. The transport
service was launched by Ten Buses using four main routes with a tariff payment of birr 0.15.
It has strengthened its service from time and increased the number of buses to one hundred
sixty three until 1966 G.C and it had constructed an office building and a garage currently
known to be Lideta area.
On august 1974 G.C., the Enterprise was transferred to ownership under the supervision of the
Government. By the year 1976 G.C, it was transferred to the national road transport
corporation‟s public transport service as main organizational unit. In the year 1981 G.C, in
order to strengthen the service of the enterprise, one hundred cross-country and fifty city buses
were purchased. The public transport service was dissolved in a newly organized, entity with
the name of public transport corporation started to administer of the company. The present
head office of the enterprise known by the name “Anbessa Garage” which includes Yeka
Depot was launched in the year 1987 G.C. In 1994 G.C, by the regulation no 187/1986 of the
Council of Minister, it was independently established as a public Enterprise with the name of
‟Anbessa city bus service enterprise”.
Anbessa city bus service enterprise provide the conventional bus services in Addis Ababa. It
has recently begun to acquire buses assembled locally by the Metal and Engineering
Corporation, a newly established military industrial complex of the Ethiopian government. It
has included in its fleet more than 500 of these locally assembled buses known as Bishoftu
buses, which bear the town‟s name where the assembly plant is located.
Page | 1
Currently, there are around 1000 city buses under the enterprise. Nearly 40% of these are out
of service due to technical issues. The enterprise also operates 93 routes in and around Addis
Ababa. Each bus has a capacity for 100 passengers (30 seated and 70 standings). These buses
cover a collective distance of 54,000 km daily and provide their services to 1.5 million people,
as indicated in the 2006/07 to 2010/11 five-year strategic document of the city administration.
Figure 1.2 when first Bishoftu Articulated buses arrived
1.1.1 Main purpose for the establishment of ACBSE
 To solve the problem of transportation in and around Addis Ababa sub city
 To give service for the customers with fair price.
 To engage within maintenance and over hauling of the buses.
 To manufacturing spare parts of the buses.
 To engage in any other activities necessary for attainment of its purpose.
1.1.2 Vision and mission of ACBSE

 Vision
 To be the leading and commendable African urban transport provider
 To see that the daily activities of the community are done in a sustainable and
satisfactory level.
Page | 2
 Mission
 Providing modern, suitable, sustainable, and speedy urban transport service
with an affordable price to the enterprise beneficiary community The enterprise
shall perform the following activities
 Undertaking re-engineering of works which can grow up its institutional
capacity in light of the procedure, organization and human resources.
 Undertaking performance centered activity, which enhances discharging its
capacity in adequate manner.
 Establishing service Improvement system for handling customer‟s complaints
suggestions; working in close collaboration with stakeholders and collaborator.
1.1.3 Major values and Principles of the Enterprise

 Sustainability
 Responsibility
 Readiness for change
 Environment safety
 Ethical issues
1.2 Organizational structures

As per the current structure of the Enterprise there are seven divisions and two services each
of them containing its sub sections;
Divisions
 Operation Division
 Technical Division
 Service Researching, Designing and supervision Division
 Property purchasing and provision Division
 Property purchasing and provision division.
Page | 3
 Finance and Human resource division

 Audit and inspection service
Figure 1.2 ACBSE organizational structure
Service
 Plan and data processing service

 Legal service
1.2.1 Major Section of the Enterprise

 Operation and transport service
The enterprise is rendering the city transport service in three bigger depots, four terminals
sixteen posts, and more than one thousand four hundred prepared buses stations. The depots of
Yeka, Shegole and Mekanissa are organized as branch station. The branch office of Jimma is
rendering transport service to Jimma city and the surrounding by having eight buses, forty two
workers and minor maintenance.
Page | 4
 Technical service
The Garage workshop is organized in a modern manner at the head office compound. Shegole
depot has capacity to properly maintain and preparing the enterprise‟s buses. In addition the
sector usually referred as central workshop has quality and efficiency to undergo individual as
well as companies‟ vehicle maintenance and this branch is accompanied by the modern
equipment and skilled work force on the field.
Figure 1.3 Depot Structure
1.3 Stuff profile of ACBSE
Anbessa city Bus Company has employees of 4098. Table 2-1 indicates all employees in four
depot sites including both genders. This information is obtained from the communication work
team Anbessa city bus organization.
NO. WORK TIME MALE FEMALE TOTAL

1. Main directorate 3 3 6
2. Second directorate 1 2 3
3. Public transportation service directorate 700 449 1149

4. Technical service program main work time 337 42 379
Page | 5
5. Finance directorate work team 12 80 92
6. Human resource work team 133 84 217

7. Purchaser and property directorate work 29 18 47
team
8. Internal auditing work team 4 9 13
9. Lawyer work team 8 5 13

10. Study and plan, budget work team 3 2 5
11. Communication work team 4 4 8

12. Information technology work team 4 18 22
13. Shegole Depot 767 418 1185
14. Mekenisa Depot 601 313 914
15. Jimma Branch 30 15 45

Total 2638 1462 4098
Table 1.1 Staff profile of ACBSE
Day Yeka Shegole Mekenisa Total

(Eth. Birr) (Eth. Birr) (Eth. Birr) (Eth. Birr)
Monday 525,752.45 326,771.00 334,813.25 1,187,336.70
Tuesday 432,989.34 361,453.56 355,543.00 1,149,985.90
Wednesday 575,653.33 318,457.43 336,765.11 1,230,875.89
Thursday 448,094.45 387,234.40 312,855.55 1,148,184.40
Friday 531, 594.00 278,011.15 406,926.60 1,216531.75
Saturday 344,275.30 484,426.85 201, 446.60 1,030,148.75
Sunday 345,801.85 294,697.95 406,159.05 1,046,659.30

Table 1.2 daily income sample of ACBSE
Page | 6
CHAPTER TWO
2. WORK, RESPONSIBILITIES AND ASSIGNMENT

During my internship time in ACBSE I have learnt different practical knowledge through
working on different tasks. While working in one of the company‟s depot, Shegole depot, I
can see different workshop and working areas. Generally I will try to cover the tasks through
these eight working areas of the company, those are: -
 Preventive maintenance shop
 Engine overhaul shop
 Gear box overhaul shop
 Differential overhaul shop
 Tire repairing shop
 Accessory shop
 Electrical shop
 Body workshop
2.1 Preventive maintenance shop
This type of maintenance is done on the vehicles to avoid the breakdown or damage of the
components and parts of the vehicle. It intends to reduce or totally eliminate breakdowns and
accidents due to mechanical failures and reduces repairing cost. It includes attention given
when a motor vehicle becomes immobilized due to failures of the components. These failures
might create an electrical failures, fuel supply failures, overheating, and breakage of other
components. The periodic maintenance is the attention provided to motor vehicle after it
operates for a specified time or covered distance. This maintenance may be done daily,
weekly, quarterly or annually. Daily maintenance by the operator for proper running of the
vehicle is known as operation maintenance. It is needed to keep the vehicle in proper working
condition. Tire inflation, battery, brakes, clutch, smoke colour, steering system, ignition
system and lights are checked in this maintenance daily.
Page | 7
Some of the preventive maintenances are;

 Checking the lubrication
There are five types of lubrication oil that are used for lubrication process. Engine oil,
gear box oil, differential oil, steering oil, and clutch oil. The engine oil and oil filters
should be changed with in 5000km. The gear box oil should be changed after 6 months
of service. The differential oil should be changed after 1 year of service and the
steering and clutch oil also should be changed after some periods of time.
 Servicing of Brake Shoe
There are some procedures while servicing brake shoe of the vehicle. The first step would be
raising the vehicle so that the opposite side of the wheel is free. Remove the wheel and drum
which will give access to the brake shoes. The brake shoe retaining spring is removed by using
brake shoe spring phase. Remove the brake shoe pivot pin and washer. Brake shoes are
removed after twisting a locking wire around the wheel cylinder to retain the pistons in
position. The complete unit of wheel cylinder is removed. Examine the back plate for any
defect and the brake drum is examined for wear and scored. It has to be turned on a brake
drum lathe if necessary. Examine the brake shoe lining for wear and damage. Install the brake
shoe assembly and adjust for proper working.
Figure 2.1 Brake shoe
Page | 8
 Servicing the steering system

The steering system converts the rotation of the steering wheel in to a rotating movement of
the road wheels in such a way that the steering wheel rim turns a long way to move the road
wheels a short way. A steering box provides a gear reduction to make changing the direction
of the wheels easier. In power assisted system a pump provides hydraulic fluid under pressure
to the steering gear pressurized fluid is directed to one side or other part of the steering gear
box to make it easier to turn the wheels. The service should include checking of different parts
of steering system. Steering wheel, steering shaft, universal joint, pitman arm, drag linkage,
and tirod should be checked. The steering oil pump is located in the side of the engine and it
pumps the lubricating oil to the steering gear box.
Figure 2.2 steering oil pump and steering box
2.2 Engine Overhaul shop

In the Engine shop, I saw two types of engine that overhaul maintenance is performed.
 DAF engine and

 Bishoftu bus engines
Page | 9
In the engine overhaul shop, there are sequences that we should follow. Some of the
procedures that we followed are;
A. Engine Disassembling
B. Cleaning Engine parts
C. Inspection
D. Engine Reassembly
A. Engine Disassembling
Removing of the intake and exhaust manifolds from cylinder block is the first step in
disassembly of an engine. Then the removal of the cylinder head is followed. Now we can
remove the valve cover and disassemble the rocker arm components. When removing the
cylinder head, keep the push-rods and rocker arms or rocker arm assemblies in exact order.
The cylinder head have been separated from the cylinder (engine) block. However, few parts
are attached to the block, such as water pump, harmonic balance (vibration damper),
compressor, injection pump, fly wheel, fuel and oil filters, oil cooler and cam shaft. So remove
these parts from the cylinder block.
Then rotate the engine so that the bottom is facing up then remove the oil pan and the oil
pump. To remove the piston and rod assemblies, position the crankshaft throw at the bottom of
its stroke. Remove the connecting rod nuts and cap. In the specified order, loosen and remove
the main bearing cap bolts and main bearing cap.
B. Cleaning Engine Parts

After the component have been disassembled, clean dust particles and rusting areas by
brushing, air pressure antirust flood, with oils and fuels to removing any unwanted particles. .
Disassembly is usually done by loosening bolts and nuts. Disassembled parts are showered by
gasoline or diesel. Since fuels have the property to dissolve oils, the mud formed by the dust
will be removed. The final cleaning and removing process will be washing all parts of the
engine or transmission in the washing machine, also cleaning and drying the parts.
Page | 10
C. Inspection
In the inspection step buses are inspected for their problems. Most of the time buses come to
the garage because of their fuel and oil consumption. In this time the diameters journals of
crankshaft, profile of camshaft, bearing diameter, piston rings and liners diameter, gaskets etc.
are checked by the mechanics for their required dimensions, required clearances and required
properties. Damaged parts are ordered from store or from machine shop since some parts are
rebuild inside the workshop. For the parts which come from machine shop it is required to
check if they are correctly made with their dimensions.
All condition as replacing and maintaining the defected parts after measuring and inspecting
process goes to gather one by one. Before assembling is started, checking the parts again
should be considered. All the disassembling parts should be clean and blown with compressed
air and diesel. Moreover, it approved by group leader and factory supervisor.
D. Engine Reassembly
While maintaining the engine we will follow procedures and steps carefully. The biggest part
of the engine is the cylinder block. The cylinder block is a large casting of metal that is drilled
with holes to allow for the passage of lubricants and coolant through the block and provide
spaces for movement of mechanical parts. It also holds the major mechanical parts of the
engine.
The cylinder head fits on top of the cylinder block to close off and seal the top of the cylinder.
The combustion chamber is an area into which the air-fuel mixture is compressed and burned.
The cylinder head contains the intake and exhaust parts of the combustion chamber. The
cylinder head also contains ports through which the air- fuel mixture enters.
The valve train is a series of parts used to open and close the intake and exhaust ports. A valve
is a movable part that opens and closes the ports. A camshaft controls the movement of the
valves. Springs are used to help the action of the valves. The cam shaft can be placed on the
top or on the side of the block. If it is placed on the side it needs to be connected with the
rocker arm by the rod. The tappet will be placed between the rod and the rocker arm. This
adjustment helps the proper opening and closing of the valves.
Page | 11
Shell bearings are used when the crank shaft placed over the Engine block and the thrust
washers are placed on the side to prevent the damage of the crank shaft. Crank shaft has two
parts, the journal bearing and crank pin.
Figure 2.3 Engine block and Engine Head
In order to prevent the leakage of oil inside the combustion chamber gasket is used. We can
also use gasket maker instead of the gasket. Crankshaft and connecting rod will be assembled
with piston and piston rings. Adjusting the entire injection pump, Engine oil pump and the fire
order at 0◦ with the reference of the crankshaft starts from adjusting the Timing Box. The
Timing Box adjustment is very important during maintenance of the Engine. Engine position
is important to adjust the Timing box. Valve timing gear or cylinder valve opening and closing
angle used for compression systems. The valve timing gear intended for opening and closing
at appropriate moments of the engine operation.
The Timing Box is operated by the crank shaft rotation. There are different gears inside the
Timing Box. Cam shaft gear, Mediator gear, injector pump gear, crank shaft gear and Engine
oil pump gear are rotating inside the Timing Box. The engine oil pump is used to pump
lubricating oil from the oil sump to the engine components.
Page | 12
Figure 2.4 Timing Box and Engine oil pump
After all the crank case, fuel pump, oil pump, water pump, oil cooler and fuel filter are
assembled together. Adjusting the fuel injection with the fuel lines, pump with the advance of
adjusting angles testing the whole engine parts before going to testing house will be done. The
Engine having all inspection and maintenance will be ready for the service.
Figure 2.5 Assembled Engine and my work on it
Page | 13
2.3 Gear Box overhaul shop

Gearbox is the power train of vehicle. The purpose of Gearbox is to use gears of various sizes
to give the engine a mechanical advantage over the driving wheels. The power comes from the
engine is transferred through the engaged clutch to the input shaft of the Gearbox. Gears in the
Gearbox housing alter the torque and speed of this power input before passing it on to other
components in the drive train. The transmission changes the Engine output to suit driving
conditions. It acts as a torque multiplier, sacrificing engine speed for an increase in torque, to
enable the Vehicle to start off and climb steep hills.
Figure 2.6 Gear box with input shaft
Inside the Gear box there are different sized gears, Gaskets, instruct plate, Cover, oil pipe,
input shaft, Bearing, coupling piece, seal ring, Ball bearing, and Sheets. An assembly of gears
is provided within the transmission to change the engine output to suit driving conditions.
There are four steps to maintain the Gear box. Those steps are Disassembly, cleaning,
inspection and reassembly. Disassemble of Gearbox is removing of gears from the housing.
Then remove the gears and the other all parts of the Gearbox. After the components
disassembled, cleaning dust particles and brushing the rusted part will be followed. After clean
all parts of the Gear box the next step is identifying part of the Gearbox those are broken and
replace them with the new one.
Page | 14
Figure 2.7 Parts of gear box and gear box housing
When reassembling the Gearbox follow the sequence and always refer to the service manual.
The assembly of the gear box should be step by step. We insert all the gears, synchronizers,
doge clutch and spacer, sliding doges and other parts of the Gear box on the input shaft
according to the manual. Each parts of the gear box should be placed on the proper position
following the manual to avoid any mistake.
Figure 2.8 Gear assembling and assembled gear box
Page | 15
First gear is the largest gear on the main shaft which is driven by the smallest gear or pinion
on the lay shaft. In this case there will be increasing of torque reduction of speed. The second
gear is less speed reduction with smaller toque increase. Third gear is the medium gear on the
main shaft which is driven by the medium gear or pinion on the lay shaft. Forth gear the
smallest gear on the main shaft is driven by the larger gear or pinion on the lay shaft with
medium speed minimum torque. The fifth gear is the smallest gear on the main shaft which is
driven by the largest gear with corresponding increase speed (Maximum), and reduced torque.
Reverse gear is usually same as the first gear, one reverse speed to reverse the direction of
vehicle. On the neutral position the front band and clutch as well as rear clutch are released by
control with the help of a selector.
Most Gearboxes in the shop are maintained because of hard shifting of lever. The result would
be the damage of the gear teeth. Problem of selector or jumping of locker, miss use of speed
and so on would cause great problem on the gear box.
2.4 Differential overhaul shop

Differential is used to transmit the power to the wheels while allowing them to rotate at
different speed. It acts as the final gear reducing speed of the transmission before the power
hits the wheels. It also used to allow the rotation of left and right hand wheels on any one axle
with different speeds. This is essential on road going vehicles as the two wheels take different
paths when the vehicle goes round a corner, hence travel different distances and the inner
wheel will rotate slower than the outer. This effect can also be seen between the front and rear
wheels of a four wheel drive vehicle so a center differential is required between the front and
rear axles.
On rear and four wheels drive vehicles the differential is invariably part of a separate axle
assembly. It should be noted that axle assemblies also contain part of the gearing required to
reduce the speed of the rotating parts from engine speed to wheel speed.
Page | 16
Figure 2.9 Disassembled components of differential
We can begin the disassembly by separating the ring gear from the differential case. Then
remove the pinion shaft lock bolt. Remove the pinion shaft, then remove the gears and thrust
washers from the case. If the differential side bearings are to be replaced, use a puller remove
the bearings. Use the correct installer for reinstallation of the side bearings. To removes the
bearings use the correct installer for reinstallation of the side bearings. Then clean and inspect
all parts. Replace any damaged or worn parts. Install the gears and thrust washers into the case
and install the pinion shaft and lock bolt. Tighten the bolt to the specified torque. Attach the
ring gear to the differential case and tighten to the specified torque.
During disassembling the differential we make sure to keep all shims and bearing races
together and identified for reinstallation in their original location and also carefully inspect the
bearings for wear or damage and determine if a bearing should be replaced.
Reassembling of differential is basically the reverse of disassembly. New parts are installed as
needed and new gaskets and seals are always used. Serviceable gears are pressed onto the
main shaft and the separate needle bearings should be held in place with petroleum jelly
(Grease) so shafts can be inserted into place.
Page | 17
2.5 Tyre repairing shop

Tires help on the suspension system by absorbing the road shock. They are also designed to
carry the weight of the vehicle, withstand side thrust over varying speeds and to transfer
braking and driving torque to the road. Since the primary purpose of tire is to provide traction,
as it rolls on the road, friction is created between the tire and the road. This friction gives the
tire its traction. When the tire is under high traction the thread will be lost. Then the tire needs
to be recapped again. There are 7 steps for the process:
A. Inspection
It used to verify that a casing is acceptable for rethreading using a thorough inspection of
each tier, inside and outside. Identify casing injuries and determine if it is repairable. Reject
or approve the casing for processing.
B. Buffing
The second process is buffing and it is done by buffing machine. This machine is used to
remove the original tread design and some of the under tread removed to provide the casing
with the required dimensions and surface texture and cementing the buffing.
C. Filling
This process is done by the filling machine. It has electrical and pneumatic system. The
electric system used to melt Cushion gum and the pneumatic system is used to press out the
cushion gum. Cushion gum is a plastic like material that will develop the bonding between
the remoulded tread and the casing. It is also used to fill the holes that are present on the tier.
D. Building
It is the process of applying new tread rubber to the buffed and prepared casing. It is done by
building machine. Building machine used to press the cushion and tread to mesh together.
E. Enveloping
In the pre-mold process the uncured cushion compound has to vulcanize while the pre-mold
tread has to be kept in the position. Therefore the tire is put in to an envelope which presses
though a vacuum system. The pre-mold tread uniformly lay on the cushion and the casing.
Page | 18
Figure 2.10 Cushion gum
F. Vulcanizing in Chamber
The purpose of curing is to apply specified heat and pressure over a period of time to un
vulcanized rubber so that the rubber is cured to the point of the best physical property and
maximum adhesion to the surrounding element .In the pre-molded process the enveloped tire
is put in to an autoclave whereas in the molded process the tire is cured in the proper tire
mould which is boiled at high temperature at 120 degree for 4 hrs.
Figure 2.11 Chamber and Recaped tier
G. Final Inspection
To insure a quality retread each tier passes thorough inside and outside visual inspection. It is
mandatory that the tier meet all customer and government regulations. Some tiers will pass
through some inspection instruments like high pressure Tester, Unacceptable tier rejected and
scrapped. The recapping shop creates the opportunity to use the thrown away tires.
Page | 19
2.6 Accessory shop

In accessory shop several part are maintained. These are foot break, relay, regulator, break
chamber, compressor, these all parts are disassembled and assembled by this time the most
changed part is seal made from rubber used to prevent leakage of oil and fuel.
 Four-way valve
Air system contains different parts with different functions. The air from the atmosphere is
sucked by the compressor. The compressor is used to collect and compress the air at high
pressure. The air from the compressor goes to the regulator of the system and to the four way
valves. The four way valve is used to distribute the air to different parts of the vehicle like
front and rear brakes, hand breaks, ventilation and accessories. This valve has a number ranges
from 21-24.
 21 – to front brake system

 22 – to rear brake system
 23 – to hand brake system
 24 – to clutch pedal, door and accessories
Figure2.12 Regulator and four way valves
Page | 20
2.7 Electric Shop
On this shop several type of devices are maintained. Among those devices starting motor and
alternator or AC generator are main devices. The starting motor is a special type of electric
motor designed to operate under great electrical loads and to produce great amounts of torque
for short period. Basically the starter motor consists of a housing, field coils (windings), an
armature, a commutator with brushes, and end frames. The starter housing or starter frame
encloses the internal parts and protects them from damage and moisture. The housing also
supports the field coils.The field coils and their pole shoes are securely attached to the inside
of the housing.
Current passing through the armature produces a magnetic field in each of its conductors. The
reaction between the armature‟s magnetic field and the magnetic fields produced by the field
coils causes the armature to rotate. This is the mechanical energy that is then used to crank the
engine.
In alternator a spinning magnetic field, which is called the rotor, rotates inside an assembly of
stationary conductors called the stator. As the spinning north and south poles of the magnetic
field pass the conductors, they induce a voltage that first flows in one direction and then in the
opposite direction. When we disassembling, inspecting, testing, and rebuilding AC generators
follow the service manual procedures because improper connections to an AC generator can
destroy it.
2.8 Body workshop

In this shop different parts of the body of the vehicle will be maintained and painting takes
place. Restoring the damaged parts of the car will be done. To restore the body of the Bus we
use different methods and materials depending on the amount of the damage. Hitting panel
with hummer using dolly block, weld a piece of plate on the damaged part and pull with the
material, push the damaged part from the inside and grinding takes place in this shop. Usually
the work is done with manual hand tools. Hummer, rods with different gage or thickness and
hand drill machines are used. Electric arc welding is also applied during maintenance. The
first step in this shop is treating the injured body.
Page | 21
This is done by Grinding, drilling, shaping and planning. Then fill by stucco and make the
surface finishing processes.
After the stucco dried we will start painting. Before actual painting begins it is essential to
prepare the surface for the paint by removing all traces of wax, grease, oil and dirt. If the paint
on the car is of poor quality or seriously deteriorated, it must be removed and re-painted again.
The process starts from preparation of mixed polyester putty using appropriate type and
amount of thickness for the required part or body of the car. Then smoothing and flattening
body of the car using different types of sand papers will follow. The next step will be
preparation of required painting color and masking the body with masking papers. Then apply
the paint using a pneumatic spray gun. The final step will be polishing in order to have a good
surface finish. It is a process of making the painted surface shiny and bright.
Figure 2.13 Bishoftu bus under body maintenance
Page | 22
2.9 My responsibilities during the internship

During my internship time I have been doing different tasks and take different responsibilities
on the project which I was given by the supervisor. Among these responsibilities I have taken
during the internship period are;
 To work with mechanics on work shop at every process.
 To work on engine shop and gear box shop
 To identify any kind of problem and propose solution.
 Help the workers with holding and caring the materials
 Cleaning and washing components of engine and gear box
 Taking care of our own safety
The organization gives such responsibilities based on their willingness and no one can force
them to do so. Accordingly they allow us to work with them and show us all the practical
things that they know.
2.10 Assignments during the internship

In the time of our internship time our company advisor and the company expected us to come
up with original problem identification and its solution. Our supervisor orders us to done
working principle of our project gear box lifter with gear drive using the solid work software.
Page | 23
CHAPTER THREE
3. TECHNICAL ASPECTS OF THE INTERNSHIP
3.1 Objective of the internship

The company internship program is established with the purpose to expose students to the real
working environment. So that the students are able to relate the theoretical knowledge gained
in the class room with practical knowledge in the company. The students will also develop
skills in safety practices, work ethics, communication, punctuality, team work and
management. This program enables us to have a closer relationship with company‟s workers.
Generally, the objectives of this training program are;
 To integrate theoretical concept with practical knowledge.
 To introduce good working
 To give opportunity for the students
 Problem solution and time usage on increasing quality of the produced output
 Enhances skill in engineering including technical writing and communication
3.2 Methods and procedures of technical task

General methods and procedures of technical tasks are;
 Observation problem
 Problem identification
 Gather information
 Interview
 Reading different manual
 Measuring and practicing with technicians
Page | 24
The Procedures that we followed while performing technical working tasks are taken by
considering the suggestion of the workers and referring different information. From the
beginning, we were critically looked at every work and ask questions about what solution they
come up with for the required problem of vehicles. From time to time we adopt how workers
perform their activities and what kind of tools they use, then we write the procedures and the
equipment on a piece of paper. For further information we refer manuals and automotive
books, and then we combine the piece of paper with the manual and write on the textbook in a
correct order.
3.3 Technical tasks

there are different technical tasks that we have been dealing with
 Adjusting the brake shoe and the brake adjustor
 Maintaining the suspension system like changing the U-bolt and I-bolt of the leaf
spring and shackle.
 We replaced grease of in race and outrace bearings
 We changed cylinder block gasket Result we observed.
 Replace engine oil and oil filter
 Changing the damaged king pin of the front wheel
 Changing the lubricating oil of differential and gear box
 Changing the cylinder liners, gaskets, and other damaged components of the engine
 Maintaining the cooling system of the vehicle like changing the radiator, hoses, water
pump and thermostats of the engine
 Changing the air cleaner of the vehicle
 Changing the turbo charger of the engine
Page | 25
3.4 Knowledge and Acquaintances Acquired

3.4.1 Technical skill gained
During the stay of four-month internship work, I have observed that how theoretical
Application is changed to practical application. Having good theoretical knowledge, I have
tried to improve my practical skills by participating in maintaining and repairing different
parts of car. Such as:
 How the lubrication system of the engine, gear box and differential is work
 How drum brake reassembled
 How the engine disassembled and reassembled
 How we can adjust the timing box of the engine
 How gearbox disassembled and reassembled
 How we can maintain brake failure
 How we can remove radiator from the vehicle
 How the cooling system of the engine work and maintained
 How the transmission system works and maintained
 How we can adjust clutch system like adjusting the pressure plate, disk and fork
3.4.2 Management skill gained

Leadership is a process of leading the careers of the company. Problems in the company come
in different time. Thus, a person who is in the position of leadership seeks optimal solution to
the problems and should be smart enough to manage those individuals whom he/she is
leading. What I gain from the internship regarding improving leadership is that to inspire
workers in to higher levels of team work. There are certain things that we must be known to
do that. These are:
Page | 26
i. Know ourselves and develop self-confidence

ii. Be technical proficient
iii. Taking responsibility for actions
iv. Make sound and timely decisions
v. Know peoples and look out for their well – being
vi. Keep workers informally
vii. Develop sense of responsibility in workers
viii. Ensure that takes are understood, supervised
3.4.3 Communication skill

Interpersonal communication is the ongoing process of interaction between individuals who
build the personal knowledge of one another as they create a meaning or work out put. It can
be learned behaviors that can be improved through knowledge, practice, feedback, and
reflection. We got various inter personal communication skills and abilities during our
internship time, they are;
 Improve my listening and speaking skill
 Improve our understanding of feelings and ideas of others
 Respect others
3.4.4 Acquaintances Acquired

During four month stay we contacted many people. This relation updates our:
 Obedience culture
 Respect behavior Ethics
 Knowledge
 Leadership and motivation
 Team work
Page | 27
3.5 Problems encountered during the internship period

I have been facing and identifying the following major challenges and problems.
 Problem of communicating with the workers
 Absence of measuring devices
 Shortage of tools and equipment
 The working place is so rough and dusty
 Time taking respond of officials to maintain vehicles
 Valve adjustment is manual and It is very time consuming.
 Engines are placed on the ground and make it difficult to taking it out
 Engine insertion in the bus after major maintenance would be very difficult
 The safety of the workers while working on the working places is not good
 Usually it is difficult to participate in practical works because of the high
amounts of students
 Sometimes the high temperature in the room makes it difficult to work
properly.
3.6 Contribution
On my internship time I have been working with the workers of the company. I was
working on the Engine shop, gear box shop and other workshops. I have some
contributions starting from removing the bolts to assembling the gear box and the engine.
Below are some of my contributions during my internship time;
 Replacing the tires of the vehicles with changing the brake shoes
 Cleaning and washing the components of Engine.
 Helping the workers with holding and caring the components of the vehicle
 Changing the oil of the engine, steering box and gear box.
 Identifying the problem of lifting and lowering of the gear box and give a solution
through our project
Page | 28
Figure 3.1 my work on the engine assembling
Page | 29
CHAPTER FOUR
4. GEAR BOX LIFTER WITH GEAR DRIVE
4.1 Introduction
Any machine part cannot be moved to a desired position with application of less amount of
external force. For placing a component in required location, the motion of component follows
commonly horizontal or vertical direction. Many machines are used to move machinery and
manpower in different directions based on the required place. A scissor lift is a portable, easily
extended and compressed, safe operating machine used for transportation of medium sized
components to its expected position. It is a machine which moves in vertical direction using
cress-cross 'X' pattern scissor arms. The required elevation of the lift is achieved based on the
number of cress-cross 'X' pattern scissor arms attached. A scissor lift is operated simply by
turning a small crank that is inserted into one end of the scissor lift. This crank is usually “Z”
shaped. The end fits into a gear mounted on the end of the screw, which is the object of force
on the scissor lift. When this crank is turned, the gear rotates, the screw rotates and this raises
the lift. The screw acts like a gear mechanism. It has teeth (the screw thread),2 which turn and
move the two arms, producing work. Just by turning this screw thread, the scissor lift can lift a
load that is several thousand pounds.
Scissor lifts are widely used in industrial applications, and also form a staple design element in
competitive robotics. Each arm of the crosses is called a „scissor arm‟ or „scissor member‟.
The upward motion is produced by the application of force, by some actuator (usually
hydraulic, pneumatic, or mechanical), to the outside of the one set of supports, elongating the
crossing pattern, and propelling the load vertically. However, the positioning of the actuator,
in terms of the point of application of the force on the pantograph, can affect the force required
of the actuator for a given load. Prudent placement of the actuator can greatly reduce the force
required and the stress levels in the adjacent scissor arms.
A scissor lift uses a simple theory of gears to get its power. As the screw section is turned, two
ends of the jack move closer together. Because the gears of the screw are pushing up the arms,
the amount of force being applied is multiplied.
Page | 30
It takes a very small amount of force to turn the crank handle, yet that action causes the brace
arms to slide across and together. As this happens the arms extend upward.
Generally there are three types of scissor lifts;
1. Hydraulic Lifts: the hydraulic scissors lift is operate using the fluid pressure that raises the
platform via power through the use of pressurized hydraulic oil. Slight speed variation is
possible owing to temperature fluctuations that can alter the viscosity of the hydraulic oil.
2. Pneumatic Lifts: the pneumatic lifts are operated using air pressure and they are very
efficient because the power supply is carried out by compressing the atmospheric air. Most of
the units don‟t required electricity and thus can be used at any place where the air is available.
3. Mechanical Lifts: the mechanical lifts are extended through a rack and pinion system or
power screw, both of which can convert rotational motion. All the electric lifts are mechanical.
The benefit of mechanical lift is that the teeth of its gear system prevent from slippage
essentially.
Our project is about gear box lifter with gear drive which is related with scissor lift and used
for raising and lowering of the gear box. In the company they follow manual method to raise
and lower the gear box using chain lifter. This method is not safe for the workers and needs
more force to move the gear box. Our project can solve this problem of the company.
4.2 Statement of the problem

Some lifting and lowering processes of components for maintenance and other services in
Anbessa city bus enterprise are somehow difficult and tedious due to many reasons. Some of
the reasons are weight of the components, lack of fully skilled technicians, lack or even
absence of modern material handling equipment and simple machines. As a project we dealing
with the process of lifting and lowering of gear box, gear box can be lift and lower using
different automated or robotic machines, but Anbessa city bus has not been using those
machines because of their cost and availability. That is technicians in the company use only
simple equipment and traditional methods. This process needs many technicians and wastes
much time. Since the gear box is very heavy to lower and raise, gear it requires very more
manual force. With this entire drawback the process becomes difficult, unsafe and time
consuming, especially an accident might happened.
Page | 31
4.3 Objectives of the project
4.3.1 General objective

Design and analysis of gear box lifter with gear drive.
4.3.2Specific objective
 Measuring maximum height that the gear box lift and weight of gear box related with
Anbessa buses.
 Designing a functional, compact and simple mechanism that would enable to lift and
lower gear box using solid work.
 Selecting material required.
 Force analysis of all parts at the highest and lowest positions of the mechanism
 Stress analysis of all parts to size all of the dimensions of each and every part.
 Preparing part drawing with dimension of each component and assembly drawing.
4.4 Literature Review

French philosopher and mathematician Blaise pascal first described the principle of the
hydraulic jack in the 17th century. In 1795, British engineer Joseph Brahma received a patent
for “certain new methods of producing and applying more power to all machinery requiring
motion and force.” It covered the first hydraulic press.
Screw type mechanical jacks were very common for cars and tracks of World War II vintage.
For example, the World War II jeeps were issued the jack, automobile, screw type capacity of
1 and ½ ton.
The concept of using a screw as a machine was first demonstrated by Archimedes in 200BC
with his device used for pumping water. There is also evidence that screws were preferred in
the Ancient Roman world. But, in the late 1400s, the Leonardo da Vinci, who first displayed
the method of use of a screw jack for lifting the loads. Its design used a threaded worm gear,
supported on bearings, which is rotated by the turning of a worm shaft to drive a lifting screw
to move the load instantly recognizable as the principle used today.
Page | 32
Manoj Patil (2012): In this general article, screw jack is to developed to overcome the human
effort. It is actually difficult job to operate for pregnant women and old person. Changing the
tire is not a pleasant experience. Especially women can‟t apply more force to operate. For that,
electric operated car jack is introduced.
Lokhande Tarachand (2014): This paper referred to Optimize the efficiency of square threaded
mechanical screw jack by varying different helix angle.[1]
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 hennery Maudsley. 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 screw,
into linear motion for moving the load. The device was efficient, reliable and easy to operate.
It was used in the construction of brides, but mostly by the railroad industry, where it was able
to lift locomotives and railway cars. The idea was based on the familiar lever and fulcrum
principle and he needed someone to manufacture it. [2]
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.
The air motor-operated power jack that appeared in 1929 with the aid of the relatively new
portable compressor technology is introduced. 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 application 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 the truck loading platforms and mill tables. [3]
Page | 33
4.5. Methodology
After we identify the specific problem encountered in gear box lifting and lowering we collect
different data.
The simple design, components required, possible mechanisms of the components needed to
perform the required task and others are already designed using solid work (software).After
measuring the total weight of gear box, dimension (length width, diameter and shape) and type
of material are determined using different methods like force and stress analysis and theories
of failure.
Length of all links is determined from the mechanism by considering the minimum and
maximum lifting position and clearance. The cross section of the links is calculated from the
force and stress analysis theories.
To meet the above major and specific objectives the following methodology are implemented.
Page | 34
4.6 Design analysis

The part design in this project is very important in strength, stress analysis and force analysis
of gear box lifter.
Design specification
 Lifting height ( ) = 2000 mm

 Human capacity = 50 N
 Carrying capacity = 300 Kg
 Factor of safety (n) = 1.5
 Design of length of links and power screw
To determine length each links and power screw, let consider the following figure given
below.
Figure: 4.1 scissor lift

A. Length each links
To determine length of each links let us consider the following assumption‟s given bellow.
 At maximum position link one will have an angle of from the horizontal.
 Clearance height between the car gear box and scissor lift is = 1200 mm.
 Height of scissor lift at minimum position is = -
= 2000 mm – 1200 mm
= 800 mm
Page | 35
By taking triangle from the above given figure at maximum position (when the load is
raised)with maximum angle of and let consider length of link be “L”, but L1 =
L2 = L3 = L4 = L1
Using trigonometric relation from the above figure,

⁄
= = =
= , L1 = , L1 = 1035.28 mm
Since L1 = L2 = L3 = L4 = L, length of each links are 1035.28 mm.
B. Length of power screw

The power screw length is determined at minimum position, because the full length of power
screw obtained at that position due to the two nuts are comes at two ends of power screw. First
we calculate angle when the link one at minimum position with horizontal ( ). By taking
the triangle given bellow from figure (1).
Using trigonometric relation from the above triangle,

⁄
= = =
Page | 36
= ( )
=
Therefore, the angle when the links at minimum position (when the load is lowered) is .
Now to find length of power screw, let consider length of power screw is “ ” and by taking
triangle from the figure (1).
Using trigonometric relation from the above triangle,
= = = , = × 1035.28
= 954.88 mm
Therefore, the total length of power screw treaded part is 954.88 mm. but the total length of
power screw calculated at half angle of minimum position ( ).
( )= = , =
= × 1035.28
= 1015.03 mm
Therefore, the total length of power screw is 1015.03 mm.
 Force analysis
The force analysis is based on the assumption that the scissor lift loaded vertically
symmetrical. The forces acting on each part determined at both maximum and minimum
position, and the greatest force is considered for the designing of each parts.
Force acting on links at maximum position

The maximum capacity of scissor lift is 300 Kg, so applied force (weight) can be calculated
as:
Page | 37
Weight = mass × gravity
= 300 Kg × 9.81
= 2943 N
To determine the force acting on each links at maximum position let consider the figure given
bellow.
Figure:4.2 force acting on link at maximum position

The compressive force acting on the links calculated by using equilibrium condition, which
the forces are resolved in to vertical and horizontal components, those are:
Horizontal components
The forces which are acting to horizontal direction are,
∑ =0
- = 0, but = ×
= ×
Then, × - × =o
× = ×
=
Therefore the force acting on each links are equal, F1 = F2 = F3 = F4 = F.
Page | 38
Vertical components
The forces which are acting to vertical direction are,
∑ =0
+ – W = 0, but = ×
= ×
Then, + × –W=0
Since, = =F
2F × –W=0
F= = = 1523.41 N
F = 1543.41 N
Therefore the reaction force acting on each links at maximum position is, F1 = F2 = F3 = F4 =
F =1543.41 N.
Force acting on links at minimum position

To determine the force acting on the each links at minimum position let consider the figure
given bellow.
Figure: 4.3 force acting on link at minimum position
Page | 39
From the above diagram, using equilibrium force condition the forces are resolved in to x and
y components. Those are:
The forces which are acting to horizontal direction are,
∑ =0
- = 0, but = ×
= ×
Then, × - × =0
× = ×
=
Therefore the force acting on each links are equal, F1 = F2 = F3 = F4 = F.
Vertical components
The forces which are acting to vertical direction are,

∑ =0
+ – W = 0, but = ×
= ×
Then, + × –W=0
Since, = =F
2F × –W=0
F= = = 3808.34 N
F = 3808.34 N
Therefore the reaction force acting on each links at minimum position is, F1 = F2 = F3 = F4 =
F =3808.34 N.
The force acting on each links are maximum at minimum position. And the forces acting on
links are equal to force acting pins.
Page | 40
Force acting on power screw at maximum position

To determine the axial forces acting on power screw, let consider axial force is” “ .from
figure given bellow by resolving forces in to vertical and horizontal components we find
reaction force on power screw.
Figure: 4.4 force acting on power screw at maximum position
The forces acting on power screw to horizontal direction are,
∑ =0
- =0 but, =
=
Then, - =0
= = 1543.41 N
Since the force acting on links at maximum position is F1 = F2 = F3 = F4 = 1543.41N
Vertical components
The forces acting on power screw to vertical direction are,
∑ =0
+ - =0 but, = ×
= ×
Then, × + × - =0
Page | 41
= 2F ×
=2× × 1543.41
= 788.58 N
Therefore the reaction force acting on power screw at maximum position is = 788.58 N.
Force acting on power screw at minimum position
To determine axial force acting on power screw let consider the figure bellow. Using
equilibrium condition resolves the forces in to vertical and horizontal components.
Figure: 4.5 force acting on power screw at minimum position
The forces acting on power screw to horizontal direction are,

∑ =0
- =0 but, =
=
Then, - =0
= = 3808.34 N
Since the force acting on links at maximum position is F1 = F2 = F3 = F4 = 3808.34 N
Vertical components
The forces acting on power screw to vertical direction are,
∑ =0
Page | 42
+ - =0 but, = ×
= ×
Then, × + × - =0
= 2F ×
=2× × 3808.34
= 7025.14 N
Therefore the reaction force acting on power screw at minimum position is = 7025.14 N.by
comparing the force acting at maximum and minimum position the greatest force is considered
for design, which is = 7025.14N. And the force acting on nut is equal to force acting on
power screw.
 Design of pin
Pins are very small thin pointed pieces of metal, and it is used to fasten two links that are
under the action of a tensile force; although the links may support a compressive force if the
joint is guided. Some pin joints such as universal joints use two pins and are used to transmit
power from one rotating shaft to another. The force acting on pins is the same as force acting
on links.
Material selection
The material selected for design pin is mild steel with the following mechanical proprieties.
 Yield strength ( ) = 100Mpa
 Ultimate strength ( )=
 Factor of safety (n) =1.5
 Force acting on pin =3808.34 N
Let consider the diameter of pin is “
From the distortion-energy theory which predicts that yielding occurs when the distortion
strain
Energy per unit volume reaches or exceeds the distortion strain energy per unit volume for
yield in simple tension or compression of the same material. The distortion-energy theory is
also called:
Page | 43
 The von Mises or von Mises – Henchy theory

 The shear-energy theory
 The octahedral-shear-stress theory
Using xyz components of three-dimensional stress, the von mises stress can be written as,
[ ( )]
√
Since the pin affected by shear stress in x and y plane only the above equation becomes,
( ) =√
√
Also the shear stress induced in each pins in x and y plane are,
, since pin have double area shear stresses
But area of pin is, Area of pin =
Therefore, √ ( )
The von Mises stress, which then can be compared against the yield strength of the material
and can be expressed as a design equation.
=
= 66.67 Mpa
Then from the above equation, √ ( )
√
66.67 Mpa = , = 62.986 mm
= 7.94 mm
Distortion-energy theory predicts for shear yield stress by the follow equation, let consider
shear yield stress as “ ”.
= 0.577
Page | 44
= 0.577 100 Mpa

= 57.7 Mpa
Also allowable shear stress is given by, let consider allowable shear stress as “ ”.
= = = 38.47 Mpa
Shear stress induced on the pin in x and y plane given by “ ” is,
= , since the pin have double area shear
To avoid failure due to shear stress acting on the pin allowable shear stress ( ) must be
greater than or equal to shear stress induced on the pin ( ).
38.47 Mpa
63.02
7.94
= 7.94
8 mm
Diameter of pin is equal by using shear yield stress and normal material yield stress which is
= 8 mm, therefore the diameter of pin is safe, and diameter of pin head is let consider us
“ ”.
= 1.5
= 1.5 8 mm
= 12 mm
Also let assume, length of pin head is 2mm.
 Design of power screw
The power screw (also known as translational screw) is a mechanical device used for
converting rotary motion in to translational and for transmitting power. The main applications
of power screw are as follow.
 To raise the load
 To obtain accurate motion in machining operation
Page | 45
 To clamp a work piece

 To load a specimen
Figure 4.6 terms screw thread
Material selection for power screw
Material selection plays a very important role in machine design, steel 1016 selected for
designing power with the following mechanical properties.
 Yield strength ( ) = 130 Mpa
Page | 46
 Ultimate strength ( ) = 455 Mpa

 Factor safety (n) = 1.5
 Acme thread
 Force acting on power screw = 7025.14 N
Distortion energy theory for plane stress is given by,
=( )
Since in power screw normal stress in x direction the above equation becomes,
=
The axial nominal normal stress or direct tensile stress ( ) in the body of the screw due to
forceis
For the safety of design the axial stress acting on power screw must be less than allowable
stress.
=
= , = 86.67 Mpa
, 86.67 Mpa
86.67 Mpa
103.204 mm
10.16 mm
For coarse pitch series from table 8.1(Shigley‟s Mechanical Engineering Design, Eighth
Edition Book)
Nominal diameter (d) = 12 mm
Pitch = 1.75 mm
Minor diameter =d–p
= 12 mm – 1.75 mm
= 10.25 mm
Since, 10.25 mm 10.16 mm it is safe diameter.
Pitch diameter ( )=d-
Page | 47
= 12 mm -
= 11.125 mm
The dimensions of power screw are specified as: M12 1.75
Lead (L) = p
= 1 1.75mm
L = 1.75 mm
The thread depth and thread width are the same and equal to half of the pitch, that is 0.875
mm.
 Design of nut
There are two nuts in the assembly of Scissor lift, nut is a stationary part having internal thread
inside which is used to rotate the screw by meshing with external thread of the screw. Nut is
also used to hold the lifting arm or links at their both end.
Material selection for nut

Material preferred for design of nut cast iron with the following mechanical properties.
 Yield strength () = 200Mpa
 Ultimate strength () = 350 Mpa
 Force acting on nut = 7025.14 N
 Factor of safety (n) = 1.5
To determine the dimension of the nut let us consider figure given bellow,
Let consider from the above front view diameter of pin”dp” , diameter of power screw “d” and
take clearance c =1.
Length of nut ( ) = 1.5 dp + 1.5 dp
= 3dp
Page | 48
=3 8
= 24 mm
Width of the nut ( ) = 1.5d + 1.5d
= 3d
= 3 12
= 36 mm
Height of the nut ( ) = d + 2c + 6dp
= 12 + 2 1+6 8
= 62 mm
Collar diameter ( ) = 2c d +3dp
= 2 1 + 12 + 3 8
= 38 mm
Fillet radius ( ) = 1.5dp
= 1.5 8, = 12mm
Torque required to raising load
Let us consider the torque required to raise the load is “ ”and this torque required for two
purposes: to overcome tread friction and to raise the load.
= ( )+
Where, = collar diameter

= minor diameter
L = lead
F = maximum force acting on nut or power screw
= Thrust-Collar Friction Coefficients
= Coefficients of Friction for Threaded Pairs
From table 8.5 and table 8.6 (Shigley‟s Mechanical Engineering Design, Eighth Edition Book)
Screw material steel dry and nut material cast iron (f = 0.20)
Hard steel on cast iron at running condition ( )
= ( )+
= 9871.32 N.mm
Page | 49
= 9871.32 N.mm
Therefore the torque required to raise load is 9871.32 N.mm.
Torque required to lowering load
Let consider torque required to lower load “ ”. It may turn out, in specific instances where
the lead is large or the friction is low, that the load will lower itself by causing the screw to
spin without any external effort. In such cases, the torque will be negative or zero. When a
positive torque is obtained from this equation, the screw is said to be self-locking.
= ( )+
= ( )+
= 5801.07 N.mm
= 5801.07 N.mm
Therefore torque required to lower load is 5801.07 N.mm.
Since the screw is subjected to a twisting moment, therefore torsional shear stress is induced.
This is obtained by considering the minimum cross-section of the screw.
The maximum nominal shear stress τ in torsion of the screw (torsional shear stress) body can
be expressed as.
= 36.513 Mpa
Therefore torsional shear stress is 36.513 mpa.
The axial stress σin the body of the screw due to force F isdetermined by dividing the axial
force (F) by the minimum cross-sectional area of the screw (Ac) i.e. area corresponding to
minor or core diameter (dr).
=
Page | 50
= 72.27 Mpa
The bending stress at the root of the thread can be expressed as,
=
Where, = minor diameter

= number of engaged threads
= = = 13.714 14
= = 50.25 Mpa
= 50.25 Mpa
According to distortion energy theory,
=( )
Substitute to that equation
=
= 73.82 Mpa
Factor of safety ( )= = = 1.76
Since, > n which is 1.76 > 1.5

Therefore power screw with nominal diameter 12 mm is safe design.
 Design of link
Links or Lifting Arms are the main component in the assembly of Scissor lift. We can say that
links are the heart of Scissor lifts.
Material selection for links
Material selected for link is mild steel with the following mechanical properties,
 Force acting on the link = 3808.34 N
 Factor safety = 1.5
 Crushing stress = 100 Mpa
Let consider figure bellow, to determine dimensions of the link
Page | 51
We know that load on links = = 1904.17 N
The link buckling load ( ) = 1904.17 1.5

= 2856.26 N
Let consider, t = thickness of link
W = width of link
Assuming that the width of the link is three times the thickness of the link, i.e. w = 3 t,
therefore cross-sectional area of the link,
A=t w
= 3t t
A = 3t2
And moment of inertia of the cross-section of the link,
I= t w3 = t (3t) 3
=
We know that the radius of gyration,
K=√ =√ = 0.866t
Since for buckling of the link in the vertical plane, the ends are considered as hinged, therefore
Equivalent length of the link,
L = 1035.28 mm
According to Rankine‟s formula (a), buckling load (Wcr),
= where, a = Rankine‟s constant
( )
Table 16.3 Values of crushing stress ( ) and Rankine‟s constant (a) for mild steel materials
from (Rs-Khurmi, A Text Book of Machine Design, 2005)
= 100 Mpa and a =
Page | 52
= =
( )
=
– 9.5 – 1814.036
Let assume Y = using quadratic equation
√ √
Y= =
By solving this equation and by taking the positive value

Y = 47.61
Now thickness of link is
t=√
=√ = 6.899 mm
Therefore thickness of link is 10 mm.
 Design of upper plate
The upper plate in a scissor lift is used to place the load and transfer it to the links. The
designing of theupper plate is undertaken similar as the base plate. The upper plate has the
similar requirements as the base plate. Also it has been found that not much of the stresses are
developed in the upper plate as well.
Material selection
Material selected for design of upper plate is alloy steel GA 1500 with the following
mechanical properties.
 Yield strength = 734 Mpa
 Ultimate strength = 615 Mpa
 Factor of safety = 1.5
 Pin diameter = 8 mm
 Power screw diameter = 12 mm
 Force acting on pin = 3766.02 N
Let consider the figure given bellow for design of upper plate.
Page | 53
Shear stress acting on the pinned area of upper plate is given by,
√
= = also
To determine the thickness of upper plat, from material selection

= = = 239 Mpa
√
239
t = 5.19 mm
Therefore the thickness of upper plate is 6 mm. to check the thickness.
Page | 54
√
100
86.5 100, therefore it safe thickness.

The distance x = 2 + + 2 washer
= 20 + 36 + 20
= 76 mm
Width of upper plate (w) = x + 2t
= 76 + 12 +2
= 100 mm
Distance p = 6 mm
Distance A =1.5 +c
= 12 + 1
= 13 mm
Distance y = 6mm
Height = 31mm
 Design base plate
The base plate in a scissor lift only provides proper balance to the structure. Considering the
size constraints, the dimensions of the base plate are taken as same as upper plate. Also it has
been found that not much of the stresses are developed in the base plate.
Lengths of pins
Pin length at crossing = 20 mm

Pin length at lower and upper plate = 76 mm
= 16 mm
= 26 mm
Pin length at nut = 56 mm
 Design of gear
Gears are defined as toothed wheels or multi loped cams which transmit power and motion
from one shaft another by means of successive engagement of teeth.
Page | 55
Figure: 4.7 terms used in spur gear
Material selection for spur gear

The material selected for gear design is cast steel with the following mechanical properties.
 Yield strength ( ) = 414 Mpa
 Ultimate strength ( ) = 620 Mpa
 Factor of safety (n) = 1.5
 Radius of lever arm (R) = 140 mm
 Torque raise load ( ) = 9871.32 mm
 Human capacity ( ) = 59N
 Module (M) = 2
For design of pinion gear, let consider torque applied on pinion gear shaft “ ”.
=R
= 140 mm 50 N
= 7000 N.mm
Velocity ratio of the two gears are let consider as “ ”.
= = = 1:1.98
1:2
Torsional shear stress induced in gear is expressed as,
Page | 56
τ= , where, = human torque
d = diameter of lever arm shaft

Allowable stress of material can be expressed as,
= = = 276 Mpa
According to distortion energy theory,

= 0.577
= 0.577 414
= 238.88 Mpa
Allowable shear stress is given by,
= = = 159.253 Mpa
For safe design allowable shear is greater than induced shear.
τ=
159.253
d 6.0719 mm
d = 6 mm
Therefore diameter of smaller shaft or lever arm shaft is 6 mm.
Dedendum or root diameter (b): is the radial distance of a tooth from the pitch circle
to the bottom of the tooth.
Root diameter (b) = 3d
= 3 6 mm
b = 18 mm
Pitch circle diameter (c):It is the diameter of the pitch circle. The size of the gear is
usually specified by the pitch circle diameter. It is also called as pitch diameter.
Pitch diameter(c) = b + 2.5 m
= 18 + 2.5 2
C = 23 mm
Addendum (e):It is the radial distance of a tooth from the pitch circle to the top of the
tooth.
Page | 57
Addendum diameter (e) = b + 4.5 m

= 18 + 4.5 2
e = 27 mm
Number of teeth on pinion gear, let consider as “ ”.
= = = 11.5
= 12
Face width (F):It is the width of the gear tooth measured parallel to its axis.
From permissible working stress for gear teeth in Lewis equation.
= where, K = load stress factor
V = pitch line velocity (v = 0.6 ⁄ )

= radial load
Y = Lewis form factor
= = = 608.696 N
K= = = 1.098
Lewis form factor (Y) based on number of teeth from table 14.2 (Shigley‟s Mechanical
Engineering Design, Eighth Edition Book)
Lewis form factor (Y) = 0.245
= , F= = = 2.965 mm
F = 3 mm
For design of larger gear let assume similar material selected with pinion gear, from velocity
ratio number of teeth on larger gear given by. Consider “ ” as number of gear teeth.
=
= 2 12
= 24
Since diameter of larger gear shaft is the same as nominal diameter (d = 12 mm) of power
screw.
Pitch circle diameter of large gear (DG) is determined from the velocity ratio,
= , = C
Page | 58
=2 23
= 46 mm
Root diameter or dedendum diameter of larger gear is “Dr” given by.
= – 2.5M
= 46 – 2 2.5
= 41 mm
Addendum diameter of larger gear is expressed as “ ”
= + 2M
= 46 + 2 2
Face width of larger gear is equals to face width of pinion gear (F= 3 mm).
 Design of key and key way

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to
connect these together in order to prevent relative motion between them.
Medium carbon steel selected for key with the following mechanical properties.
 Shear strength = 42 Mpa
 Crushing strength = 70 Mpa
 Factor of safety = 1.5
From table 13.1(Rs-Khurmi, A Text Book of Machine Design, 2005), the cross section of
key based on shaft diameter are,
For shaft diameter = 6 mm
 Width of key (W) = 2 mm
 Thickness of key (T) = 2 m
For shaft diameter = 12 mm
 Width of key = 5 mm
 Thickness = 5 mm
Length of key is equals to face width of gear.
Page | 59
 Design of lever arm

It is an arm keyed at right angle to the end of a shaft, by which motion is imparted to the
power screw. It mainly suffers from torsional stresses so medium carbon steel is used as it
combines merits of malleability and sufficient torsional strength. Z- Shape lever arm is used
for this project.
 Diameter of lever arm shaft = 6 mm

 Radius of lever arm(r) = 140 mm
 Modules of rigidity (G) = 2
 Torque applied to lever arm = 7000 N.mm
From relation of = to find length of link,
J= = 64 = 339.29mm4
=2 0.02 = 0.126
L= = = 1223.7 mm
Therefore the length of lever arm is 1223.7 mm.
CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1 Conclusion
Portable Gear box lifter is designed for high load resistance. The gear box lifter is simple in
use and does not required routine maintenance. We can use both the mild steel and cast iron
Page | 60
are good at their different aspects. Mild steel has greater durability strength and it is also cheap
and easily available. As these properties plays an important role in designing gear box lifter.
So in designing gear box lifter mild steel has greater importance.
All the studies in this project show that the maximum stress occurs at the carrier member.
From the analysis of the design it is obtained that all the design are safe.
5.2 Recommendation
During my internship program I observed so many problems in the company. If these

problems are solved or minimized, the company can get many additional profits. Beside this
makes a comfortable situation for the company employees to do their work tasks with
responsibility. Then the company should solve or minimize the following problems.
The Company should receive students according to its capacity
 Some employers especially technicians and mechanics need more safety, about them self and their
work.
 the company must focus on importing the spare parts for the required time.
 The material should be arranged in their station and supplied on its required time such as bolt, nuts,
washers etc.
The Company should employ more educated employees.
Give enough salary to the worker to keep them a long time
Give full maintenance for the machine before it stops working
Assign adviser to the student to help and advise the work experience what he has and
Adviser should be giving his respect to the student without consider status.
Reference
[1]. Scissor lift apparatus for work platforms and the like- Richard E.Cullity.
[2]. Donald Watkins “Scissor lift mechanism” (2004).
[3]. Enoch L. Newlin “Scissor lift mechanism employing telescopable electro-mechanical
based lift actuation arrangement” (2000).
[4]. Design and kinematic analysis of gear powered scissor lift- a.roys jeyange, m.babu.
Page | 61
[5]. Designed a belt-driven transportation system-Todd J. Bacon.

[6]. Scissors Type Lifting Platform by Hubert Wanner - US6464205B2.
[7]. Mathematical analysis of Actuator forces in a scissor lift, Technical document 1550, May
1989 by H. Spackman AD-A225220.
[8]. Spackman, H. (1989). Physical analysis of scissor Lifts. United States military research
publication.
[9]. A text book of machine Design by R.S Kurmi, and J.K Gupta.
[10]. Mechanical engineering design, eighth edition by Richard Gordon
Budynas.J. KeithNisbett.
Appendix
………………………………………………maximum height
………………………………………………….clearance height
Page | 62
………………………………………………….height of scissor lift

n……………………………………………………..factor of safety
L…………………………………………………….length of link
……………………………………………………length of power screw
…………………………………………………….force acting on power screw
……………………………………………………yield strength
…………………………………………………….von mises stress
…………………………………………………...allowable strength
…………………………………………………...ultimate strength
……………………………………………………..torque raise
………………………………………………………thrust collar friction coefficient
f……………………………………………………… coeffient of friction for thread pairs
…………………………………………………….torque lower
……………………………………………………buckling load
I……………………………………………………….moment of inertia
…………………………………………………….human capacity
M………………………………………………………module
R……………………………………………………….radius of lever arm
…………………………………………………….gear velocity ratio
…………………………………………………….radial load
Y………………………………………………………lewis form factor
…………………………………………………….number of teeth on large gear
…………………………………………………….number of teeth on pinion gear
Page | 63
Page | 64
Page | 65
Page | 66
Page | 67
Page | 68
Page | 69
Page | 70
Page | 71
Page | 72
Page | 73
Page | 74
Page | 75
Page | 76
Page | 77
Page | 78
Page | 79
Page | 80

Finished

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Finished

Uploaded by

Copyright:

Available Formats

Arba Minch University

Arba Minch Institute of Technology

A Report on Internship Work At

By: Daniel Anbelu ID: Ramit/501/08

October 10, 2019 G.C

CHAPTER THREE ....................................................................................................................... 24

Figure 1.2 ACBSE organizational structure…………………………………………………...4

Figure 1.3 Depot Structure…………………………………………………………………….5

Figure 2.1 Brake shoe………………………………………………………………………….8

Figure 2.2 steering oil pump and steering box…………………………………………………9

Figure 2.3 Engine block and Engine Head……………………………………………………12

Figure 2.4 Timing Box and Engine oil pump …………………………………………….......13

Figure 2.5 Assembled Engine and my work on it……….……………………………………13

Figure 2.6 Gear box with input shaft……………………………………………………….....14

Figure 2.7 Parts of gear box and gear box housing…………………………………………....14

Figure 2.8 Gear assembling and assembled gear box ………………………………………...15

Figure 2.9 Disassembled components of differential………………………………………....17

Figure2.12 Regulator and four way valves……………………………………………………20

Figure 2.13 Bishoftu bus under body maintenance…………………………………………...22

Figure 3.1 my work on the engine assembling……………………………………………………………………………………29

Figure: 4.1. Gear box lifter …………………………………………………………………...35

Figure: 4.2. Force acting on links at maximum position……………………………………...38

Figure: 4.3. Force acting on links at minimum position………………………………………39

Figure: 4.4. Force acting on power screw at maximum position……………………………...41

Figure: 4.5. Force acting on power screw at minimum position……………………………...42

Figure: 4.6. Terms screw thread……………………………………………………………...46

Figure: 4.7. Acme thread profile……………………………………………………….…….56

1.1 Company background and overviews

Figure 1.2 when first Bishoftu Articulated buses arrived

1.1.1 Main purpose for the establishment of ACBSE

1.1.2 Vision and mission of ACBSE

1.1.3 Major values and Principles of the Enterprise

1.2 Organizational structures

 Finance and Human resource division

Figure 1.2 ACBSE organizational structure

 Plan and data processing service

1.2.1 Major Section of the Enterprise

Figure 1.3 Depot Structure

1.3 Stuff profile of ACBSE

NO. WORK TIME MALE FEMALE TOTAL

3. Public transportation service directorate 700 449 1149

5. Finance directorate work team 12 80 92

6. Human resource work team 133 84 217

9. Lawyer work team 8 5 13

11. Communication work team 4 4 8

15. Jimma Branch 30 15 45

Table 1.1 Staff profile of ACBSE

Day Yeka Shegole Mekenisa Total

Tuesday 432,989.34 361,453.56 355,543.00 1,149,985.90

Wednesday 575,653.33 318,457.43 336,765.11 1,230,875.89

Thursday 448,094.45 387,234.40 312,855.55 1,148,184.40

Friday 531, 594.00 278,011.15 406,926.60 1,216531.75

Saturday 344,275.30 484,426.85 201, 446.60 1,030,148.75

Sunday 345,801.85 294,697.95 406,159.05 1,046,659.30

2. WORK, RESPONSIBILITIES AND ASSIGNMENT

2.1 Preventive maintenance shop

Some of the preventive maintenances are;

 Servicing of Brake Shoe

Figure 2.1 Brake shoe

 Servicing the steering system

Figure 2.2 steering oil pump and steering box

2.2 Engine Overhaul shop

 DAF engine and