Chaitanya Ghule CPPPP

BUTTON OPERATED HYDRAULIC JACK
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
S.S.POLYTECHNIC 1
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,
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. Desale.D.D.)
S.S.POLYTECHNIC 2
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

Has been successfully carried out & submitted by
At Shree Samarth Polytechnic
Department of Mechanical Engineering
2023-24
Internal Examiner External Examiner

Date :-
Place :-
S.S.POLYTECHNIC 3
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 :-
S.S.POLYTECHNIC 4
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,
S.S.POLYTECHNIC 5
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.
S.S.POLYTECHNIC 6
CONTENTS
Sr. No. Title Page No.

Title 1
Certificate 2,3
Examiner Certificate 4
Acknowledgement 5
Abstract 6
Contents 7,8
List Of Figures 9
Photographs 10
1. Introduction 11-13
1.1 Hydraulics
1.2 Hydraulics Basics
2. Literature Survey. 14-15
2.1 Introduction
2.2 Working Principle
2.3 Project Layout
3. Problem Definition 16
4. Methodology 17
5. Basic Systems/ Devices. 18-26
5.1 Hydraulic Press

5.2 Electric System
5.3 Hydraulic Intensifier
5.4 Hydraulic Jack
5.5 Types of Hydraulic Jack
S.S.POLYTECHNIC 7
6. Design. 27-34
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 35-44
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
Safety Precaution’s
8. Silent features 45
8.1 Advantages
8.2 Limitations
Applications
9. Cost sheet 46-47

9.1 Cost estimation
Cost of project
10.  Result. 48
Conclusion
11. References. 49
S.S.POLYTECHNIC 8
List of Figure
Fig. Title of Figure Page

No. No.
1.1 Pascal law 13
2.1 Project Layout 15
5.1 Principle of hydraulic press 18

5.2 Electric System 19
5.3 Hydraulic intensifier 19-21
5.4 Hydraulic jack 21-22

5.5 Air hydraulic jack 22-23
5.6 Bottle hydraulic jack 23-24
5.7 Hydraulic floor jack 24
5.8 Toe jack 25
5.9 Pneumatic jack 25-26
5.10 Trailer hydraulic cylinder jack 26
6.1 Hydraulic cylinder designed for jack 27
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
S.S.POLYTECHNIC 9
PHOTOGRAPHS
S.S.POLYTECHNIC 10
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
S.S.POLYTECHNIC 11
 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
S.S.POLYTECHNIC 12
Pascals’ Low
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
S.S.POLYTECHNIC 13
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.
S.S.POLYTECHNIC 14
 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:
S.S.POLYTECHNIC 15
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.
S.S.POLYTECHNIC 16
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
S.S.POLYTECHNIC 17
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.
S.S.POLYTECHNIC 18
5.2 Electric System
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
S.S.POLYTECHNIC 19
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.
S.S.POLYTECHNIC 20
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.
S.S.POLYTECHNIC 21
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 TYPES OF HYDRAULIC JACK:
(1) AIR HYDRAULIC JACK

Basically jack climb up on the jack rod (Part of the lifting trestle) with the
desired pressure, to lift up the load. Its action is same as a monkey that climbs a trunk
tree; i.e., first it holds up on to the trunk with its legs and lunges upwards, then it holds
on to the trunk with its hands and lifts its legs up. At any time, either its hands or legs
have a grip on the trunk, which prevents it from falling down.
Fig.:5.5.
Air Hydraulic Jack.
S.S.POLYTECHNIC 22
In the same manner, air hydraulic jack, air hydraulic bottle jack and jack is
provided with two pairs of jaws, a lower pair of jaws and an upper pair of jaws for an
excellent grip. During lifting, both the pairs are "locked". In this position the jack can
only move upwards. At the time of lifting, the lower pair of jaws grips the trestle rod
while the jack lifts up. After completing the full stroke, the upper pair of jaws grips the
trestle rod, however, the base of the jack moves upward. During the process of
lowering, any one of the pairs is always locked.
Lightweight and build for heavy-duty use. The quick-lift mechanism allows a
substantially shortened ram lifting time without load. A flow control valve prevents
sudden falls of the ram. Featured a specially processed air pump for low noise. The
built-in safety valve prevent use beyond rated the rated capacity or lifting limit.
(2) 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
S.S.POLYTECHNIC 23
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.
(3) HYDRAULIC FLOOR JACK:
Fig.:5.7.
Hydraulic Floor Jack
In a floor jack (aka 'trolley jack') a horizontal piston pushes on the short end of
a bell crank, with the long arm providing the vertical motion to a lifting pad, kept
horizontal with a horizontal linkage. Floor jacks usually include castors and wheels,
allowing compensation for the arc taken by the lifting pad. This mechanism provides a
low profile when collapsed, for easy maneuvering underneath the vehicle, while
allowing considerable extension.
S.S.POLYTECHNIC 24
(4) TOE JACK:
Fig.:5.8.
Toe Jack.
(5) PNEUMATIC JACK:
A pneumatic jack is a hydraulic jack that is actuated by compressed air - for

example, air from a compressor - instead of human work. This eliminates the need for
the user to actuate the hydraulic mechanism, saving effort and potentially increasing
speed. Sometimes, such jacks are also able to be operated by the normal hydraulic
actuation method, thereby retaining functionality, even if a source of compressed air is
not available.
S.S.POLYTECHNIC 25
Fig.:5.9.
Pneumatic Jack.
(6) TRAILER HYDRAULIC CYLINDER JACK:
Fig.:5.10.
Trailer hydraulic cylinder jack.
S.S.POLYTECHNIC 26
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.
S.S.POLYTECHNIC 27
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
S.S.POLYTECHNIC 28
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)
S.S.POLYTECHNIC 29
Fig.:6.3.
Exploded view of Hydraulic Bottle Jack.
S.S.POLYTECHNIC 30
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
S.S.POLYTECHNIC 31
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
S.S.POLYTECHNIC 32
= 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.
S.S.POLYTECHNIC 33
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
S.S.POLYTECHNIC 34
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.
S.S.POLYTECHNIC 35
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.
S.S.POLYTECHNIC 36
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.
S.S.POLYTECHNIC 37
 Develops good vacuum.
S.S.POLYTECHNIC 38
 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
S.S.POLYTECHNIC 39
S.S.POLYTECHNIC 40
Fig.:7.3 Control Unit Assembly
S.S.POLYTECHNIC 41
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.
S.S.POLYTECHNIC 42
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.
S.S.POLYTECHNIC 43
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.
S.S.POLYTECHNIC 44
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.
S.S.POLYTECHNIC 45
Chapter No.:9
COST SHEET
9.1.1 COST ESTIMATION:
Sr. Part Name Material wt. Rate/kg Total

No. in kg or Qty. Rate
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 (12 V)
800
3. Switch (6A)
30
4. Wire (1 foot X 10 ₹)
10
5. Motor (12V DC)

950
6. Transmission system
500
S.S.POLYTECHNIC 46
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/-
S.S.POLYTECHNIC 47
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.
S.S.POLYTECHNIC 48
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
 Minimalist cryptography for low-cost RFID tags (extended abstract). In:

Blonde
 C., Climate, S. (eds.) SCN 2004. LNCS, vol. 3352, pp. 149–164. Springer,
 Heidelberg, (2005). https://doi.org/10.1007/978-3-540-30598-9_11
 Minimalist cryptography for low-cost RFID tags (extended abstract). In:

Blonde
C., Climate, S. (eds.) SCN 2004. LNCS, vol. 3352, pp. 149–164. Springer,
 Heidelberg, (2005). https://doi.org/10.1007/978-3-540-30598-9_11
 Iceman, R.A., Nerada, B.I. Users authentication and privacy control of RFID card.
Department of Computer System and Communications, Faculty of Computer
Science and Information Systems, University Technology Malaysia, October 2012
 M.: RFID and privacy (Chap. 28). Security, Privacy, and Trust in Modern Data
 Management, pp. 433–450.Heidelberg 1c (2017).https://doi.org/10.1007/978- 3-

540-69861-6_28
 A.S.: Classification of RFID attacks. In, proceedings of 2nd International

Workshop
 On RFID Technology - Concept, Applications, Challenges, Porto, Portugal, pp.
S.S.POLYTECHNIC 49
Teachers Evalution sheet

Name of
Student…………………………………………….................................................................................
.................................................................................................................................................................
Enrollment
No…………………………………………………….............................................................................
..................................................................................................................................................................
Name of
Programmed…………………………………………………………………………………………….
semester………………………………………………………………
Course Title:…………………………………………………………
Code…………………………………………………………………….
Title of Micro-project:…………………………………………
Course Outcome Achieved.
…………………………………………………………………….……………………………………
……………………
………………………………………………………...
…………………………………………………………………………………………………………
…………………….
.…………………………………………….
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……………..……………………………………………………..
…………………………………………………………………………………………………………
………………………………………………………Evaluation As Per
S.S.POLYTECHNIC 50
sr.no Characterestics to be Poor Average Good Excellent

assessed (marks1-3) (Marks4-5) (Marks6-8) (Marks9-10
1 Relevance to the cource
2 Literature
Survey/Information
Collection
3 Project Proposal
4 Completion of the
Target as per Project
Proposal
5 Analysis of Data
&Representation
6 Quality of
Protoype/Model
7 Report Preparation
8 Presentation
9 Defense
Micro-Project Evaluation Sheet
Process Assessment Product Assessment

Part-a Project Project Methodology Part-b Project Individual Total
Proposal(2 (2Marks) Report/Working Presentation/Viv a Marks
Marks) Model (4Marks) 10
(2Marks)
S.S.POLYTECHNIC 51
Note
Every Course Teacher is Expected to Assign Marks of Group Evolution in first three column
& Individual Evolution in 4th Column for each Group of Students as per Rubrics.
Comment/Suggestions About Team Work /Leadership/Inter Personal

Communication (if any)
………………………………………………………………………………………………………
………………………
…………………..
………………………………………………………………………………………………………
………………………
…………….
………………………………………………………………………………………………………
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Any Other Comment:
………………………………………………………………………………………………………
………………………
…………………...
………………………………………………………………………………………………………
……………………….
.
………………………………………………………………………………………………………
………………………
……………………..
………………………………………………………………………………………………………
………………………
……………
Name And Distignation of the faculty member………………………………
Signeture…………………………………
S.S.POLYTECHNIC 52

Chaitanya Ghule CPPPP

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BUTTON OPERATED HYDRAULIC JACK

“BUTTON OPERATED HYDRAULIC JACK”

MR. DOME ADESH SONYABAPU 2214660289

MR. GHULE CHAITANYA ASHOK 2214660292

MR. AVDHUT MAYUR MOHAN 2214660299

MR. SATHE DARSHAN SANJAY 2214660302

Under the guidance of

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

DEPARTMENT OF MECHANICAL ENGINEERING

SHREE SAMARTH POLYTECHNIC, MHASNE PHATA, PARNER, AHMEDNAGAR

SHREE SAMARTH ACADEMY’S

SHREE SAMARTH POLYTECHNIC

This is to certify that project report,

MR. DOME ADESH SONYABAPU

MR. GHULE CHAITANYA ASHOK

MR. AVDHUT MAYUR MOHAN

MR. SATHE DARSHAN SANJAY

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. Desale.D.D.)

MAHARASHTRA STATE BOARD OF TECHNICAL

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

This is to certify that the project work entitled

“BUTTON OPERATED HYDRAULIC JACK”

MR. DOME ADESH SONYABAPU

MR. GHULE CHAITANYA ASHOK

MR. AVDHUT MAYUR MOHAN

MR. SATHE DARSHAN SANJAY

At Shree Samarth Polytechnic

Department of Mechanical Engineering

Internal Examiner External Examiner

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

Prof. Zanjad .S.V

MR. DOME ADESH SONYABAPU

MR. GHULE CHAITANYA ASHOK

MR. AVDHUT MAYUR MOHAN

MR. SATHE DARSHAN SANJAY

This project work titled “BUTTON OPERATED HYDRAULIC

Sr. No. Title Page No.

5. Basic Systems/ Devices. 18-26

5.1 Hydraulic Press

7. Construction and working 35-44

7.1 Working of jack

9. Cost sheet 46-47

Fig. Title of Figure Page

5.1 Principle of hydraulic press 18

5.3 Hydraulic intensifier 19-21

5.4 Hydraulic jack 21-22

5.6 Bottle hydraulic jack 23-24

5.7 Hydraulic floor jack 24

5.8 Toe jack 25

5.9 Pneumatic jack 25-26

5.10 Trailer hydraulic cylinder jack 26

6.1 Hydraulic cylinder designed for jack 27

6.2 Hydraulic cylinder designed for jack (Exploded view)

6.3 Exploded view of hydraulic bottle jack

7.1 Part of rotary vane pump