Chapter 2 Concept Design Development

2.1. Design Process and Considerations

Designing a hydraulic jack is a complex process that involves several considerations. The
design process involves several stages, including conceptualization, design, analysis,
prototyping, testing, and production. The first stage involves conceptualization, where the
designer identifies the problem to be solved and the potential solutions. In the case of designing
a hydraulic jack, the problem could be how to lift heavy objects, which the solution could be the
use of hydraulic pressure.

The second stage involves design, where the designer creates a detailed design that specifies the
components required and how they will be assembled. In the case of designing a hydraulic jack,
the designer would need to specify the parts required, such as the piston, cylinder, hydraulic
pump, and hydraulic hoses, among others. The designer would also need to consider the size,
weight, and shape of the jack to ensure that it is portable and easy to use.

The third stage involves analysis, where the designer assesses the design to determine its
performance and the potential risks. In the case of designing a hydraulic jack, the designer
would need to consider the weight of the object that the jack will lift, the pressure required to
lift the object, and the safety measures required to prevent accidents. The designer would also
need to consider the operating conditions of the jack, such as the temperature, humidity, and
pressure.

The fourth stage involves prototyping, where the designer builds a working model of the jack to
test its performance and identify any design flaws. In the case of designing a hydraulic jack, the
designer would need to test the jack's ability to lift heavy objects, its stability, and the ease of
use. The designer would also need to identify any design flaws and make the necessary
adjustments.

The final stage involves testing and production. In the case of designing a hydraulic jack, the
designer would need to test the jack in various operating conditions to ensure that it meets the
required performance standards. After testing, the design would be finalized, and the jack would
be produced in large quantities. The designer would also need to consider the cost of production
and the market demand to ensure that the jack is priced competitively.

In conclusion, designing a hydraulic jack involves a complex process that requires careful
consideration of the design, analysis, prototyping, testing, and production stages. The designer
needs to identify the problem to be solved, create a detailed design, assess the design's
performance, build a working model, test the jack in various operating conditions, and produce
the jack in large quantities. The designer also needs to consider the size, weight, and shape of
the jack, the operating conditions, the required pressure and safety measures, the ease of use,
and the cost of production. Overall, the design process requires an interdisciplinary approach
that involves various fields such as mechanical engineering, physics, and materials science.
Elements considered in the design of a hydraulic jack

Hydraulic jacks are essential pieces of equipment for a wide range of industries including
construction, mining, and automotive. A hydraulic jack is designed to lift heavy loads, and it
achieves this through the use of hydraulic oil, which is used to increase pressure within the jack.
The design of hydraulic jacks is critical as it determines their effectiveness and safety. In this
essay, I will discuss the elements that are considered in designing a hydraulic jack.

1. Load capacity - This refers to the amount of weight that the jack can handle. The load
capacity is usually determined by the size of the piston and the maximum pressure that the
hydraulic pump can generate. A jack with a high load capacity is ideal for lifting heavy
machinery and equipment.

2. Lifting height - This refers to the maximum height that the jack can lift a load. The lifting
height is determined by the length of the hydraulic cylinder. The cylinder length directly
influences the jack's overall size, so designers must balance the lifting height with the jack's
portability.

3. Safety - Safety is paramount in any design, and hydraulic jacks are no exception. Improper
use of a hydraulic jack can result in accidents, so designers must consider safety from the onset.
Safety features such as overload protection, pressure relief valves, and safety locks are often
incorporated into hydraulic jack designs.

4. Portability - Hydraulic jacks are often used in various work environments, so designers must
ensure that they are easy to move from one location to another. The weight of the jack, the size
of the handles, and the mobility of the wheels all play a significant role in the jack's portability.

5. Durability - Hydraulic jacks are subjected to heavy loads and use, so they must be made with
materials that can withstand the rigorous demands. The material used in the manufacture of the
jack must be strong, corrosion-resistant, and durable. Additionally, regular servicing and
maintenance are critical in ensuring that the jack remains functional and safe to use.

In summary, the design of a hydraulic jack is critical to its function, safety and longevity. Design
factors such as capacity, lift, safety, portability and durability play an important role in the design
of an effective and safe hydraulic jack. By considering these factors, designers can develop
highly efficient, durable hydraulic jacks suitable for a variety of industries.

2.2. Design Specification/ Requirement List (Define how the System must do it)

design specification
Device Driving Capacity (ton) Minimum Maximum
Mechanism Height (mm) Height (mm)
Bottle jack Hydraulic 6.5 214 341
To lift a 6.5-ton weight with a maximum and minimum height of 341mm and 214mm
respectively, a hydraulic jack system with the following specifications and requirements is
necessary:

1. Load Capacity: The hydraulic jack must have a load capacity of at least 6.5 tons (14,300 lbs.)
to lift the weight.

2. Lifting Range: The hydraulic jack must have a lifting range that accommodates the maximum
and minimum height requirements of 341mm and 214mm, respectively.

3. Pumping Speed: The hydraulic jack must have a pumping speed that is sufficient to lift the
weight to the required height in a reasonable amount of time.

4. Safety Features: The hydraulic jack should be equipped with safety features such as overload
protection, safety valves, and locking mechanisms to ensure safe operation.

2.3. Concept Models

2.3.1. Functional descriptions

Hydraulic jacks are widely used in different industries, from automotive to construction.
They are designed to lift heavy loads and apply force through the compression of an
incompressible hydraulic fluid. They consist of various components working together to
perform the lifting operation.

The hydraulic jack's primary component is the hydraulic cylinder, which contains a
piston connected to a piston rod. The piston divides the cylinder into two
compartments, one filled with hydraulic fluid and the other with air or gas. The piston
and piston rod together create the lifting force when the hydraulic fluid is pumped under
pressure. As the pressure increases, the piston moves up, and the load on top of it is
lifted.

Another crucial component of a hydraulic jack is the hydraulic pump, which creates
pressure in the hydraulic fluid inside the cylinder. The pump can be operated manually,
with a lever, by foot, or by an electric motor. The pump assembly commonly comprises
a reservoir to hold the hydraulic fluid, an intake port for fluid entry, an output port for
fluid discharge, and a pressure relief valve to prevent overloading or damaging the
components.

The release valve is another essential part of the hydraulic jack responsible for
controlling the descent of the jack's load. When the valve is opened, the hydraulic fluid
is allowed to flow back to the reservoir, and the load slowly descends. The valve is
located in the hydraulic cylinder, and it is typically controlled by a handle attached to
the cylinder's release mechanism.
To increase stability and safety during lifting, the base plate is another significant
component of a hydraulic jack. The base plate is typically made from solid steel and
has a broad flat surface area to provide support for the jack and the load. It helps
distribute the force evenly across the ground, ensuring that the jack doesn't tip over or
sink into soft surfaces, which can result in accidents or damage to the jack.

Lastly is the handle of the hydraulic jack, which is used for manual pumping of the
hydraulic fluid. The handle is usually attached to the hydraulic pump and can be
adjusted to a comfortable height and angle for the operator. The handle is designed to
provide optimum leverage to make the pumping operation less strenuous, allowing the
user to lift heavier loads with ease.

In conclusion, the hydraulic jack consists of various components that work together to
perform the lifting operation, such as the hydraulic cylinder, hydraulic pump, release
valve, base plate, and handle. Understanding the functional description of each
component's role is vital for operating hydraulic jacks safely and effectively. The
knowledge of the hydraulic jack's components is essential for graduate students in
mechanical engineering, automotive engineering, and civil engineering, among others,
as they will often encounter hydraulic jacks in their field of study or workplace.
2.4. Selected Concepts

2.4.1. Design objectives, key features

The design objectives of hydraulic jacks include
 Safety
 ease of use
 durability, and
 efficiency.

The key features of hydraulic jack design are the cylinder, piston, pump, and valve mechanism.
Safety is one of the primary objectives in designing hydraulic jacks. Jacks should be capable of
lifting a heavy load without any risk of buckling, bending, or failing. A high-quality hydraulic
jack should have enough safety features, like a relief valve, to prevent sudden or unexpected
drops of the load. Also, hydraulic jacks should be made with sturdy materials that can handle
heavy loads. The materials used for hydraulic jack design should be resistant to the corrosive
and abrasive elements of the environment.

The ease of use is a key feature of hydraulic jack design objectives. Hydraulic jacks should be
intuitive to use and safe for anyone. They should be easy to assemble, and the instructions
should be clear and concise. Hydraulic jacks should also be lightweight and portable as per their
design. The design should allow for easy storage and transport while not compromising the
power or lifting capacity of the jack.

Another objective in hydraulic jack design is durability. The materials used in the design of
hydraulic jacks are typically strong enough to withstand heavy loads. However, wear and tear of
the jack mechanism parts are the common factors decreasing the life of hydraulic jacks. To
address this, hydraulic jack designers should ensure that the moving parts of the jack are
lubricated often with suitable lubricants for optimal performance. Materials, like high-grade
metal alloys, brass, and stainless steel, should be used to create hydraulic jacks that are durable,
long-lasting, and can withstand harsh environments.

Efficiency is another key objective in hydraulic jack design. Hydraulic jacks should be efficient
in terms of energy use, speed, and lifting capacity. They should have high-pressure resistance,
and the lifting capacity should be proportional to the pressure applied. Modern hydraulic jacks
have high-speed pumps and hydraulic systems, which allow for fast lifting and positioning of
the load.

To achieve these objectives, designers must consider the key features of hydraulic jack design,
including the cylinder, piston, pump, and valve mechanism. With a well-designed hydraulic
jack, the lifting of heavy loads becomes easy and safe. The primary considerations for hydraulic
jack designers should be the safety, ease of use, durability, and efficiency of the jack to keep up
with the dynamic industrial and automotive environments.
2.4.2. Alternative design concepts
There are several alternative design concepts for achieving the goal of a hydraulic jack,
depending on the specific requirements and constraints of the application. Over time, different
concept models for hydraulic bottle jacks have been developed to improve their operation and
functionality. some of the alternative hydraulic bottle jack models available and the advantages
they offer will be discussed here.

One concept model for hydraulic bottle jacks is the Multi-stage hydraulic bottle jack. This
type of jack features two or three hydraulic stages that allow it to lift heavier loads than standard
bottle jacks. The multi-stage hydraulic bottle jack is ideal for applications such as lifting
vehicles and heavy machinery, making it a popular choice in automotive and construction
industries.

Another concept model is the Low-profile hydraulic bottle jack. This type of jack is designed
to be shorter in height, making it suitable for applications where space is limited. The low-
profile hydraulic bottle jack is commonly used for lifting cars and trucks where the jack must fit
underneath the vehicle's frame and the space is tight.
One other concept model is the Air hydraulic bottle jack. This type of jack works by using
compressed air to build up hydraulic pressure, which then lifts the load. The air hydraulic bottle
jack offers faster lifting times than traditional hydraulic jacks, making it a popular option in
industrial applications where time is of the essence.

A concept model that has become increasingly popular in recent years is the Electric hydraulic
bottle jack. This type of jack uses an electric motor to generate hydraulic pressure, making it
ideal for applications where portability and ease of use are important. Electric hydraulic bottle
jacks are commonly used for home repairs and maintenance, making them a great addition to
any DIY enthusiast's toolbox.
In conclusion, the hydraulic bottle jack is a common and essential tool across various industries.
As technology advances, new concept models have been developed to address the limitations of
traditional hydraulic jacks. These models cater to different needs and preferences of users
making them an essential asset in any industry. By exploring these concept models, industries
can make informed decisions about the type of hydraulic bottle jack that works best for their
specific needs.

2.4.3. Evaluation and comparison of competing design concepts

Multi- Low- Air HJ Electri Hj

stage profile c
HJ HJ
Selection weigh Rating scor Ratin scor Ratin scor Rating scor
criteria t e g e g e e
(10) (10)
(10) (10)
Safety 20% 9 1.8 8 1.6 9 1.8 8 1.6
Positional 35% 10 3.5 8 2.8 9 3.15 7 2.45
Accuracy
Ease of 10% 8 0.8 9 0.9 7 0.7 10 0.8
control
Ease of 20% 7 1.4 8 1.4 9 1.8 6 1.2
manufactur
e
Durability 15% 9 1.35 8 1.2 7 1.05 6 0.9
Total 100% 8.85 7.9 8.5 6.95
score
Rank 1 3 2 4
Continue develo
? p

2.4.4. Presentation and comments on the concepts

Based on safety, safety ratings can vary depending on various factors, including the specific
design, construction quality, and proper use and maintenance. However, based on general safety
considerations, here is a ranking of the following hydraulic jacks and a rating out of 10:
1. Multi-stage hydraulic jack - 9/10: Multi-stage hydraulic jacks are generally safe to use as they
provide greater stability and control during lifting. However, it's important to ensure proper
maintenance of the jack, including checking for leaks and maintaining the hydraulic fluid level.

2. Low-profile hydraulic jack - 8/10: Low-profile hydraulic jacks are generally safe to use, but
they can be unstable if not positioned correctly. It's important to ensure that the lifting surface is
level and stable before using a low-profile hydraulic jack.

3. Air hydraulic jack - 9/10: Air hydraulic jacks are generally safe to use, but proper maintenance
is necessary to prevent leaks and ensure the jack is functioning properly. It's also important to
ensure the jack is properly positioned before use.

4. Electric hydraulic jack - 8/10: Electric hydraulic jacks are generally safe to use, but it's
important to ensure proper maintenance of the jack including the wires.

Based on positional accuracy, here is a ranking of the following hydraulic jacks and a rating out
of 10:

1. Multi-stage hydraulic jack - 10/10: Multi-stage hydraulic jacks have excellent positional
accuracy due to their ability to extend and retract in small increments. This allows for precise
positioning of the load, making them ideal for applications that require high accuracy.

2. Low-profile hydraulic jack - 8/10: Low-profile hydraulic jacks have decent positional
accuracy, but they may not be as precise as multi-stage jacks due to their limited range of
motion. However, they are still suitable for many applications that require accurate positioning.

3. Air hydraulic jack - 9/10: Air hydraulic jacks have good positional accuracy, but their
accuracy may be affected by factors such as air pressure and the condition of the jack. Proper
maintenance and calibration can help ensure accurate positioning.

4. Electric hydraulic jack - 7/10: Electric hydraulic jacks may have limited positional accuracy
due to the speed and range of their motion. However, they can still be suitable for many
applications that do not require high levels of precision. Proper maintenance and calibration can
help improve accuracy.

Electro-hydraulic jacks are superior to multi-stage hydraulic jacks, low-profile hydraulic jacks,
and hydraulic-air jacks because they operate the jacks with simple electricity, making them
easier to control.

Pneumatic jacks consisting of simple parts are superior because they are easier to manufacture
than electric jacks which contain complex parts that are not easy to manufacture.

In terms of durability, multi-stage hydraulic jacks and low-profile hydraulic jacks are more stable
than the other two and are the most durable.