PROJECT REPORT

ON

“BUTTON OPERATED HYDRAULIC JACK”

In the partial fulfillment of the requirement for the Diploma in Mechanical Engineering

SUBMITTED BY

MR. DOME ADESH SONYABAPU 2214660289

MR. GHULE CHAITANYA ASHOK 2214660292

MR. AVDHUT MAYUR MOHAN 2214660299

MR. SATHE DARSHAN SANJAY 2214660302

Under the guidance

of

Prof.ZANJAD.S.V

SUBMITTED TO

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

DEPARTMENT OF MECHANICAL ENGINEERING

SHREE SAMARTH POLYTECHNIC, MHASNE PHATA, PARNER, AHMEDNAGAR

SHREE SAMARTH ACADEMY’S

SHREE SAMARTH

POLYTECHNIC

DEPARTMENT OF MECHANCALENGINEERING
 CERTIFICATE

This is to certify that project report,

MR. DOME ADESH SONYABAPU

MR. GHULE CHAITANYA ASHOK

MR. AVDHUT MAYUR MOHAN

MR. SATHE DARSHAN SANJAY

Has satisfactorily carried out and completed the project work

entitled,
“BUTTON OPERATED HYDRAULIC JACK”

This work is being submitted for the award of diploma in mechanical engineering.

It is submitted in the partial fulfillment of the prescribed syllabus of Maharashtra State

Board Of Techincal

Education For the Academic

Year 2023-24

Guide Head of Department Principal

(Prof.Zanjad.S.V) (Prof. Shelar.R.G.) (Prof. Patare.A.M.)

 MAHARASHTRA STATE BOARD OF TECHNICAL
EDUCATION

Shree Samarth Polytechnic, Mhasne phata, tal : Parner, Dist: Ahamadnagar

Department of Mechanical

Engineering 2023-24

This is to certify that the project work entitled

“BUTTON OPERATED HYDRAULIC JACK”

Has been successfully carried out & submitted by

MR. DOME ADESH SONYABAPU

MR. GHULE CHAITANYA ASHOK

MR. AVDHUT MAYUR MOHAN

MR. SATHE DARSHAN SANJAY

At Shree Samarth Polytechnic

Department of Mechanical

Engineering 2023-24

Internal Examiner External Examiner

Date :-
Place :-
 CERTIFICATE

This is certify that project work entitled “BUTTON OPERATED HYDRAULIC JACK”
a bonafide work carried out by following students in partial fuifillment for the award of
“Diploma in Mechanical Engineering” during the year 2023-24 as required by the
Maharashtra state Board of Technical Education, Mumbai. The Project report has been
approved asit satisfies the Academic requirements in respect of project work prescribed by
MSBTE, Mumbai.

GROUP MEMBER ENROLLMENT NO. EXAM SEAT NO.

1. MR. DOME ADESH SONYABAPU 2214660289

2. MR. GHULE CHAITANYA ASHOK 2214660292

3. MR. AVDHUT MAYUR MOHAN 2214660299

4. MR. SATHE DARSHAN SANJAY 2214660302

Guided By

Prof. Zanjad

.S.V

Sign:-

Date :-

Place :-
 ACKNOWLEDGEMENT

It gives me great pleasure to express my gratitude and heart full thanks to all those who are
helping me in complete this project

I want to thank to “Prof. Zanjad .S.V.”, who has always encouraged and help me in
making this project. In addition to this, I am grateful to other faculties too who made me in
right direction and gave me their precious time and expert guidance whenever necessary
through which I could achieve this extent. We are indeed to very thankful to our college
principal Prof. Desale D.D. and Head of department Prof. Shelar R.G. For their kindly
help
. We are also thankful to all the staff of Mechanical Engineering Department by their
co- operation the project is completed successfully and also thankful to all the friend to
give us many help regarding this project

At last but not the least I am feeling glad to say about my family whose
wishes are always with me, without which it was not possible for me to reach this
extent.
I hope my work is praised and my efforts render fruitful result.

THANK YOU..!

Projected By,

MR. DOME ADESH SONYABAPU

MR. GHULE CHAITANYA ASHOK

MR. AVDHUT MAYUR MOHAN

MR. SATHE DARSHAN SANJAY

 ABSTRACT

This project work titled “BUTTON OPERATED HYDRAULIC

JACK” has been conceived having studied the difficulty in lifting the any type
of light vehicles. Our survey in the regard in several automobile garages,
revealed the facts that mostly some difficult methods were adopted in lifting the
vehicles for reconditioning.

Now the project has mainly concentrated on this difficulty, and hence a
suitable device has been designed. Such that the vehicle can be lifted from the
floor land without application of any impact force. The fabrication part of it has
been considered with almost case for its simplicity and economy, such that this
can be accommodated as one of the essential tools on automobile garages.
 CONTENTS

Sr. No. Title Page No.

Title 1

Certificate 2

Examiner Certificate 3

Acknowledgement 4

Abstract 5

Contents 6

List Of Figures 7

Photographs 8
1. Introduction 10-13

1.1 Hydraulics
1.2 Hydraulics Basics
2. Literature Survey.

2.1 Introduction
2.2 Working Principle
2.3 Project Layout
3. Problem Definition
4. Methodology 14
5. Basic Systems/ Devices.

5.1 Hydraulic Press

5.2 Hydraulic Brakes
5.3 Hydraulic Intensifier
5.4 Hydraulic Jack
5.5 Types of Hydraulic Jack
6. Design.
6.1 Hydraulic Cylinder
6.2 Design consideration of Hydraulic Cylinder
6.3 Power transmission
6.4 Calculations
6.5 Motor specifications
6.6 Hydraulic jack specifications
7. Construction and working

7.1 Working of jack

7.2 Hydraulic pump
7.3 Rotary vane pump
7.4 Control Unit
7.5 Relief valve
7.6 Oil reservoir
7.7 DC motor
7.8 Installation
7.9 Maintenance
7.10 Safety Precaution’s
8. Silent features

8.1 Advantages
8.2 Limitations
8.3 Applications
9. Cost sheet
9.1 Cost estimation
9.2 Cost of project

10. • Result.

• Conclusion

11. References.
 List of Figure

Fig. Title of Figure Page

No. No.
1.1 Pascal law
2.1 Project Layout
5.1 Principle of hydraulic press
5.2 Hydraulic brakes
5.3 Hydraulic intensifier
5.4 Hydraulic jack
5.5 Air hydraulic jack
5.6 Bottle hydraulic jack
5.7 Hydraulic floor jack
5.8 Toe jack
5.9 Pneumatic jack
5.10 Trailer hydraulic cylinder jack
6.1 Hydraulic cylinder designed for jack
6.2 Hydraulic cylinder designed for jack (Exploded view)
6.3 Exploded view of hydraulic bottle jack
7.1 Part of rotary vane pump
7.2 Working of rotary vane pump
7.3 Control unit assembly
7.4 Relief valve view
PHOTOGRAPHS
 Chapter No.:1

INTRODUCTION

1.1 HYDRAULICS:

Hydraulics is a topic in applied science and engineering dealing with the

mechanical properties of liquids. Fluid mechanics provides the theoretical foundation
for hydraulics, which focuses on the engineering uses of fluid properties. In fluid
power, hydraulics is used for the generation, control, and transmission of power by
the use of pressurized liquids.

Hydraulic topics range through most science and engineering disciplines, and
cover concepts such as pipe flow, dam design, fluidics and fluid control circuitry,
pumps, turbines, hydropower, computational fluid dynamics, flow measurement, river
channel behavior and erosion.

1.2 HYDRAULIC BASICS:

• PRESSURE

Pressure is force exerted against a specific area (force per unit area) expressed
in psi (pounds per square inch), Bar or Pascal. Pressure can cause an expansion, or
resistance to compression, of a fluid that is being squeezed. A fluid is any liquid or
gas (vapor).

An example of pressure is the air (gas) that fills an automobile tyre. As a tyre
is inflated, more air is squeezed into it than it can hold. The air inside a tyre resists the
squeezing by pushing outward on the casing of the tyre. The outward push of the air is
pressure. Equal pressure throughout a confined area is a characteristic of any
pressurized fluid. For example, in an inflated tyre, the outward push of the air is
uniform throughout. If it were not, a tyre would be pushed into odd shapes because of
its elasticity.

P = F/A

Units of pressure:

MKS Units - Kgf/m² and Kgf/cm²

SI Units - Newton/m² and N/mm²

N/mm² is known as Pascal and represented by Pa. Other commonly used units of
pressure are psi(pound per square inch) and bar.

1 Pascal (N/m²) = 10^-5 Bar = 145.04x10^-6 psi

 • FORCE:

The force is an external agent which produces or tends to produce change in

the state of rest, motion, shape or size of an object and is expressed in Newton. It is a
vector quantity. The Newton is the SI unit for force

An example of force is to raise a body, to displace a body from one place to

the other, to stop a moving body etc. The relationship of force, pressure, and area is as
follows:

F = P.A

Where,

F = force

P= Pressure in psi

A = Area

• PASCAL'S LAW:

Blaise Pascal formulated the basic law of hydraulics in the mid 17th century.
He discovered that pressure exerted on a fluid acts equally in all directions. His law
states that pressure in a confined fluid is transmitted undiminished in every direction
and acts with equal force on equal areas and at right angles to a container's walls.

Fig.:1.1
Pascal’s law
 According to this law, "In a closed liquid the pressure applied at any part is
equally transmitted in all directions and in the same amount".

Or

"If a liquid is in equilibrium then the pressure in every part of it is equal."

i.e.

P₁= P₂

F/A=f/a

F = fA / a

• FLOW:

Flow is the movement of a hydraulic fluid caused by a difference in the

pressure at two points. In a hydraulic system, flow is usually produced by the action
of a hydraulic pump a device used to continuously push the hydraulic fluid. The two
ways of measuring flow are velocity and flow rate.

• VELOCITY:

Velocity is the average speed at which a fluid's particles move past a given
point, measured in m/s. Velocity is an important consideration in sizing the hydraulic
lines that carry a fluid between the components.

• FLOW RATE:

Flow rate is the measure of how much volume of a liquid passes a point in a
given time, measured in Liter per minute (LPM). Flow rate determines the speed at
which a load moves and therefore, is important when considering power.

• VISCOSITY:

Viscosity is defined as the property of a fluid which offers resistance to

movement of one layer of fluid over another adjacent layer of fluid.

Units of Viscosity:

MKS Units - Kgf-sec / m²

CGS Units -

dyne-sec/cm² SI Units -
Newton-sec/m²
 Chapter No.:2

LITERATURE SURVEY

2.1 INTRODUCTION:

This project work titled “Motorized Hydraulic Jack” has been studied the
difficulty in lifting any type of light vehicles. The project is mainly concentrated on
the lifting of vehicle for different purposes and hence a suitable device has been
designed such that the vehicle can be lifted easily from the floor without any impact
on vehicles. The fabrication part of it has been considered with almost case for its
simplicity and economy, such that this can be accommodated as one of the essential
tools on automobile garages.

The D.C. motor is coupled with the hydraulic jack by cam mechanism. The
cam shaft moves up and down depends upon the rotation of D.C motor by cam
mechanism. This is a simple type of automation project.

2.2 WORKING PRINCIPLE

➢ PRINCIPLE PASCAL’S LAW:

“It states that the intensity of pressure at any point in a fluid at rest is
the same in all direction”

Old system of car lifting.

 ➢ WORKING PROCEDURE:

The block diagram of motorized hydraulic jack is shown in fig. The

lead- acid battery is used to drive the D.C. motor. The D.C.motor shaft is
connected to the cam wheel. If the power is given to the D.C. motor, it will
run so that the cam wheel also runs

➢ ADVANTAGES:
• Handling is easy

• No Manual power

• Easy to Repair.

• Replacement of parts are easy

2.3 Project Layout:

 Chapter No.:3

PROBLEM DEFINATION

When we was used any hydraulic car jack for lifting the vehicle, then we want
to take more efforts for lifting the car. The hydraulic car jack lifting speed is very
slow compared to new, the human lifting the jack in upward direction a speed doesn’t
have a continuously same or fast speed to lifting the jack. Human lifting jack they
needs too much energy for this work and also they are tired.

We need a car jack for lifting of the vehicle easily, it will take more space, and
we are not move the jack easily because of the weight of jack. We want a small,
compactable, less weight jack to move anywhere and easily without more efforts.

To solve these major problems, we manufactured the motorized hydraulic car

jack in which human efforts for lifting car will reduces. We want to only switch on
the power button of the jack and it will start lifting the vehicle automatically. In these
we also give a more important future is less weight, compact in size. It will occupied
less space and less efforts for taking anywhere we want.
 CHAPTER NO. 4

METHODOLOGY

GROUP DISCUSSION ABOUT TITIE

FIND THE 5 TITLES

FINAL SELECTION OF TITLE

FINDING IMFORMATION

MAKING A DESIGN OF MACHINE

ASSEMBLE AND WELDING OF MACHINE

REQUIREMENT OF MODIFICATION OF PROJECT

RESULT
 Chapter No.:5

BASIC SYSTEMS/DEVICES.

5.1 HYDRAULIC PRESS

Another useful application of the force magnifying action of liquid pressure is

the hydraulic jack or hydraulic press Figure-2.

The pressure exerted by the force on the small piston on the left of the diagram
is transmitted through the liquid. This means that large objects can be lifted by the
cylinder on the right or large forces can be exerted on object held beneath the top
plate as shown by the hydraulic press in Figure 2.

Fig.:5.1
Principle of Hydraulic Press.

APPICATIONS:
Hydraulic presses are commonly used for forging of metal parts. Some of the
largest in the world were built by the Heavy Press Program.

5.2 HYDRAULIC BRAKES:

Automotive brake systems are complex hydraulic circuits. In a hydraulic brake

system, the master cylinder serves as the main fluid pump and moves the liquid
through the system.
 The lines used to carry the liquid may be pipes, hoses, or a network of
internal bores or passages in a single housing, such as those found in a master
cylinder. Valves are used to regulate hydraulic pressure and direct the flow of the
liquid. The output device is the unit that uses the pressurized liquid to do work. In the
case of a brake system, the output devices are brake drum wheel cylinders and disc
brake calipers.

Fig.:5.2.
Hydraulic Brakes.

5.3 HYDRAULIC INTENSIFIER:

A hydraulic for intensifier is a hydraulic machine transforming hydraulic

power at low pressure into a reduced volume at higher pressure. Such a machine may
be constructed by mechanically connecting two pistons, each working in a separate
cylinder of a different diameter. As the pistons are mechanically linked, their force
and stroke length are the same. If the diameters are different, the hydraulic pressure in
each cylinder will vary in the same ratio as their areas: the smaller piston giving rise
to a higher pressure. As the pressure is inversely proportional to the area, it will be
inversely proportional to the square of the diameter.

The working volume of the intensifier is limited by the stroke of the piston.
This in turn limits the amount of work that may be done by one stroke of the
intensifier. These are not reciprocating machines (i.e. continually running multi-stroke
machines) And so their entire work must be carried out by a single stroke. This
limits their
usefulness somewhat, to machines that can accomplish their task within a single
stroke. They are often used where a powerful hydraulic jack is required, but there is
insufficient space to fit the cylinder size that would normally be required, for the
lifting force necessary and with the available system pressure. Using an intensifier,
mounted outside the jack, allows a higher pressure to be obtained and thus a smaller
cylinder used for the same lift force. Intensifiers are also used as part of machines
such as hydraulic presses, where a higher pressure is required and a suitable supply is
already available.

Some small intensifiers have been constructed with a stepped piston. This is a
double-ended piston, of two different diameters, each end working in a different
cylinder. This construction is simple and compact, requiring an overall length little
more than twice the stroke. It is also still necessary to provide two seals, one for each
piston, and to vent the area between them. A leak of pressure into the volume between
the pistons would transform the machine into an effective single piston with equal
area on each side, thus defeating the intensifier effect.

Fig.:5.3.
Hydraulic Intensifier.
 A mechanically compact and popular form of intensifier is the concentric
cylinder form, as illustrated. In this design, one piston and cylinder are reversed:
instead of the large diameter piston driving a smaller piston, it instead drives a smaller
moving cylinder that fits over a fixed piston. This design is compact, and again may
be made in little over twice the stroke. It has the great advantage though that there is
no "piston rod" and the effective distance between the two pistons is short, thus
permitting a much lighter construction without risk of bending or jamming.

5.4 HYDRAULIC JACK:

Hydraulic jacks are device used to lift the loads. Hydraulic jacks are used for
shop works, lifting vehicles, lifting houses from their foundation. Hydraulic jacks are
often used to lift elevators in low and medium rise buildings.

A hydraulic jack uses a fluid, which is incompressible, that is forced into a

cylinder by a pump plunger. Oil is used since it is self-lubricating and stable. When
the plunger pulls back, it draws oil out of the reservoir through a suction check valve
into the pump chamber. When the plunger moves forward, it pushes the oil through a
discharge check valve into the cylinder.

Fig.:5.4.
Hydraulic jack.
 The suction valve ball is within the chamber and opens with each draw of the
plunger. The discharge valve ball is outside the chamber and opens when the oil is
pushed into the cylinder. At this point the suction ball within the chamber is forced
shut and oil pressure builds in the cylinder.

Hydraulic jack is a device used lifting a jack to automobile, heavy machines.

Thus, a hydraulic jack is a mechanical arrangement that uses the power of fluids
(hydraulic - study of mechanical property of fluids) to lift really heavy objects and we
are using oil, hence the jack as a means of power transmissions.

5.5 USE BOTTLE JACK

In a bottle jack the piston is vertical and directly supports a bearing pad that
contacts the object being lifted.

Fig.:5.6.
Bottle Hydraulic Jack
 With a single action piston the lift is somewhat less than twice the collapsed
height of the jack, making it suitable only for vehicles with a relatively high
clearance.

For lifting structures such as houses the hydraulic interconnection of multiple

vertical jacks through valves enables the even distribution of forces while enabling
close control of the lift.
 Chapter No.:6

DESIGN.

Design consists of application of scientific principles, technical information

and imagination for development of new or improvised machine or mechanism to
perform
a specific function with maximum economy &efficiency Hence a careful design
approach has to be adopted.

6.1. HYDRAULIC CYLINDER:

The cylinder fabricated for the jack have a sleeve in which the piston
reciprocates while operation. The cylinder material is cast iron and welded with an
iron base plate. The plate is gas welded below the hollow cast iron cylinder. There is
an opening for oil in the base of cylinder.

A cast iron head cover is designed for covering the cylinder from upper end.
The piston have an oil rubber ring to seal the fluid in cylinder while operation. The
piston rod is fitted with the piston and screw nut on other end. The head cover is
locked with the help of circle lock. A hole is made in the head cover to release air
from the upper hollow portion of cylinder while reciprocating motion.

When fluid (oil) pushed by the pump into the cylinder from the inlet opening
given below, it pushes the piston up in the cylinder and thus linear motion is obtained
by displacement of piston in the cylinder.

CYLINDER SPECIFICATION

✓ Cylinder internal diameter: 76mm

✓ Cylinder outer diameter: 94 mm

✓ Stroke 116.5 mm

✓ Volume of cylinder 528.22 ml

✓ Base plate diameter 115 mm

✓ Piston length 15 mm

6.2 DESIGN CONSIDERATION OF HYDRAULIC

CYLINDER:
 A hydraulic actuator receives pressure energy and converts it to mechanical
force and motion. An actuator can be linear or rotary. A linear actuator gives force
and motion outputs in a straight line. It is more commonly called a cylinder but is also
referred to as a ram, reciprocating motor, or linear motor.
 A rotary actuator produces torque and rotating motion. It is more commonly
called a hydraulic motor or motor. Cylinders are linear actuators which convert fluid
power into mechanical power. They are also known as JACKS or RAMS. Hydraulic
cylinders are used at high pressures and produce large forces and precise movement.
For this reason they are constructed of strong materials such as steel and designed to
withstand large forces.

Fig.:6.1.
Hydraulic Cylinder Designed For Jack

Lifting capacity: 1000kg

Pump max pressure: 22 bar @1000 rpm

⇨ 224337.56 kgf/m²

W = PXA
⇨ 1000224337.56 x 3.14 xr²
 r = .0376 m = 37.67 mm

Therefore Diameter, rx 2 = 75.35 mm

(Approx. 76 mm considered)

Fig.:6.2
Hydraulic Cylinder Designed For Jack (Exploded view)
 Fig.:6.3.
Exploded view of Hydraulic Bottle Jack.
6.3 POWER TRANSMISSION:
In this jack power is transmitted with the help of gears.

Gears are generally used for one of four different reasons:

• To reverse the direction of rotation.

• To increase or decrease the speed of rotation

• To move rotational motion to a different axis

• To keep the rotation of two axis synchronized

Power is transmitted from the motor to pump, the gear fitted on the motor spline is
the driver gear and the gear fitted to the pump shaft is the driven gear. The driver gear
have 24 teeth’s while the driven gear have 68 teeth’s.

If two gears are in mesh, then the product of speed and teeth is conserved
 Therefore

S₁ x T₁ = S₂ x T₁
Here

T= Number of Teeth’s

S = Speed or Rpm

Thus,

Driver gear teeth’s (T₁) = 24

Driven gear teeth’s (T₂) = 68

24 x S₁ = 68 x S₂

⇨ S₁/S₂ =2.833

The ratio of rpm of the driver to the driven gear is 2.833

6.4 Calculations:

Here,
W- Weight of the car.

C- Distance between the center of gravity and rear

axle. b- Distance between the CG and font axle.

l- Length between the axle of front and rear

wheel. h- Height of center of gravity.

Acceleration for stable,

Wf = (C/L)* W............For front wheel

& Wf = (b/L) * W.........For Rear Wheel

Wf = (C/L)* W

= (179/268) * 1800
 = 1202.23 Kg

& Wf = (b/L) * W

= (89/268) * 1800

= 597.76 Kg

Here, for lifting the back side of car we need 598 N of force required and for
lifting the front side the required force is 1202 N approx.

Again, for one tire of backside the net required force is 299 N i.e. (598/2) &
for front side it is (1202/2) = 601 N.

So, we required the hydraulic jack which have the lifting capacity up to 1000
Kg i.e. 1 Ton & we got with capacity up to 2 Ton.

For Ft = 601 N, lifting this force we required 60 to 65 n of force for small

cylinder to create pressure for lift required weight.

Now,

F = m*a

F = 6.4285 * 9.8

F=63N

Hence, Torque, = F * r

Here, r = the distance of crank in slider crank mechanism from the fixed point of
jack and the crank shaft of DC

= 63 * 0.35
= 22.05 N-m
= 224.91 Kg-cm

Now, by observing the lifting time of hydraulic jack, we required the speed of 100
to 120 rpm. Hence, we considered the 120 rpm required.

So,
Power, P= 2 π NT/60

= 2π*120*22.05 / 60

P = 276 Watt

Hence, according to our calculation there is no perfect DC motor available in market

but by approximation of our calculation the motor is available of other specification.
6.5 Motor Specification:

✓ Name: MYZ3- 350 W DC motor

✓ Motor Magnet Type Permanent Magnet

✓ Operating Voltage 12 to 24 V

✓ Torque 22 N-m i.e. 225 kg-cm

✓ Max. Current approx. 13 to 19 A

✓ Type of motor DC

✓ Power 350 Watt

✓ Speed 2000 to 6000 rpm

6.6 Hydraulic Jack Specifications:

✓ Name Hydraulic Bottle Jack

✓ Material Alloy Steel, Cast Iron

✓ Capacity 2 ton 30 ton

✓ Usage or application Heavy duty vehicle lifting

✓ Lifting Height 181-370 mm

 CHAPTER NO. 7

CONSTRUCTION AND WORKING

7.1 WORKING OF JACK:

The cylinder of the jack is placed according to the lifting position of the
vehicle. After that terminal wires are connected according to polarity, positive
terminal wire is connected to the positive terminal of the battery with the help of
battery clip, while negative terminal is connected to the vehicle body at any point near
to the jack. Now after connections jack is ready to lift the load or vehicle. When the
starter switch is pushed. The motor starts rotating the pump. Thus pump pushes the
high pressure fluid into the control unit. This fluid passes through the delivery valve
and moves to the cylinder with the help of flexible hydraulic hose. As soon as oil goes
into the cylinder the piston in the cylinder starts moving up. Pump sucks the oil from
tank and delivers it to the cylinder. The jack starts lifting the load and stops after
completion of stroke of the piston. Now after releasing the switch the vehicle remain
raised, as the return flow of oil is stopped by the delivery valve fitted in the control
unit. The relief valve reliefs the pressure if the load is exceeding the maximum lifting
capacity and also if switch is not released after completion of stroke.

Now to lower down the load on jack the oil filled in the cylinder which tends
to keep the vehicle lifted is released with the help of release valve. The oil filled in the
cylinder is drained in the tank and the load comes down slowly. In this way the oil
circulates from cylinder to tank and tank to cylinder during operation. A block
diagram of jack is shown in the figure.

7.2 HYDRAULIC PUMP:

Hydraulic pumps convert mechanical energy from a prime mover (engine or

electric motor) into hydraulic (pressure) energy. The pressure energy is used then to
operate an actuator. Pumps push on a hydraulic fluid and create flow. A rotary vane
pump is used in the jack to create the pressure difference in fluid medium.

7.3 ROTARY VANE PUMP:

A rotary vane pump is a positive-displacement pump that consists of vanes

mounted to a rotor that rotates inside of a cavity. In some cases these vanes can be
variable length and/or tensioned to maintain contact with the walls as the pump
rotates.

In a vane-type pump, a slotted rotor splined to a drive shaft rotates between

closely fitted side plates that are inside of an elliptical- or circular shaped ring.
Polished, hardened vanes slide in and out of the rotor slots and follow the ring contour
by centrifugal force. Pumping chambers are formed between succeeding vanes,
carrying oil from the inlet to the outlet. A partial vacuum is created at the inlet as the
space between vanes increases. The oil is squeezed out at the outlet as the pumping
chamber's size decreases.
 Because the normal wear points in a vane pump are the vane tips and a ring's
surface, the vanes and ring are especially hardened and ground. A vane pump is the
only design that has automatic wear compensation built in. As wear occurs, the vanes
simply slide farther out of the rotor slots and continue to follow a ring's contour. Thus
efficiency remains high throughout the life of the pump.

7.3.1 CONSTRUCTION AND WORKING OF PUMP:

A slotted rotor is eccentrically supported in a cycloidal cam. The rotor is

located close to the wall of the cam so a crescent-shaped cavity is formed. The rotor is
sealed into the cam by two side plates. Vanes or blades fit within the slots of the
impeller. As the rotor rotates (yellow arrow) and fluid enters the pump, centrifugal
force, hydraulic pressure, and/or push rods push the vanes to the walls of the housing.
The tight seal among the vanes, rotor, cam, and side plate is the key to the good
suction characteristics common to the vane pumping principle.

The housing and cam force fluid into the pumping chamber through holes in
the cam (small red arrow on the bottom of the pump). Fluid enters the pockets created
by the vanes, rotor, cam, and side plate.

Fig.:7.1.
Parts of Rotary Vane Pump

As the rotor continues around, the vanes sweep the fluid to the opposite side of
the crescent where it is squeezed through discharge holes of the cam as the vane
approaches the point of the crescent (small red arrow on the side of the pump). Fluid
then exits the discharge port.
 Fig.:7.2
Working of rotary vane pump

7.3.2 PUMP SPECIFICATION:

✓ Type :Rotary vane pump

✓ No. of blades 10

✓ Body Material : Aluminum

✓ Max. Pressure : 25 bar at 1000 rpm

✓ Max. Flow : 10 Lpm (liter per min) at 1000 rpm

✓ Rotation : Clockwise

7.3.3 ADVANTAGES AND DISADVANTAGES OF

VANE PUMP:
❖ ADVANTAGES:

• Handles thin liquids at relatively higher pressures.

• Compensates for wear through vane extension. . Sometimes
preferred for solvents, LPG.
• Can run dry for short periods.
• Can have one seal or stuffing box.
• Develops good vacuum.
 ❖ DISADVANTAGES:

• Can have two stuffing boxes.

• Complex housing and many parts.
• Not suitable for high pressures.
• Not suitable for high viscosity.
• Not good with abrasives.

7.3.4 APPLICATIONS OF VANE PUMP:

• Aerosol and Propellants.

• Aviation Service- Fuel Transfer, Deicing.

• Bulk Transfer of LPG and NH,

• Auto Industry - Fuels, Lubes, Refrigeration Coolants.

• Bulk Transfer of LPG and NH,

• LPG Cylinder Filling.

• Alcohols.

• Refrigeration - Freon’s, Ammonia.

• Solvents.

• Aqueous solutions.

7.4 CONTROL UNIT:

Control unit controls the direction of flow and pressure of the fluid in the
system. It is a major part of the system, the control unit reliefs the excess pressure and
stops the stock of oil filled the cylinder to return back. Control unit provides manual
and automatic control on the pressure and flow of oil in the system. Weather it is from
pump to cylinder or cylinder to tank

7.4.1 CONSTRUCTION AND WORKING OF CONTROL UNIT:

The control unit for the jack is fabricated on an aluminum block. Relief valve,
release valve (Manual Shut off valve) and delivery valves (By pass valve) are fitted in
the control unit. The assembly of control unit is shown in the figure 20. Connections
are made with the help of steels pipes, rubber hose and banjo bolts. When high
pressure fluid enters the control unit it passes through the delivery valve which acts as
a one way
Fig.:7.3 Control Unit Assembly
 7.5 RELIEF VALVE:

Fig: 7.4
Relief Valve Section View

Valve allows oil to flow from pump to cylinder and restrict the opposite flow
of oil from cylinder pump. There is a relief valve fitted between the main gallery and
flow gallery the excess pressure during the operation is drained in the reservoir by the
relief valve. There is a return valve fitted between the delivery and flow lines. This
return valve (On-Off valve) is manually operated valve used to drain the stock of the
cylinder.

7.6 OIL RESERVOIR:

There is a plastic tank fitted in the jack of 700ml volume. The total oil
required in the jack is 600ml. There are two openings in the tank one is connected to
the inlet of the pump and another is connected to the return flow from the control unit.
The connections are made with the help of rubber and steel pipes. There is a
cap on the top of the tank for refilling it. Tank is mounted with the help of thin metal
sheet in the jack. Hydraulic oil of 46 grade is used in the jack. As the pump used is
vane pump so the oil of low viscosity as grade 46 is used

7.7 DC MOTOR:

Motor is a device which converts electrical energy into mechanical energy. A

DC Motor is used in the jack to rotate the pump DC motor is used because the current
available at vehicle battery is DC current. Motor have to terminals positive and
negative. Negative terminal of the motor is itself the body of motor.
Motor Specification:

✓ Type : Permanent magnet DC motor

✓ Power input :12V DC

✓ Power output : 0.4KW 0.5 H.P.

✓ Rotation : Clockwise

7.8 INSTALLATION:

• BASE PLATE:

All the components are mounted with the help of bolts in an aluminum plate
this plate is the base plate.
Base plate size - 254mm x 203mm x 10mm (LxBxt)

• CONNECTION PIPES:

Steel pipes of 8 mm diameter are used for connection between pump and
control unit. Return and inlet pipes are rubber pipes. The cylinder and the control unit
is connected with a flexible hydraulic hose pipe. This hose pipe have maximum
working pressure capacity of 40 Mpa.

• PUMP AND MOTOR MOUNTING:

Pump and motor are mounted on the base plate with the help of three vertical
mounting plates. These mounting plates are aluminum plates. Pump and motor are
mounted such that in order to provide the proper mating of gears used to transmit the
power. A small tolerance is provided between the gears in order to avoid the
interference of teeth and noise.

• COUNTROL UNIT MOUNTING:

Control unit is mounted in the base plate at the delivery side of the pump with
the help of a bolt. The control unit is connected with the tank as return flow with the
help of rubber pipe and also connected with the outlet of the pump with the help of
steel pipe.

• ELECTRICAL CONNECTION:

Electric connections are made with two terminal wires as positive and negative
terminals. Positive terminal wire is an insulated copper wire of thickness 5 mm and 15
feet length. This wire has a battery clip on one end which is to be connected at the
positive terminal of the battery of the vehicle. A starter switch is fitted for on off
operation of the jack. Negative terminal wire is also a copper wire of thickness 5mm
and length 3 feet. This wire is small in length and also have a clip on one end.
 This negative terminal wire is connected with jack body as earth and while
operation it is connected to the vehicle body acting as a negative terminal.

7.9 MAINTENANCE:

When the jack is not in use, keep the cylinder piston fully started. Store the
jack on its base and in a well-protected area where it will not be exposed to corrosive
vapors, abrasive dust, or any other harmful elements.

Visually inspect the jack before each use. Take corrective action if any of the
following problems are found:

• Cracked or damaged housing.

• Excessive wear, bending, or other damage.

• Loose hardware.

• Leaking hydraulic fluid.

• Scored or damaged piston rod.

7.10 SAFETY PRECAUTIONS:

• Inspect the jack before each use; do not use the jack if it is damaged, altered,
or in poor condition.

• To prevent tipping, set up the jack on a hard, level surface.

• The load must not exceed the rated lifting capacity of the jack. Lift only dead
weight.

• Center the load on the jack saddle, because off-center loads can damage the
seals and cause hydraulic failure.

• Use the jack for lifting purposes only. This jack is designed to LIFT loads, not
support loads. Immediately support a lifted load with jack stands.

• Use only approved hydraulic fluid, such as 32, 46, 68 Grade Hydraulic Oil
or equivalent.

These warnings cannot cover every situation, so have safety foremost in our mind when
setting up a job.
 Chapter No.:8

SILENT FEATURES
Advantages, disadvantages and applications of Motorized Hydraulic Car Jack are as
follows,

8.1 Advantages:

Following are some advantages of hydraulic jack:

✓ It occupies less space.

✓ They are also less likely to jam due to rust in the screw thread.

✓ It is highly effective with heavy loads.

✓ It lifts loads without the effort.

✓ It is easier to use.

✓ It is a bit lighter than screw jacks.

8.2 Limitations:

Below are some disadvantages of Hydraulic Jack.

✓ It is susceptible to failure if the oil seals are worn out, this can cause
serious problems.

✓ It has relatively slow speed.

✓ Hydraulic oil leak can cause soil and water pollution.

8.3 Application:

Following are some applications of Hydraulic jack.

✓ Lifting a car or any other vehicle for changing its tires.

✓ They are used in lifting platforms.

✓ They are used in material handling equipment.

✓ They are used in earth moving equipment.

 Chapter No.:9

COST SHEET

9.1.1 COST ESTIMATION:

Sr. Part Name Material wt. Rate/kg Total

No. in kg or Rate
Qty.
1
Square pipe 5 kg 70 350

2
M.S. Sheet 0.5 kg 90 50

3 Miscellaneous cost
400

9.1.2 Cost of Standard Parts.

Table No. 9.1.2 Cost of Standard Parts.

Sr. Part Name Rate

No.
1. Hydraulic jack (3000 kg)
1050

2. Battery (6 V+6 V)
800

3. Switch (6A)
30

4. Wire (1 foot X 10 ₹)
10

5. Motor (12V DC)

950

6. Transmission system
500
9.1.3 Cost of manufactured parts:

Table No. 9.1.3 Cost of manufactured parts.

Sr. Part Name Cost ₹

No.
1. Machine foundation frame 500

2. Battery foundation frame 200

3. Motor fitting frame 100

9.1.3 Machining Cost.

Table No. 9.1.3 Machining cost.

Sr.
Name of Machine Tool Time Rate/1hr Cost
No.

1. Cutting m/c Cutting Blade 15 min 450 115

2.
Drill m/c Drill Bit 10 min 100 17

3.
Grinding m/c Facing Tool 20 min 100 34

4.
Welding m/c Arc Welding 45 min 150 113

9.2 COST OF PROJECT:

= Cost of material + cost of manufactured part + cost of standard parts +
cost of machining

= 400 + 800 + 3,340 + 400

Total cost= 4,819/-

 CHAPTER NO. 10

10.1 Result:

Each and every project is never complete as new things are learned further
modifications can be done. Thus we have tried to make Motorized Hydraulic Car Jack
which will decrease the human efforts for lifting car to change the tire. Although there
is higher initial cost involved we have tried to make the system cost effective.

This is just the beginning, we can add different enhancements to make the
system more effective so that it will work round year. The Motorized Hydraulic Car
Jack using this system compared with the prevalent system at present has many
advantages.

The Motorized Hydraulic Car Jack is used to lift the heavy loaded vehicle
without any efforts we can lift it very easily in one start of switch. Each project will
get better than previous one as practice can make us perfect.

10.2 Conclusion:

This project as a working hydraulic jack performed well and according to the
design it is working with its full capacity of lifting 3000kg load. The model is
working fine as expected during design. We all worked in a team to get these positive
results. We machined the components by own and got help from others to fabricate
the components like control unit, cylinder, Base plate, mountings etc.

We thought creatively throughout the project and solved every problem occurred
regarding to project. We used all of our knowledge which we gained in our
engineering curriculum. We used knowledge of Hydraulics, Machining, CAD, and
Power Transmission with gears etc.

Overall we are proud of what we have produced. Before we began this project we
don't have much experience with hydraulic machines, metal cutting and power
transmission. Overall we have gained a huge set of skills in areas in which we think
will be essential to us further down the line. And finally it's a team work whatever we
achieved.
 CHAPTER NO. 11

REFERENCES

• https://www.metrohydraulic.com/cylinders/

• https://www.apexhydraulics.co.uk/guide-hydraulic-cylinders/

• https://www.hydraulicjackind.com/range_of_hydraulic_cylinders.htm

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• Minimalist cryptography for low-cost RFID tags (extended abstract). In:

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• Heidelberg, (2005). https://doi.org/10.1007/978-3-540-30598-9_11

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