A

PROJECT STAGE-I REPORT

ON

DESIGN AND FABRICATION OF AUTOMATED MOTORIZED

MECHANICAL JACK

SUBMITTED BY

Mr. BIRAJDAR VINAYAK

Mr. GAIKWAD AJAY
Mr. MASHALE ABHISHEK
Mr. SHILEDAR SABEER

UNDER THE GUIDANCE OF

Prof. S. K. KHILLARE

DEPARTMENT OF MECHANICAL ENGINEERING

PRADNYA NIKETAN EDUCATION SOCIETY, PUNE.

NAGESH KARAJAGI ORCHID COLLEGE OF ENGINEERING &
TECHNOLOGY, SOLAPUR 413002

(AFFILIATED TO DR. BABASAHEB AMBEDKAR TECHNOLOGICAL

UNIVERSITY, LONERE)
2020 – 2021
 CERTIFICATE

This is to certify that the project stage-I entitled DESIGN AND FABRICATION
OF AOTOMATED MOTORIZED MECHANICAL JACK has been completed
by following students of B.Tech. Final Year (MECH.) class in satisfactory manner
under my guidance.
Mr. BIRAJDAR VINAYAK
Mr. GAIKWAD AJAY
Mr. MASHALE ABHISHEK
Mr. SHILEDAR SABEER

The project is found to be complete in partial fulfillment for the award of B.Tech. of
Mechanical Engineering of Dr. Babasaheb Ambedkar Technological University,
Lonere.

(S.K.KHILLARE) (Dr. S. S. METAN)

PROJECT GUIDE HOD

(Dr. J. B. DAFEDAR)
PRINCIPAL

DEPARTMENT OF MECHANICAL ENGINEERING

PRADNYA NIKETAN EDUCATION SOCIETY, PUNE.
NAGESH KARAJAGI ORCHID COLLEGE OF ENGINEERING &
TECHNOLOGY, SOLAPUR -413002
(AFFILIATED TO DR. BABASAHEB AMBEDKAR TECHNOLOGICAL
UNIVERSITY, LONERE)
2020 – 2021

2
 Code of Ethics for Plagiarism

1. I/We know that plagiarism means taking and using the ideas, writings, works or
inventions of another person as if they were one’s own. I/We know that
plagiarism not only includes verbatim copying, but also the extensive use of
another person’s ideas without proper acknowledgement (which includes the
proper use of quotation marks). I/We know that plagiarism covers this sort of use
of material found in textual sources and from the Internet.

2. I/We acknowledge and understand that plagiarism is wrong.

3. I/We understand that my research must be accurately referenced. I/We have

followed the rules and convention concerning referencing, citation and the use of
quotation as set out in the Departmental Guide.

4. This project work is my/our own work, or my/our group’s unique group project
work. I/We acknowledge that copying someone else’s work or part of it, is wrong,
and that submitting identical work to others constitutes a form of plagiarism.

5. I/We have not allowed, nor will I/We in the future allow, anyone to copy my/our
work with the intention of passing it off as their own work.
……………………………………………………………

……………………………………………………………

…………………………………………………………

……………………………………………………………

(Name & Signature of the Student/s)

Place: NKOCET, Solapur

Date:

3
 DECLARATION

By the UG/PG (B.Tech.. /M.Tech.) Student

I/We hereby declare that the Report of the UG/P.G. Project Work entitled

…………………………………………………………………………………………
…………………………………………………………………………………………
……………………………………………………………………………………………

Which is being submitted to the Dr. Babasaheb Ambedkar Technological

University, Lonere In Partial ful-fillment of the requirements for the award of the
Degree Bachelor/Master of
……………………………………………………………in the department of
……………………………………………………………………..…. ,is a
bonafide report of the work carried out by me/us. The material contained in this
report has not been submitted to any University or Institution for the award of any
degree.

……………………………………………………………

……………………………………………………………

……………………………………………………………

……………………………………………………………

(Name & Signature of the Student/s)

Place: NKOCET, Solapur

Date:

4
INDEX

5
6
7
LIST OF FIGURES

8
 ACKNOWLEDGEMENT
We are glad to perform the entitled as DESIGN AND FABRICATION OF
AUTOMATED MOTORIZED MECHANICAL JACK for final year B. Tech. in
mechanical engineering as per our syllabus by DBATU.

We must acknowledge special gratitude our guide Prof. S. K. Khillare for

giving us valuable time, guidance, excellent support and encouragement which pushed
us to complete our project successfully.

We are also thankful to our principal Dr. J. B. Dafedar and head of department
Dr. S. S. Metan for granting permission our project work and last but not least we would
like to thank everyone who helped as directly and indirectly in successfully completion
work.

1 BIRAJDAR VINAYAK

2 GAIKWAD AJAY

3 MASHALE ABHISHEK

4 SHILEDAR SABEER

9
Project No. : G-37

Project Title. : Design and Fabrication of Automated Motorized Mechanical

Jack

Team Members : 1) Birajdar Vinayak

2) Gaikwad Ajay

3) Shiledar Sabeer

4) Mashale Abhishek

Project Guide : Prof. S. K. Khillare

Abstract: A jack is a device which is used to raise part of vehicle in order to facilitate

vehicle maintenances or breakdown repairs. In normal jack system a mechanical jack is

used for lifting the vehicles. The most common form is a car jack, garage jack, floor jack

which lifts vehicles so that maintenance can be performed. Jacks are generally used to

increase mechanical advantage (lifting the vehicle).Generally jacks undergo buckling

when they reach maximum load conditions. For this reason, we have to develop the

system which can use toggle jack which is automatic in operation using electric motor.

Vehicle’s battery can be used as a source of power for this motor. This project attempts to

overcome this difficulty and a suitable device is to be designed such that the vehicle can

be lifted from the floor without any application of impact force. The operation remains to

be an essential part of the system although with changing demands on physical input, the

degree of mechanization is increased.

Keywords: Mechanical jack, electric motor, battery.

10
 CHAPTER 1

INTRODUCTION TO AUTOMATED MOTORIZED MECHANICAL SCREW

JACK

1.1 Introduction To Motorized Screw

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.

1.2 Introduction

The motorizedscrew jack has been developed to cater to the needs of smalll and medium
automobile garages, which are normally man powered with minimum skilled labor. In
most automobile garages the vehicles are lifted by using screw jack. This needs high man
power and skilled the labor.

In order to avoid all such disadvantages, the motorized jack has been designed in such
way that it can be used to lift the vehicle very smoothly without any impact force. The
operatioin is made simple so that even unskilled labour can use it with ease.

The D.0 motor is coupled with the screw jack by gear arrangement. The screw jack shaft
rotation depends upon the rotation of D.0 motor. This is a simple type of automation
project.

This is an era of automation where it is broadly defined as replacement of manual effort

by mechanical power in all degrees of automation. The operation remains to be an

11
essential part of he system although with changing demands on physical input, the degree
of mechanization increased.

Degrees of automation are of two types, viz.

1. Full automation. 2. Semi automation.

In semi automation a combination of manual effort and mechanical power is required

Whereas in full automation human participation is very negligible.

1.3 Need for Automation

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc.

Automation plays an important role in mass production.

For mass production of the product, the machining operations decide the sequence of
machining. The machines designed for producing a particular product are called transfer
machines. The components must be moved automatically from the bins to various
machines sequentially and the final component can be placed separately for packaging.
Materials can also be repeatedly transferred from the moving conveyors to the work place
and vice versa.

Nowadays, almost all the manufacturing processes are being atomized in order to deliver
the products at a faster rate. The manufacturing operation is being atomized for the
following reasons:

i) To achieve mass production

ii) To reduce man power

iii) To increase the efficiency of the plant

iv) To reduce the work load

v) To reduce the production cost

vi) To reduce the production ti

12
 CHAPTER 2

LITERATURE REVIEW

2.1 Power Screw

A power screw is a technical device used for converting rotary motion into linear
motion and Iran a power screw is also called a translation. Translator motion the screw
the read in transmitting power rather than the machine components. The main application
on so power screws are as follows:

(1) To obtain accurate ignition machining operations

e.g.: lead-screw of lathe

( 2) To load a specimen

e.g.: universal testing machine

There depending upon the holding arrangement, power screw operating different ways. In
some cases, the screw rotates bearing, while in motion. The lead screw example of this
category. 1 not her application then is kept stationary and the screw move in an axial
reaction A screw jack and machine the example soft this category's power screw the
following advantages:

• A power screw has large load carrying capacity

. • The overall dimensioned the power screw

There are applications of power screw application where high efficiency desired and
application where low efficiency is desired. The applications where high efficiency is
expected are power transmission application such as lead screw and presses. The
applications where low efficiency is desired for the purpose of self-locking are screw
jacks, clamp sand vices. The efficiency of a power screw is increased if Sliding friction is
replaced by rolling friction. This principle is use in recalculating balls screw [1].

13
2.2 Forms of Threads

The threads used for fastening purposes, such as V threads are not suitable for power
screw. The purpose off stunning threads is to provide high frictional force which less
possibility of loosening the parts axial body threaded joint. On the other hand the purpose
o power transmission I n.Therefore Power Screws with small range of thread such as
trapezoidal threads, are preferred for power transmission [1].

There are two popular types of thread used for power screws, viz., square and Isometric
trapezoidal, as shown in Fig.2.1 The advantages of square threads over trapezoidal
threads are as follow:

(i) The efficiency of square threads is in or than that of trapezoidal threads.

(ii There is no radial pressure or side thrust on the nut. This radial pressure is
called bursting' pressure on the nut.

Fig. 2.1 Square threads Fig. 2.2 Trapezoidal

threads

14
2.3 Shafts

A shaft is a rotating machine element which is used to transmit power from one
place to another. The power is delivered to the shaft by some tangential force and the
resultant torque (or twisting moment) set up within the shaft permits the power to be
transferred to various machines linked up to the shaft. In order to transfer the power from
one shaft to another, the various members such as pulleys, gears etc.

These members along with the forces exerted upon them causes the shaft to bending.
In other words, we may say that a shaft is used for the transmission of torque and bending
moment. The various members are mounted on the shaft by means of keys or splines [5]•

2.4 Material Used For Shafts

The material used for shafts should have the following properties:

1. It should have high strength.

2. It should have good machinability.

3. It should have low notch sensitivity factor.

4. It should have good heat treatment properties.

5. It should have high wear resistant properties. [510]

2.5 Manufacturing Of Shafts

Shafts are generally manufactured by hot rolling and finished to size by cold
drawing or turning and grinding. The cold rolled shafts are stronger than hot rolled shafts
but with higher residual stresses. The residual stresses may cause distortion of the shaft
when it is machined, especially when slots or keyways are cut. Shafts of larger diameter
are usually forged and turned to size in a lathe [5 10].

15
2.6 Friction in Screws with a Square Thread

The reaction on the thread surface may be taken as uniformly distributed at radius
r, this distributed reaction the problem become analogous to the motion of body of weight
W up an inclined plane of the same slope as the thread and under the action of a
horizontal of force P For the determination of P

Couple producing motion =Qz=Pr

16
 CHAPTER 3

PARTS OF MOTORIZED SCREW JACK

3.1 D. C. Motor (Permanent Magnet)

Description of DC Motor

An electric motor is a machine which converts electrical energy to mechanical

energy. Its action is based on the principle that when a current-carrying conductor is
placed in a magnetic field, it experiences a magnetic force whose direction is given by
Fleming's left hand rule.

When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound or
series wound or comp6und wound motors.

3.1.1 Fleming's Left Hand Rule

Keep the force finger, middle finger and thumb of the left hand mutually
perpendicular to one another. If the fore finger indicates the direction of magnetic field
and middle finger indicates direction of current in the conductor, then the thumb indicates
the direction of motion in the conductor

17
 Fig. 3.1 Fleming's Left Hand Rule

3.1.2 Principle of Operation of DC Motor

A uniform magnetic field in which a straight conductor carrying no current is

placed. The conductor is perpendicular to •the direction of the magnetic field.

The conductor is shown as carrying a current away from the viewer, but the field due to
the N and S poles has been removed. There is no movement of the conductor during the
above two conditions. When the current carrying conductor is placed in the magnetic
field, the field due to the current in the conductor supports the main field above the
conductor, but opposes the main field below the conductor.

The result is to increase the flux density in to the region directly above the
conductor and to reduce the flux density in the region directly below the conductor. It is
found that a force acts on the conductor, trying to push the conductor downwards as
shown by the arrow. If the current in the conductor is reversed, the strengthening of flux
lines occurs below the conductor, and the conductor will be pushed upwards.

Now consider a single turn coil carrying a current. In view of the reasons given
above, thone side of the coil will be forced to move downwards, whereas the other side
will be forced to move upwards. The forces acting on both the coil sides will be of same
magnitude. But their direction is opposite to one. another. As the coil is wound on the
armature core which is supported by the bearings, the armature will now rotate. The
commutator periodically reverses the direction of current flow through the armature.
Therefore the armature will have a acontinuous rotation.

A simplified model of such a motor is shown in figure VI. The conductors are
wound over a soft iron core. DC supply is given to the field poles for producing flux. The
conductors are connected to the DC supply through brushes.

A simple 2-pole DC electric motor has 6 parts, as shown in the diagram below.

18
 Fig. 3.2 Parts of DC Electric Motor

An electric motor is all about magnets and magnetism: a motor uses magnets to
create motion. Opposites attract and likes repel.

So if there are 2 bar magnets with their ends marked north and south, then the
North end of one magnet will attract the South end of the other. On the other hand, the
North end of one magnet will repel the North end of the other (and similarly south will
repel south). Inside an electric motor these attracting and repelling forces create rotational
motion. In the diagram above, you can see two magnets in the motor, the armature (or
rotor) is an electromagnet, while the field magnet is a permanent magnet (the field
magnet could be an electromagnet as well, but in most small motors it is not to save
power).

3.2 Batteries

3.2.1 Introduction

In isolated systems away from the grid, batteries are used for storage of excess
solar energy which can be converted into electrical energy. In fact for small units with
output less than one kilowatt, batteries seem to be the only technically and economically
available storage means. Since both thephoto-voltaic system and batteries are high in

19
capital costs, it is necessary that the Overall system be optimized with respect to available
energy and local demand pattern. To be economically attractive the storage of solar
electricity requires a battery with a particular Combination of properties:

(1) Low cost

(2 ) Long life

(3) High reliability

(4) High overall efficiency

(5) Low discharge

(6) Minimum maintenance

(A) Ampere hour efficiency

(B) Watt hour efficiency

3.2.2 Lead Acid Wet Cell

Where high values of load current are necessary, the lead-acid cell is the type
most commonly used. The electrolyte is a dilute solution of sulfuric acid. In the
application of battery power to start the engine in an auto mobile, for example, the load
current to the starter motor is typically 200 to 400A. One cell has a nominal output of
2.1V, but lead-acid cells are often used in a series combination of three for a 6-V battery
and six for a 12-V battery.

The lead acid cell type is a secondary cell or storage cell, which can be recharged.
The charge and discharge cycle can be repeated many times to restore the output voltage,
as long as the cell is in good physical condition. However, heat with excessive charge and
discharge currents shortens the useful life to about 3 to 5 years for an automobile battery.
The different types of secondary cells, the lead-acid type has the highest output voltage,
which allows fewer cells for a specified battery voltage.

20
3.2.3 Construction

Inside a lead battery, the positive and negative electrodes consist of a group of
plates welded to a connecting strap. The plates are immersed in the electrolyte, consisting
of 8 parts of water to 3 parts of concentrated sulfuric acid. Each plate is a grid or
framework, made of a lead-antimony alloy.

This construction enables the' material, which is lead oxide, to be pasted into the
grid. In manufacture of the cell, a forming charge produces the positive and negative
electrodes. the forming process, the active material •in the positive plate is changed to
lead peroxide . The egative electrode is spongy lead.

Automobile batteries are usually shipped dry from the manufacturer. The
electrolyte is ut in at the time of installation, and then the battery is charged. With
maintenance-free •batteries, ttle or no water is needed to be added in normal service.
Some types are sealed, except for a ressure vent, without provision for adding water.

3.2.4 Current Ratings

Lead-acid batteries are generally rated in terms of how much discharge currents
they can upply for a specified period of time; the output voltage must be maintained
above a minimum Level, this is 1.5 to 1.8V per cell. A common rating is ampere-hours
based on a specific discharge time. Typical values for automobile batteries are 100 to 300
mah.

As an example, a 200 mah battery can supply a load current of 200/8 or 25A,
used on 8h discharge. The battery can supply less current for a longer time or more
current for a shorter time. Automobile batteries may be rated for -cold cranking power",
which is related to the job of starting the engine. A typical rating is 450A for 30s at a
temperature of 0 degree F.

The ratings for lead-acid batteries are given for a temperature range of 77 to80°F.
Higher temperature increases the chemical reaction, but operation above 110°F shortens
the battery life.

21
 Low temperatures reduce the current capacity and voltage output. The ampere-
hour capacity is reduced approximately 0.75% for each decreases of 1° F below normal
temperature rating. At 0°F the available output is only 60 % of the ampere-hour battery
rating.

In cold weather, therefore, it is very important to have an automobile battery unto

full charge. In addition, the electrolyte freezes more easily when diluted by water in the
discharged condition.

3.3 Screw Jack

The screw jack used in this project is a 5 tonne bottle (cylindrical) jack. It mainly consists
of the body, screw, nut and thrust bearings. In this type of a jack, the nut remains
stationary while the screw rotates and helps in lifting or lowering of the load.

Capacity: 5Ton Min height: 200MM Max height: 300MM Net Weight: 8KG Lifting
height: 100 mm

Fig. 3.3 Screw Jack

3.3.1 Spur Gear

The spur gears, which are designed to transmit motion and power between parallel shafts,
are the most economical gears in the power transmission industry.

3.3.2 Application

i) Material handling

22
ii )Feed drives

iii) Machine tools

iv)Conveyors

3.4 Types

3.4.1 Internal Spur Gear

The internal gears are spur gears turned "inside out." In other words, the teeth
are cut into the inside diameter while the outside diameter is kept smooth. This design
allows for the driving pinion to rotate internal to the gear, which, in turn, allows for clean
operation. Intended for light duty applications, these gears are available only in brass.
When choosing a mating spur gear, always remember that the difference in the number of
teeth between the internal gear and pinion should not be less than 15 or 12.

3.4.2 External Spur Gear

Perhaps the most often used and simplest gear system, external spur gears are
cylindrical gears with straight teeth parallel to the axis. They are used to transmit rotary
motion between parallel shafts and the shafts that rotate in opposite directions. They tend
to be noisy at high speeds as the two gear surfaces come into contact at once.

3.4.3 Design Considerations for A Gear Drive

In the design of a gear drive, the following data is usually given:

I . The power to be transmitted.

2. The speed of the driving gear.

3. The speed of the driven gear or the velocity ratio.

4. The centre distance.

The following requirements must be met in the design of a gear drive:

23
(a) The gear teeth should have sufficient strength so that they will not fail under static
loading or dynamic loading during normal running conditions.

(b) The gear teeth should have wear characteristics so that there life is satisfactory.

(c) The use of space and material should be economical.

(d) The alignment of the gears and deflections of the shafts must be considered because
they affect the performance of the gears.

3.5 Switch

A switch is used in order to start or stop the entire operation of the screw jack.
The type of switch that is used is known as a toggle switch. A toggle switch is a class of
electrical switches that are manually actuated by a mechanical lever, handle, or rocking
mechanism.

Fig. 3.4 Switches

Toggle switches are available in many different styles and sizes, and are used in
countless applications. Many are designed to provide, e.g., the simultaneous actuation of
multiple sets of electrical contacts, or the control of large amounts of electric current or
mains voltages. The word "toggle" is a reference to a kind of mechanism or joint
consisting of two arms, which are almost in line with each other, connected with an
elbow-like pivot. However, the phrase "toggle switch" is applied to a switch with a short

24
handle and a positive snap-action, whether it actually contains a toggle mechanism or not.
Similarly, a switch where a definitive click is heard, is called a "positive on-off switch".

Control cables are used in order to connect the battery to the motor and the switch.

Fig. 3.5 Cables

Cables A base for the entire set-up has also been used. The motor is mounted on an
inverted U shaped support frame.

3.5.1 Working Principle

The lead-acid battery is used to drive the D.C.motor. The D.C. motor shaft is
connected to the spur gear. If power is given to the D.C. motor, it will run so that the spur
gear also runs to slow down the speed of the D.C. motor. The screw jack moves the screw
upward, so that the vehicle lifts from ground.

The vehicle is lifted by using the lifting platform at the top of the screw jack. The
motor draws power supply from the battery. The lifting and uplifting is done by changing
the battery supply to the motor

3.5.2 Advantages

1. The loaded light vehicles can be easily lifted.

2. Checking and cleaning are easy, because the mainparts are screwed.

3. Handling is easy

25
4. No Manual power required.

5. Easy to Repair.

6. Replacement of parts are easy

3.5.3 Disadvantages

I. Cost of the equipment is high when compared to ordinary hand jack.

2. Care must be taken for the handling the equipment such connection, battery charging
checkup, etc. as proper wiring

3.5.4 Applications

1. It is useful in auto-garages.

2. This motorized screw jack is used for lifting the vehicles. Thus it can be useful for the
following types of vehicles in future; Maruti, Ambassador, Fiat, Mahindra

26
 CHAPTER 4

SCREW JACK

screw jack is a portable device consisting of a screw mechanism used to raise or

lower the load. The principle on which the screw jack works is similar to that of an
inclined plane. There are mainly two types of jacks-hydraulic and mechanical. A
hydraulic jack consists of a cylinder and piston mechanism. The movement of the piston
rod is used to raise or lower the load. Mechanical jacks can be either hand operated or
power driven.

Jacks are used frequently in raising cars so that a tire can be changed. A screw jack is
commonly used with cars but is also used in many other ways, including industrial
machinery and even airplanes. They can be short, tall, fat, or thin depending on the
amount of pressure they will be under and the space that they need to fit into. The jack is
made out of various types of metal, but the screw itself is generally made out of lead.

While screw jacks are designed purposely for raising and lowering loads, they are
not ideal for side loads, although some can withstand side loads depending on the
diameter and size of the lifting screw. Shock loads should also be avoided or minimized.
Some screw jacks are built with anti-backlash. The anti-backlash device moderates the
axial backlash in the lifting screw and nut assembly to a regulated minimum.

A large amount of heat is generated in the screw jack and long lifts can cause
serious overheating. To retain the efficiency of the screw jack, it must be used under
ambient temperatures, otherwise lubricants must be applied. There is oil lubricants in to
enhance the equipment's capabilities. A part fromproper maintenance, to optimize the
capability and usefulness of a screw jack it is imperative to employ •it according to its
design and manufacturer's instruction. Ensure thatyou follow the speed, load capacity,
temperature recommendation and other relevant factors for application.

27
 4.1 The Screw

The screw has a thread designed to withstand an enormous amount of pressure. This
is due to the fact that it is generally holding up heavy objects for an extended amount of
time. Once up, they normally self lock so that they won't fall if the operator lets go, and
they hold up well to the wear of repeated use. If they are made with a ball nut, they will
last longer because there is less friction created with this type of jack. However, they will
not self lock. This can be dangerous and handled carefully.

4.2 Operation

The jack can be raised and lowered with a metal bar that is inserted into the jack.
The operator turns the bar with his hands in a clockwise direction. This turns the screw
inside the jack and makes it go up. The screw lifts the small metal cylinder and platform
that are above it. As the jack goes up, whatever is placed above it will raise as well, once
the jack makes contact. The bar is turned until the jack is raised to the level needed. To
lower the jack the bar is turned in the opposite direction. An automatic screw jack has
gears inside the jack that are connected to the screw. Theses gears are connected by other
gears and bars that are turned by a power source to raise and lower the jack.

Although a jack is a simple and widely used device, the use of any lifting device
is subject to certain hazards. In screw-jack applications, the hazards are dropping, tipping
or slipping of machines or their parts during the operation. These hazards may result
inserious accidents. The main reasons of such accidents are as follows:

(i) The load is improperly secured on the jack

(ii) The screw-jack is over loaded.

(iii) The centre of gravity of the load is off centre with respect to the axis of the jack

(iv) The screw-jack is not placed on hard and level surface.

(v) The screw-jack is used for a purpose, for which it is not designed.

28
Proper size, strength and stability are the essential requirements for the desip, jack from
safety considerations.

4.3 Construction Of Screw Jack

screw jack consists of a screw and a nut. The nut is fixed in a cast iron frame and
remains Spat' The rotation of the nut inside the frame is prevented by pressing a set screw
against it. The screw • rotated in the nut by means of a handle, which passes through a
hole in the head of the screw. The head carries a platform, which supports the load and
remains stationary while the screw is being rotated. A washer is fixed to the other end of
the screw inside the frame, which prevents the screw to be completely turned out of the
nut.

4.3.1 Features

All jacks have safety features to protect the user from accidental injury. Wide bases
help to stabilize a jack and prevent tilting or sinking into soft soil. Most car jacks also
come equipped with their own handle or cranking mechanism, but alternately many of
these also will accept the at end of a tire tool to jack up a vehicle. When in the extended
position, jacks will have a stop point that prevents the user from overextending the jack
beyond its rated capabilities. When in the contracted position, jacks that are provided by
the manufacturer will have a storage area specially formed or designed for the jack to rest
in when not in use.

4.3.2 Benefits

Equipping motorists with car jacks has provided many benefits to those who are on
the road. Most importantly, jacks have equipped drivers with the ability to change a tire
in an emergency situation without having to call for assistance, which can save service
fees and potential towing fees as well.

Car jacks also provide the home auto enthusiast with a tool to use in maintenance of
their own vehicle with the simpler task such as changing brake pads, and belts. When

29
used appropriatety with safety in mind, car jacks are an essential resource for anyone
owning or operating a motorized vehicle.

4.4 Types

Jacks are of mainly two types- mechanical and hydraulic. They vary in size
depending on the load that they are used to lift

4.4.1 Mechanical Jacks

Fig. 4.1 Mechanical Jack

A mechanical jack is a device which lifts heavy equipment. The most common
form is a car jack, floor jack or garage jack which lifts vehicles so that maintenance can
be performed. Car jacks usually use mechanical advantage to allow a human to lift a
vehicle by manual force alone. More powerful jacks use hydraulic power to provide more
lift over greater distances. Mechanical jacks are usually rated for maximum lifting
capacity. :

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4.4.2 Scissor Jack

Scissors jacks are also mechanical and have been in use at least since the
1930s.

A scissor jack is a device constructed with a cross-hatch mechanism, much like a scissor,
to lift up a vehicle for repair or storage. It typically works in just a vertical manner. The
jack opens and folds applying pressure to the bottom supports along the crossed pattern to
move the lift. When closed, they have a diamond shape.

Scissor jacks are simple mechanisms used to drive large loads short distances.
The power screw design of a common scissor jack reduces the amount of force required
by the user to drive the mechanism. Most scissor jacks are similar in design, consisting of
four main members driven by a power screw.

Fig. 4.2 Scissor Jack

A scissor jack is operated simply by turning a small crank that inserted into one
end of the scissor jack. This crank is usually "Z" shaped. The end fits into a ring hole
mounted on the end of the screw, which is the object of force on the scissor jack. When
this crank is turned, the screw turns, and this raises the jack. The screw acts like a gear
mechanism. It has teeth (the screw thread), which turn and move the two arms, producing
work. Just by turning this screw thread, the scissor jack can lift a vehicle that is several
thousand pounds.

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4.4.3 Construction

A scissor jack has four main pieces of metal and two base ends. The four metal
pieces are all connected at the corners with a bolt that allows the corners to swivel. A.
screw thread runs across this assembly and through the corners.

As the screw thread is turned, the jack arms travel across it and collapse or come
together, forming a straight line when closed. Then, moving back the other way, they
raise and come together. When opened, the four metal arms contract together, coming
together at the middle, raising the jack. When closed, the arms spread back apart and the
jack closes or flattens out again'

4.4.4 Design and Lift

A scissor jack uses a simple theory of gears to get its power. As the screw
section is turned, two ends of the jack move closer together. Because the gears of the
screw are pushing up the arms, the amount of force being applied is multiplied. It takes a
very small amount of force to turn the crank handle, yet that action causes the brace arms
to slide across and together. As this happens the arms extend upward. The car's
gravitational weight is not enough to prevent the jack from opening or to stop the screw
from turning, since it is not applying force directly to it. If you were to put pressure
directly on the crank, or lean your weight against the crank, the person would not be able
to turn it, even though your weight is a small percentage of the cars.

4.4.5 Bottle (Cylindrical) Jacks

Bottle screws may operate by either

(i) Rotating the screw when the nut is fixed; or

(ii) Rotating the nut and preventing rotation of the screw.

Bottle jacks mainly consist of a screw, a nut, thrust bearings, and a body. A
stationary platform is attached to the top of the screw. This platform acts as a support for

32
the load and alsc assists it in lifting or lowering of the load. These jacks are sturdier than
the scissor jacks and car lift heavier loads.

4.4.6 Hydraulic Jack

Hydraulic jacks are typically used for shop work, rather than as an emergency jack
to be carried with the vehicle. Use of jacks not designed for a specific vehicle requires
more than the usual care in selecting ground conditions, the jacking point on the vehicle,
and to ensure stability when the jack is extended. 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. 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.

Fig. 4.3 Hydraulic Jack

Cylindrical jack In a bottle jack the piston is vertical and directly supports a
bearing pad that contacts the object being lifted. With a single action piston the lift is

33
somewhat less than twice the colla p se d 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 5

POWER SCREWS

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5.0 Introduction Of Power Screws

A power screw is a mechanical device used for converting rotary motion into
linear w motion and transmitting power. A power screw is also called translation screw. It
uses helical traslator motion of the screw thread in transmitting power rather than
clamping the machine components.

5.1 Applications

The main applications of power screws are as follows:

(i) To raise the load, e.g. screw-jack,

(ii) To obtain accurate motion in machining operations, e.g. lead-screw of lathe,

(iii) To clamp a work piece, e.g. vice, and

(iv) To load a specimen, e.g. universal testing machine.

There are three essential parts of a power screw, viz.screw, nut and a part to hold
either the screw or the nut in its place. Depending upon the holding arrangement, power
screws operate in two different ways. In some cases, the screw rotates in its bearing,
while the nut has axial motion. The lead screw of the lathe is an example of this category.
In other applications, the nut is kept stationary and the screw moves in axial direction.
Screw-jack and machine vice are the examples of this category.

5.2 Advantages

Power screws offer the following advantages:

(i) Power screw has large load carrying capacity.

(ii) The overall dimensions of the power screw are small, resulting in compact
construction.

(iii) Power screw is simple to design

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(iv) The manufacturing of power screw is easy without requiring specialized machinery.
Square threads are turned on lathe. Trapezoidal threads are manufactured on thread
milling machine.

(v) Power screw provides large mechanical advantage. A load of 15 kN can be raised by
applying an effort as small as 400 N.Therefore, most of the power screws used in various
applications like screw-jacks, clamps, valves and vices are usually manually operated.

(vi) Power screws provide precisely controlled and highly accurate linear motion
required in machine tool applications.

(vii) Power screws give smooth and noiseless service without any maintenance.

(viii) There are only a few parts in power screw. This reduces cost and increases
reliability.

(ix) Power screw can be designed with self-locking property. In screw-jack application,
self locking characteristic is required to prevent the load from descending on its own.

5.3 Disadvantages

The disadvantages of power screws are as follows:

(i) Power screws have very poor efficiency as low as 40%.Therefore, it is not used in
continuous power transmission in machine tools, with the exception of the lead screw.
Power screws are mainly used for intermittent motion that is occasionally required for
lifting the load or actuatino the mechanism.

(ii) High friction in threads causes rapid wear of the screw or the nut. In case of square
threads, the nut is usually made of soft material and replaced when worn out. In
trapezoidal hreads a split- type of nut is used to compensate for the wear.

5.4 Forms Of Threads

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 There are two popular types or threads used for power screws viz. square and
trapezoidal.

5.4.1 Advantages Of Square Threads

The ad vantages of square threads over trapezoidal threads are as follows:

The efficiency of square threads is more than that of trapezoidal threads.

(ii) There is no radial pressure on the nut. Since there is uniform. no side thrust, the
motion of the nut is The- fife of the nut is also increased.

5.4.2 Disadvantages of Square Threads

The disadvantages of square threads are as follows:

(i) Square threads are difficult to manufacture. They are usually turned on lathe with
single-point cutting tool. Machining with single-point cutting tool is an expensive
operation compared to machining with multi-point cutting tool.

(ii) The strength of a screw depends upon the thread thickness at the core diameter.
Square threads have less thickness at core diameter than trapezoidal threads. This reduces
the load carrying capacity of the screw.

(iii) The wear of the thread surface becomes a serious problem in the service life of the
power screw. It is not possible to compensate for wear in square threads. Therefore, when
worn out, the nut or the screw requires replacement.

5.4.3 Advantages of Trapezoidal Threads

The advantages of trapezoidal threads over square threads are as follows:

(1) Trapezoidal threads are manufactured on thread milling machine. It employs multi-
point cutting tool. Machining with multi-point cutting tool is an economic operation
compared to machining with single point-cutting tool. Therefore, trapezoidal threads are
economical to manufacture.

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(ii) Trapezoidal thread has more thickness at core diameter than that of square
thread.Therfore; a screw with trapezoidal threads is stronger than equivalent screw with
square threads. Such a screw has large load carrying capacity.

(iii) The axial wear on the surface of the trapezoidal threads can be compensated by
means of a split-type of nut. The nut is cut into two parts along the diameter. As wear
progresses, the looseness is prevented by tightening the two halves of the nut together,
the split-type nut can be used , only for trapezoidal threads.

5.4.4 Disadvantages Of Trapezoidal Threads

The disadvantages of trapezoidal threads are as follows:

(I) The efficiency of trapezoidal threads is less than that of square threads.

(ii) Trapezoidal threads result in side thrust or radial pressure on the nut. The radial
pressure or bursting pressure on nut affects its performance.

5.5 Torque Requirement Lifting Load

The screw is considered as an inclined Plane with inclination a. When the load is being
raised, following forces act at a point on this inclined plane

(I) Load W: It always acts in vertically downward direction.

(ii) Normal Reaction N: It acts Perpendicular (normal )to the inclined lane.

(iii) Frictional Force μN: Frictional force acts opposite to the motion. Since the load is
moving up the inclined plane, frictional force acts along the inclined plane in downward
direction.

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 Fig. 5.1 Torque Requirement Lifting Load

(iv) Effort P: The effort P acts in a direction perpendicular to the load W.It may act
towards right to overcome the friction and raise the load.

For an equilibrium of horizontal forces,

P =μ N cos α+ N sin α (a)

For an equilibrium of vertical forces,

W= N cos α + μN sin α (b)

The coefficient of friction μ is expressed as,

μ = tan Θ (c)

Where Θ is the friction angle.

p = W tan (Θ- α ) (d)

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 CHAPTER 6

CONCLUSION

Screw Jacks are the ideal product to push, pull, lift, lower and position loads of
anything from a couple of kilograms to hundreds of tonnes. The need has long existed for
an improved portable jack for automotive vehicles. It is highly desirable that a jack
become available that can be operated alternatively from inside the vehicle or from a
location of safety off the road on which the vehicle is located. Such a jack should
desirably be light enough and be compact enough so that it can be stored in an
automobile trunk, can be lifted up and carried by most adults to its position of use, and
yet be capable of lifting a wheel of a 4,000-5,000 pound vehicle off the ground. Further,
it should be stable and easily controllable by a switch so that jacking can be done from a
position of safety. It should be easily movable either to a position underneath the axle of
the vehicle or some other reinforced support surface designed to be engaged by a jack.
Thus, the product has been developed considering all the above requirements. This
particular design of the motorized screw jack will prove to be beneficial in lifting and
lowering of loads.

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