1

CHAPTER 1

INTRODUCTION

A hydraulic jack is a device used to lift heavy loads. The device itself is light, compact and
portable, but is capable of exerting great force. The device pushes liquid against a piston;
pressure is built in the jack's container. The jack is based on Pascal's law that the pressure of a
liquid in a container is the same at all points.

A hydraulic jack is a jack that uses a liquid to push against a piston. This is based on Pascal’s
Principle. The principle states that pressure in a closed container is the same at all points. If
there are two cylinders connected, applying force to the smaller cylinder will result in the same
amount of pressure in the larger cylinder. However, since the larger cylinder has more area, the
resulting force will be greater. In other words, an increase in area leads to an increase in force.
The greater the difference in size between the two cylinders, the greater the increase in the force
will be. A hydraulic jack operates based on this two cylinder system.

Pressure on a confined fluid is transmitted undiminished and acts with equal force on equal
areas and at 90 degrees to the container wall.

A fluid, such as oil, is displaced when either piston is pushed inward. The small piston, for a
given distance of movement, displaces a smaller amount of volume than the large piston, which
is proportional to the ratio of areas of the heads of the pistons. Therefore, the small piston must
be moved a large distance to get the large piston to move significantly. The distance the large
piston will move is the distance that the small piston is moved divided by the ratio of the areas
of the heads of the pistons. This is how energy, in the form of work in this case, is conserved
and the Law of Conservation of Energy is satisfied. Work is force times distance, and since the
force is increased on the larger piston, the distance the force is applied over must be decreased.

An electrically operated Hydraulic-type jack comprising a support base, a housing, a jack body,
a lifting ram which is contained in the jack body, a motor which is contained in the housing
and spur gears for transmitting the driving power of the motor to the lifting ram.
(Wikimedia,2017)
 2

The remote is used for control the jack from distance. in case of heavy object the jack can be
operated remotely. No need to control manually, this project reduces the accident.
1.1 LITERATURE REVIEW
A hydraulic jack is a mechanical device used as a lifting device to lift heavy loads or apply
great forces. A hydraulic mechanical jack employs the mechanism of a hydraulic power system
in the lifting of heavy equipment .(how hydraulic jacks work,2017) The most common form is a
car jack, floor jack or garage jack which lifts vehicles or trucks so that maintenance can be
performed. Hydraulic jacks are usually rated based on its maximum lifting capacity which
could include: 1.5 tons, 3 tons, 20 tons or 30 tons.. This works in such a way that it can be used
to lift heavy duty trucks very smoothly without any impact force and also a simple operation so
that even unskilled labour can use it with ease. This is an era of automation where it is broadly
defined as the replacement of manual effort with mechanical power in all degrees. The
mechanical automation remains to be an essential part of the system although it comes with
some physical changes on the jack; the degree of mechanization is greatly increased. Hydraulic
jacks uses fluid, which is incompressible, that is forced into a cylinder by a pump plunger
Hydraulic 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.
(how stuff works,2005). At this point the suction ball within the chamber is forced shut and oil
pressure builds in the cylinder. In other cases, some hydraulic jacks have horizontal pistons
which push 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. The incorporating of castors and wheels
allows for the compensation of the arc taken by the lifting pad; this mechanism provides a low
profile when collapsed, for easy maneuvering underneath the truck while allowing considerable
extension .The d c motor is coupled with the hydraulic jack by gear arrangement with the
rotation of the d c motor determining the lifting speed of the hydraulic jack.(Wikimedia,2017)

A mechanical jack is a device which lifts heavy equipment and vehicles so that maintenance
can be carried out underneath .A hydraulic jack is a device that uses a liquid to push against a
piston. This is based on Pascal’s Principle. The principle states that pressure in a closed
 3

container is the same at all points. If there are two cylinders connected, applying force to the
smaller cylinder will result in the same amount of pressure in the larger cylinder. However,
since the lager cylinder has more area, the resulting force will be greater. In other words, an
increase in area leads to an increase in force. The greater the difference in size between the two
cylinders, the greater the increase in the force will be. (S.K. Amedorme1,2016) A hydraulic
jack operates on this two cylinder system. Many trends (screw or hydraulics) have gone down
around the lifting applications in the automobile workshops. Increasing the mechanical
advantage of doing work remains the objective of these developments. (Dr.Ramachandra
CG,2013)

1.2 LITERATURE GAP

Upon reading the above review, one can spot many literature gaps which can be incorporated in
the current design. Increasing the “mechanical advantage of doing work” can be done by a
variety of ways. This includes using a larger piston diameter of ‘60cm’. this makes sure bigger
size loads can be placed on the ram(8). The second literature gap one could spot is a switch
which operates manually. In old devices, there was mechanical pushing of lever so that oil
pressure builds up near the ram. However in this device we will be using a electric motor which
pulls the oil with the help of a gearing tooth. This brings me to my next literature gap which is
usage of gears so that the motion of the ram can be reversed by a simple gearing arrangement.
On the same paper we can see another literature gap which is that the ram must be manually
brought back to initial position by manual force as there is no reverse gear incorporated but in
my project, the ram can be brought back to its initial position without the application of manual
force.(9). As we all know application of hydraulic oil in lifting heavy car bodies will be time
consuming and energy consuming as well. However if the jack is placed incorrectly and the
user is using the remote to lift the car, he can observe the car wont rise from the ground. That
can take long as it takes lot of time to lift the car gradually.
 4

1.3 MOTIVATION

The motivation for this project came from its benefits to the society. Even today people are
using traditional scissor jacks to manually bend down and place the jack and lift it which can be
tiresome. In a society where car mishaps happen every day, changing tyre with scissor jacks can
be frustrating. If changing a car tire can be this frustrating imagine an old person or a women in
the scenario, it can be devastating, so keeping them in mind I decided to fabricate the electro
hydraulic jack which can be operated from a safe distance. The jack is hydraulic so there is no
risk of high pressure like in the traditional pneumatic jacks. The jack will work with any source
of electric power like car cigar lighter. Normally people wont know the safe jacking locations
of the car and place it incorrectly and wait for the car to lift. However with this jack one can
just hear a click sound from the circuit board which means the lifting ram is in range of surface
of the car. If its not the circuit wont run and the click sound cant be heard. Only if the sensor is
in range of a nearby surface which the lifting ram can lift, then only the jack lifts the car. If this
wasn’t there then unnecessary lowering and raising of ram will waste tremendous amount of
power and time.

1.4 OBJECTIVES

The objectives of the project are as follows:

1. To fabricate an electro hydraulic jack using a 12V dc motor.

2. To optimize the size of the jack to as small as possible without affecting its efficiency

3. To make a remote control assembly for the jack

4. To add an IR sensor to the jack for ease in operation.

5. To successfully lift a car using the jack.

 5

CHAPTER 2

METHODOLOGY AND EXPERIMENTAL WORK

2.1 TECHNICAL SPECIFICATIONS

The products are safe and reliable, rational structure and operation of the Light advantages. The
car is the preferred tools necessary escorts.

12V electric cars special hydraulic jack

Mini Height: 130 MM
Max Height: 300 MM
Rated Voltage: 12 V
Rated Current: 10 A
Lifting Time: 30 second
Max lifting weight: 1500KG
Applicable for: car less than 1500 KG
Weight: 3.3 KG
Size: 17CM *14 CM *13.5 CM
Protection: if overload, current will be off automatic,it can be continue to work
automatic after 5 second

2.2 PROJECT EXECUTION STAGES

1.Planning an project idea

This stage is basically searching for ideas for the project. Upon finding many project concepts I
decided to go with a hydraulic based project as it was more exciting to see how hydraulic oil
can be used to lift heavy loads.
 6

2. Describing the project objectives and constraints.

The ways in which the project can help the society needs to be addressed. The features which
can be incorporated on the project was discussed at this point. Constraints were to see if I had
the time to complete the desired project and also its cost.

3. Designing the electro hydraulic jack

While designing the jack I had to consider many variables like force, pressure, volume and the
power of the jack. These were calculated before implementing fabrication. I also calculated the
spur gear dimensions in order to match its application. Another part of the design process was
choosing the standards, I decided to follow ISI standards. The hydraulic oil used follows ISO
standards. 2d and 3d modeling was done using solid works to get a clear idea before fabricating
the jack. The 2d and 3d modeling figures are attached in the figure section.

4. Fabrication
In this stage first I had to make a cost statement to see how much the cost of all the materials in
the jack would amount to. Then I went to the market to buy it. the fabrication of the jack
involved milling, drilling, welding and grinding. I had to use the process of air bleeding to
remove the vacuum from the jack and make it air tight. I also bought electrical components like
motor, circuit board parts, IR remote and the IR sensor. Upon attaching all the circuit boards
with the jack assembly. The jack was constructed and functional.

5. Testing
Upon fabrication I decided to implement it. The jack turned out to lift a max weight of
1.5tonnes safely. Lifting loads higher than that took too much time and the lift rate was
unpromising. The jack was so compact that the jack could easily fit into a car luggage space.
That was one of the main objectives of the jack. The IR sensor worked well by turning off and
on the circuit at the right time. The remote also served its purpose by giving a long range
operation to its user.
 7

2.3 DESIGN APPROACH DETAILS

12V electric cars special hydraulic jack

Rated Voltage: 12 V
Rated Current: 10 A
Max lifting weight: 1000KG
Size: 17CM *14 CM *13.5 CM

Load=9810N(max load)

Electrical work = 12V*10A=120W

Material chosen: mild steel

Design of pump cylinder:

Dimensions of the cylinder
Height=70mm
Inside Diameter=50mm
Tensile strength of mild steel=120N/mm2
Thickness of pump cylinder=5mm.
Outside diameter = Di+2t=50+2*5=60mm
Pressure developed =18bar (gear pump)
F=P*A
Area of the hollow cylinder = 3.14*(outer radii2- inner radii2 )=2202.43mm2
F=1.8N/mm2*2202.43mm2=4000N

Design of ram cylinder

Max Height=300mm
Outside diameter=100mm
Inside diameter=90mm
Area =6361.73mm2
 8

F=P*A
F=1.8*6361.73

=11449.8N (max lifting capacity)

Ram cylinder piston diameter

D=√ (4*A/∏)

= √ (4*6361.73/∏)

=90mm

Volume of ram cylinder=∏*(502-402)*300

=847800mm3=847.8cc of oil is required to displace the ram entirely.

Design of reservoir

However we take 30 per cent extra oil to be present in the reservoir.

So 130%*847.8=1102.4cc

For finding the dimensions of the reservoir(reservoir is a rectangular container)

V=1102000mm3 = L*B*H=200*200*27.5mm

I will be choosing the dimensions of base plate as 170mm*140mm to contain all the
components.

Hex nuts size preference

The nuts used on the base plate and in the assembly were of ASME and ISO standards.
M60 nut was used for mounting hydraulic cylinder. M52 nut was used for hydraulic oil tank.
M39 nut was used for motor clamp. The nut sizes were used as reference only.
 9

Design of spur gear

12V dc motor specifications.
Voltage=12Volts
Current = 10ampere
Power = 12*10= 120W
Speed =200rpm.
Gear ratio =3
Gear Duration=54*107 cycles
Material chosen = C40 steel
Power transmitted = 120W

Calculation of initial design torque.

Mt = P*60/2∏N
= 120*60/2*3.14*2000
=0.57
Assume open type symmetric scheme
Kd * k = 1.3
[Mt ] = 0.745Nm

Calculation of Young’s modulus, design bending stress and design contact stress
From PSG design data book 8.14
E=2.15*105N/mm2 (Kalaikathir Achchagam,2012)

Design bending stress

PSG book page 8.18
Choose rotation in 2 directions since jack must lift and lower its ram.
=1.4*bending life factor*endurance limit/n* fillet stress concentration
Assume surface hardness >350
Life cycle > 25*107
PSG data book page 8.20
Kbl = 0.7 (Kalaikathir Achchagam,2012)
 10

Factor of safety for steel, normalized or tempered

N=2

Fillet stress concentration

For steel normalized
Fillet stress concentration =1.5

Endurance limit
PSG design book pg 8.19,
Alloy steel taken C40 steel
Endurance limit = 0.35* ultimate tensile strength+120 (Kalaikathir Achchagam,2012)
PSG design book Pg1.9
Tensile strength = 58.68 N/mm2average value (Kalaikathir Achchagam,2012)
Endurance limit = 035* 58.7+120 = 340.5N/mm2

Design bending stress

=1.4*0.7*340.5/2*1.5
Design bending stress = 111.2N/mm2

Design contact stress

PSG design book pg8.16
Design contact stress=CR*HRC*Kcl (Kalaikathir Achchagam,2012)
HRC= 40 to 55
CR=26.5
For C40 hardened and tempered
For Kcl ,PSG design book page 8.17
In option of steel, hardness>350, cycle >25*10^7
The value is 0.585 (Kalaikathir Achchagam,2012)
Design contact stress CR *HRC* Kcl
=26.5*55*0.585
=852.65N/mm2
 11

Centre distance
PSG design book pg 8.13
A= (i+1) 3√(0.742*E*[Mt])/(design contact stress*gear ratio * Φ) (Kalaikathir
Achchagam,2012)

Φ=b/a
In PSG data book page 8.14
Its value is 0.1 to 0.3 (Kalaikathir Achchagam,2012)
A= (4)* 3√(0.742*2.15*10^5*0.5)/(852.63*3 *0.3)
A=19.4mm

Selection of no. of teeth for pinion and gear

Assume for pinion Z1 as 17teeth
Z2=3*17 = 51teeth

Calculation of module
PSG design book page8.22
M=2*a/(Z1+Z2)
M=0.57mm
Recommended value m=5mm

Revision of center distance

PSG data book pg 8.22 (Kalaikathir Achchagam,2012)

A = 0.57*(17+51)/2
A =19.38mm

D=0.57*17=9.69mm

Revision of design torque

[Mt] =0.745Nm
 12

Revision of K and Kd values

Assume K is 1.03 for symmetric
IS 8,>350, pitch line velocity of 8m/s gives Kd value of 1.4 from page 8.15 PSG design book.
[Mt] 0.745*1.4*1.03 (Kalaikathir Achchagam,2012)
=1.07Nm

Check for bending stress

Bending stress= i+1[Mt]/(a*m*b*y)

Y from pg 8.18 of PSG design data book is 0.366

Bending stress = 3+1/(19.38*0.57*0.366) (Kalaikathir Achchagam,2012)
Bending stress = 0.989N/mm2
Comparing design bending stress, the current value is lesser so design is safe.

Check for contact stress

Pg 8.13 of PSG design book,
Contact stress = 0.74*(4)/19.38*√(4)*2.15*10^5*0.745/(3*b) (Kalaikathir Achchagam,2012)
ɸ=b/a
0.3=b/19.38
b=5.84
Contact stress = 0.74*(4)/19.38*√(4)*2.15*10^5*0.745/(3*5.84)
=29.2N/mm2
Since calculated contact stress is less than design value, its design is safe.
Thus the gear is safe to operate.

Calculation of cylinder

Area of cross section of the ram cylinder = 3.14*d2/4

=314* 4.552/4
=0.0016mm2
Pressure under the cylinder to withstand the force.
 13

Load acting is 1.5tonne=1500kg=15,000N

Pressure = 15000/ 0.0016
P=9.375*106N/m2
According to Pascals law, the pressure acting at the bottom of the ram cylinder must be same as
the one in the plunger cylinder.
In order to support this load the force acting on the small cylinder must be
F =(P*A)
F=9.375*106N/m^2 * (0.022*3.14)/4
F=2943.75N
Torque required

T = Torque =? Nm

P = Power = 12*10=120W

N1 = at low speed = 60 rpm

N₂ = at high speed = 120 rpm

CASE 1: case 2:

T = (P) ÷ (2π N₁) T = (P×60) ÷ (2π N₂)

T = (120×60) ÷ (2×Π×60) T = (120×60) ÷ (2×Π×120)

T = 19 Nm T = 9.5NM
 14

BUFFER&DRIVER

When the user programs the schedule for the automation using Graphical User Interface
software, it actually sends 5-bit control signals to the circuit.. This circuit takes the 5-bit
control signal, isolates the CONTROLLER from this circuitry, boosts control signals for
required level and finally fed to the driver section to actuate relay. These five relays in
turn sends RC5 coded commands with respect to their relay position. (Parth M,2016)

First the components used in this Module are discussed and then the actual circuit is
described in detail.

HEX BUFFER / CONVERTER [NON-INVERTER] IC 4050: Buffers does not affect the
logical state of a digital signal (i.e. logic 1 input results into logic 1 output where as logic
0 input results into logic 0 output). Buffers are normally used to provide extra current
drive at the output, but can also be used to regularize the logic present at an interface. And
Inverters are used to complement the logical state (i.e. logic 1 input results into logic 0
output and vice versa). Also Inverters are used to provide extra current drive and, like
buffers, are used in interfacing applications. (Wikimedia,2017).This 16-pin DIL packaged
IC 4050 acts as Buffer as-well-as a Converter. The input signals may be of 2.5 to 5V
digital TTL compatible or DC analogue the IC gives 5V constant signal output. The IC
acts as buffer and provides isolation to the main circuit from varying input signals.

These relays with +12V working voltage can be used to produce five command signals with
RC5 format. The N/O [Normally Open] contact of each relay produces one command signal
with the help of RC5 Transmitter Circuit.
 15

IR transmitter

Circuit Description:

The Infra Red Transmitter is made very simple by employing the dedicated & commercially
available . (howstuffworks,2005)

Since the Circuit is intended to send only one signal code, IC1 is configured for address one
[refer the table in IC description] by making all the Address Input pins, Code pins to zero or
ground. As soon the switch S1 is switched ON, the circuit gets its working voltage of 9 Volts
through pin-20. Inside the IC, it creates the address 1 as a command code and sent to the output
pin-19.

This command signal output from the IC1 is given through a resistor R1 to the base of the
Transistor T1. The output from this transistor T1 is fed to the base of another Transistor T2.
These two transistors amplify the command signal to the sufficient level and then drive the IR
LEDs. The Collector of both the transistors is connected to the pair of Infra Red LEDs. When
the transistor T2 goes to saturation region, that means starts

conducting, the current will flow through the two series IR LEDs. Thus they illuminate for that
period and gets off. This process continues as per the switch S1 is pushed ON and the pulses
will be sent through IR LEDs continues. Thus the command signal is transmitted to IR receiver
successfully.

IR Receiver, Driver & Circuit Breaker

The ‘packets’ of infra-red light transmitted from the IR Transmitter of the user remote control
are received on a sensor module which is sensitive to infra-red light.. And that electrical pulse is
fed to driver circuit, which in result supply trigger pulse to Schmitt Trigger circuit. The circuit
components are explained as:

IR RECEIVER EYE: An IR Receiver Eye is a module, which is encapsulated with Photo

Transistor whose semiconductor junction is mounted beneath an optical lens. It is normally
used in its open base configuration and act as a light-to-voltage converter. The base is open; the
value of the reverse current across collector and emitter will depend on the amount of
 16

illumination on the base face. In dark conditions it is near zero and under bright light it is tens
or hundreds of mA.

Circuit Description:

This circuit activates the relay whenever there is a presence of Infra Red Rays.

Power Supply: The mains voltage is step-down to 6V using a transformer. This secondary 6V is
rectified using full-wave rectifier, which is composed by D1 & D2 diodes. This is further
filtered using electrolytic capacitor C2 and fed to regulator IC1. This three-terminal IC
stabilizes the input and gives out the constant +5V as working voltage for the circuit.

IR Receiver: The IR Sensor Module has 3 terminals: signal input, supply pin and the ground
pin. This module works on regulated +5Votls, and exceeding this limit may cause the damage
of it. So, this Sensor is given through a biasing resistor R1 and grounded pin is given to
negative terminal of the supply. Whenever the Infra Red rays falls on this Sensors eye [that
black mole on Sensor] it produces varying signal voltages at output pin. .The output of this
amplifier is fed to a buffer situated in IC2. This buffer or converter enhances the current
capacity of the signal and send to driver stage. The signal output is monitored by observing the
glowing indicator LED D4.

Driver & Circuit Breaker: The driver is built around TR1 and a low-impedance. When user
doesn’t press any key, the receiver does not receive any IR rays from the opposite end, and
hence No signals to TR2 base.

As this E-Power Supply unit’s Receiver senses interrupt of IR Rays from the opposite IR
Transmitter, it alerts driver section. The IR signal from the buffer enters the base of TR2, it
undergoes saturation and activates the relay RL1. Since, relay RL1’s N/O [Normally Open]
pins are connected to Schmitt Trigger Circuit.
 17

Fabrication of hydraulic cylinder

Parts Of Hydraulic Jack:-

Parts Of Cylinder

Cylinder Barrel:-

The cylinder barrel is mostly a seamless thick walled forged pipe that must be machined
internally. The cylinder barrel is ground and/or honed internally. (K Sainath,2014)

Cylinder Base Or Cap:-

In most hydraulic cylinders, the barrel and the bottom portion are welded together. This can
damage the inside of the barrel if done poorly. Therefore, some cylinder designs have a screwed
or flanged connection from the cylinder end cap to the barrel. In this type the barrel can be
disassembled and repaired.

Cylinder Head:-

The cylinder head is sometimes connected to the barrel with a sort of a simple lock. In general,
however, the connection is screwed or flanged.

Piston Rod:-

The piston rod is typically a hard chrome-plated piece of cold-rolled steel which attaches to the
piston and extends from the cylinder through the rod-end head. In double rod-end cylinders, the
actuator has a rod extending from both sides of the piston and out both ends of the barrel. The
piston rod connects the hydraulic actuator to the machine component doing the work. This
connection can be in the form of a machine thread or a mounting attachment, such as a rod-
clevis or rod-eye. These mounting attachments can be threaded or welded to the piston rod or,
in some cases, they are a machined part of the rod-end.
 18

Piston Rod Construction:-

The piston rod of an hydraulic cylinder operates both inside and outside the barrel, and
consequently both in and out of the hydraulic fluid and surrounding atmosphere.

Metallic Coatings:-

Smooth and hard surfaces are desirable on the outer diameter of the piston rod and slide rings
for proper sealing. Corrosion resistance is also advantageous. A chromium layer may often be
applied on the outer surfaces of these parts.. High quality stainless steel such as AISI 316 may
be used for low stress applications. Other stainless steels such as AISI 431 may also be used
where there are higher stresses, but lower corrosion concerns.

Ceramic Coatings:-

Due to shortcomings of metallic materials, ceramic coatings were considered. Initially ceramic
protection schemes seemed ideal, but porosity was higher than projected.

Length:-

Piston rods are generally available in lengths which are cut to suit the application. As the
common rods have a soft or mild steel core, their ends can be welded or machined for a screw
thread.

Gland (End Cap):-

The cylinder head is fitted with seals to prevent the pressurized oil from leaking past the
interface between the rod and the head. This area is called the rod gland. It often has another
seal called a rod wiper which prevents contaminants from entering the cylinder when the
extended rod retracts back into the cylinder. The rod gland also has a rod wear ring. This wear
ring acts as a liner bearing to support the weight of the piston rod and guides it as it passes back
and forth through the rod gland. In some cases, especially in small hydraulic cylinders, the rod
gland and the rod wear ring are made from a single integral machined part.
 19

Components of the jack

Base plate

The base plate was made at certain dimension to hold all the component of the jack assembly.
For making the base plate, I had to use drilling operation to make ducts in the plate. The ducts
were made throughout the base plate as internal drilling would be hard. The outlets of the ducts
were closed with an hex bolt.

Hex bolt

The hex bolt was made from threading operation on a lathe.

Motor Shell casing and hydraulic cylinder casing

The motor shell casing and cylinder casing was made from c40 steel. The steel sheets were
rolled with plate rolling machines. Then after rolling in circular shape their ends were welded
together and then the weld deposits were removed by sandering.

Gear assembly

The gear assembly was made from gear blanking by milling process. It was attached to the
motor shaft afterwards.

Oil tank-The oil tank was made of rubber so that it could withstand the high pressure of the jack
operation.

Air bleeding

The setup was needed to remove air from the ducts. So air bleeding was performed so as to
make the jack air tight.
 20

Components of the hydraulic jack assembly.

1.1Base plate

1.2.Motor clamp
 21

1.3.Gear pump front

1.4. Hydraulic cylinder

 22

1.5.Oil tank

1.6.Motor case
 23

1.7.Screw for cylinder

 24

1.8. Screw for oil tank

 25

1.9. Screw for motor clamp

 26

2.4 Realistic and design constraints addressed

The main constraint I came across was the inability of the jack to lift the load of 2 tons as
planned as most of the automobile comes with mass of 1 to 2 tons. 2 tons lifting capacity would
have made the jack more handy. This was not possible as the jack lifting 2 tons mass would
require a better motor. Installing a bigger motor will make the assembly more bulky, expensive
and heavy. So I decided not to.
Another constraint in the project is the maintenance of the jack. The lifting jack needs to be
oiled up at each operation or else it may not work smoothly.
Power is also a major constraint in this jack, the jack uses a lot of power for its application.
Time constraint was also there as I had planned more features on the jack but couldn’t do all of
them.
2.5 CODE AND STANDARDS
The following are the standards used in making this hydraulic jack assembly
ISO standards followed in designing hex nuts
Hydraulic oil used also follows ISO standards
Steel used also follows ISO standards and SAE standards.
 27

CHAPTER 3

RESULTS AND DISCUSSION

3.1 PARAMETERS UNDER STUDY AND PERFORMANCE METRICS

After implementing all the design steps, the fabrication of remote control electro hydraulic jack
is made possible.
For this section of the report I will be comparing 2 important variables to analyze the jack
efficiency.
Load and time
Under experimentation it was shown that gradual increase in load is directly proportional to
time taken for the jack to rise to its full height.
S.no Load applied (kg) Time taken for full lift (s)
1 0 40
2 1200 195
3 1500 315

The mode of experimentation was done on the following cars

Toyota innova(1500kg) and Honda civic(1200kg)
 28

350 load(kg) vs take taken for f ull lift(s)

300

250

t
i 200
m
e time take for full lift (s)
150
t
a
k 100
e
n
50

0
0 200 400 600 800 1000 1200 1400 1600
load applied(kg)

It can be seen from the table that the time taken to lift the heavier car takes more time compared
to the lighter car.

The other parts of the jack were working well. The circuit parts like infrared allowed me to
operate the jack from a distance of around 5metres. The IR sensor worked well and was
shutting off the jack if the car surface distance was greater than 3cm(from the cylinder head)
The picture below shows the picture of the hydraulic jack
29
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CHAPTER 4

CONCLUSION

The electro hydraulic jack was planned to help the society. Initially I planned the jack to be
made for a longer time but the work was finished in time. The jack was able to lift 1.5 tons even
though I planned it to lift at least 2 tons. However the jack was able to lift the 1.5 tons vehicles
with no issues. I had planned to make more alterations in the jack so that its lifting time would
be reduced by reducing the size of the ducts or reducing the distance between the gear and the
hydraulic cylinder so that losses would be minimal. The components of the jack were as
compact as possible so I couldn’t make changes.

4.1 Contributions to literature

The project remote controlled electro hydraulic jack with IR sensor adds more features to the
existing hydraulic jacks. From the project it can be shown that the traditional mechanical jacks
make the user tiresome. So this jack needing no manual power can work with ease. The remote
helps the user to operate at a far distance and don’t need them to bend down for long time. The
IR sensor shows if the jacking location is correct on the car or not. This is because there are
many times where vehicles may topple due to wrong jacking location.

These features were not observed in many traditional hydraulic jacks.

4.2 Scope for future work

Even though the jack model comes with many useful features. Many more features can be
added to the jack to make it more user friendly. One example is making the hydraulic jack in
built so that one does not need to get down from the car to place the jack. The car systems must
be able to deploy the jack on user demands. The car lcd display must display the lift of the car
through a live video. The jack must be modified in such a way that it can be operated by
rotating the car steering wheel. All this can help for further improvement of the electro
hydraulic jack.
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CHAPTER 5
REFERENCES

Book references

1. Design Data: Data Book Of Engineers By PSG College-Kalaikathir Achchagam -

Coimbatore – 2012

Journal reference
1. K.Sainath, MohdSalahuddinbMohdJibranBaig,MdAzam Ali Farooky, Mohammed
Siddique Ahmed,MohdRiyazUddin, Faraz Ur Rehman Azhar, Md Shaffi, ,Design of
Mechanical Hydraulic Jack, IOSR Journal of Engineering (IOSRJEN) Vol. 04, Issue 07
(July. 2014),1-28.
2. Parth M. Patel, Parth S. Patel, Vaaibhav H shah, Suril R. shah, Automatic hydraulic jack
inbuilt in a four wheeler, International journal of scientific and technology research
volume 5, issue 08, August 2016,1-3
3. Dr. Ramachandra C G, Krishna Pavana, Shivraj Shet and Venugopal Reddy
Virupaxappa B, DESIGN AND FABRICATION OF AUTOMOTIVE HYDRAULIC
JACK SYSTEM FOR VEHICLES, International Journal of Advances in Engineering
Research, (IJAER) 2013,Vol. No. 6, Issue No. VI, Dec,1-14
4. S.K. Amedorme1 , Y.A.K. Fiagbe, Modification of an Existing Small Hydraulic Jack
for Lifting Light Duty Vehicle, International Journal of Science and Technology
Volume 5 No. 11, November, 2016 ,1-6

Website reference
1. "Digital Buffer." Wikipedia. Wikimedia Foundation, 10 Mar. 2017. Web. 27 Feb. 2017.
2.“How Hydraulic jacks works”. How hydraulic jacks work.N.p.,n.d.web.27 February 2017.
3. "How Remote Controls Work." HowStuffWorks. N.p., 10 Nov. 2005. Web. 27 Feb. 2017.
4. Jack(device).” Wikipedia. Wikimedia Foundation,24 Feb 2017.web.24 Feb 2017.