PROJECT REPORT ON

HYDRAULIC LIFT FOR

LIFTING HEAVY MATERIALS

SUBMITTED TO:-
JOHN GOULD
SUBMITTED BY:-
TRIBHUVAN SHARMA
STUDENT ID [2905083]
MANAGING MECHATRONICS

COURSE: - GRADUATE DIPLOMA IN MECHATRONICS

WELINGTON INSTITUTE OF TECHNOLOGY

CONTENTS
 ABSTRACT.

 SCOPE.

 COMPONENTS REQUIRED.

 SPECIFICATIONS.

 BLOCK DIAGRAM.

 PROJECT PLANNING

 BUDGET REPORT.

 CASH FLOW RATE.

 RESOURCE USAGE.

 HAZOP study.

 INTRINSIC FAIL SAFE DESIGN.

 COMMISSIONING REPORT.

 REFRENCES.
ABSTRACT:-
This report is on a hydraulic lift whose functioning is predominantly governed
by a microcontroller. It can lift heavy loads e.g. heavy machinery, cars or
trucks, or even a bigger group of 25 to 30 people from one floor of a building to
another.

SCOPE:-
Generally the commonly used lifts have got more mechanical components and
we all know that mechanical components are subjected to more wear and tear,
create unwanted heat due to friction and require more maintenance. Hydraulic
system can generate more power and are more robust as compared to
conventional pulley block and tackle system used in lifts and when this system
is incorporated with electronic controls and programming it becomes more
efficient, cost economic, and requires less maintenance thus giving smooth
functioning.

TIME:-
It takes one week for initial research, planning and analysis. For designing and
building the actual lift it takes two weeks and one more week for
implementation and testing the project. So it takes all in all 4 weeks to finish the
project.

COMPONRNTS REQUIRED:-

1. Microcontroller.

2. DC generator.

3. Hydraulic motor.

4. Flow control valve.

5. Current sensor.
 6. RPM transmitter.

7. Lifting cylinder with piston.

8. Alarm.

SPECIFICATIONS:-

1. Microcontroller
It is the heart of the whole assembly because it contains all the data and
programmes in its memory. It is connected to all the input and output devices
and gives commands to all the components to do their desired actions. E.g.
Arduino. It can be programmed in different ways as per desired by the
operator.

2. DC generator.
It is connected to the hydraulic motor and provides torque to the shaft of the
motor. It acts both as motor and generator.In the lifting operation, the DC
generator acts as a motor and drives the hydraulic motor in such a rotational
direction that hydraulic fluid is conveyed from storage tank through the
control valve arrangement and into the hydraulic cylinder. In the lowering
operation, the piston conveys, under the influence of the load, the hydraulic
fluid back through the control valve arrangement and into the storage tank.
The hydraulic motor operates in motor operation and drives the DC
generator, operating as a generator.

3. Hydraulic motor.
Its function is to pump the liquid up from the storage tank into the hydraulic
cylinder during lifting operation and pump it back to the storage tank while
lowering operation.

4. Flow control valves.

 It controls the amount of fluid that has to be pumped into the hydraulic
lifting cylinder. It gets its signals from the microcontroller and supplies a
particular amount of fluid thus governing the speed of the lift.

5. Current sensor.
It creates an interface between the input circuit and DC generator and it
assures that the predetermined value of the torque of the DC generator is
maintained.

6. RPM transmitter.

An rpm transmitter is coupled to the shaft of the hydraulic motor, which

transmits a signal corresponding to the rpm of the hydraulic motor to the
lifting mechanism control. The lifting mechanism control comprises
regulation means, which, depending on the determined rpm, influences the
excitation of the DC generator in such a way that a predetermined desired
rpm can be maintained in motor operation, as well as in generator operation.

7. Lifting cylinder with piston.

It is the hydraulic cylinder with a piston with which the lifting cage is
attached. So when the fluid under pressure lifts up the piston the lifting cage
gets lifted up.

8. Alarm.
Alarm in a hydraulic lift is a fault indicator which is incorporated in the
output circuit which rings up in any kind of malfunctioning and unexpected
operation of the lift.

Block diagram:-

Hydraulic
DC motor
motor
 Lifting cage

Storage tank
Project planning
Budget report:-
Cash flow rate:-
Resource usage:-
HAZOP STUDY:-

HAZOP study is well-proven structured team-based method for hazard

identification at process design completion or for planned modifications. The
technique makes detailed examination of the process and engineering
intention of new or existing facilities to assess the hazard potential of
operation outside the design intention, or malfunction of individual items of
equipment and their consequential effects on the facility as a whole.

HAZOP is led by an experienced facilitator. A hazard that has been

overlooked can have a significant impact on the overall success of the
venture. An effective HAZOP provides the most penetrating design review,
covering safety, environment, operations, and maintenance.

HAZOP ensures that potential deviations from intended design function are
identified and corrected and actions for necessary process or instrumentation
improvements can planned.

PURPOSE, OBJECTIVE AND SCOPE OF THE STUDY:

 To check the safe operation of the system.
 To prevent the hazard that may occur.
 To reduce the impact on environment.
 Develop safety measures to deal with emergency cases.

HAZOP team members.

1. Mechanical engineer.
2. Electronics engineer.
3. Maintenance engineer.
 Guide words Parameters Explanation.

No Bursting of pipes Never happens. Pipes are

designed so as to bear more
carrying fluid. pressure. More over flow
control valves are there.
Rare Motor or pump stops Happens very rarely. May be
due to some problem in the
working. armature coil or extra pressure
build-up. .
Less Excessive noise and Because all the mechanical
parts are controlled
friction. electronically by programming
in microprocessor.
Never. Leakage of fluid. Because the pipes are insulated
with extra epoxy coating.

INTRINSIC FAIL SAFE DESIGN

Intrinsic fail safe design is designed so as to make the parts safe even when they
start working in unexpected manner. Fail-safe design always starts with an
assumption as to the most likely kind of wiring or component failure, and then
tries to configure things so that such a failure will cause the circuit to act in the
safest way, the "safest way" being determined by the physical characteristics of
the process. These fundamental principles extend to non-electrical systems as
well: identify the most common mode of failure, and then engineer the system
so that the probable failure mode places the system in the safest condition.
Here in our project we are using two basic ways to make our design fail safe.

Orderly shutdown:-
In this shutdown procedure the whole of lift shuts down in a synchronized and
orderly manner after all work in progress has been completed permitting the
restart of the system without any damage of parts components and programming
of the lift.
Emergency shutdown:-
When the lift starts deviating from its normal working cycle resulting in some
severe damage to anything, it has to be shutdown and stopped to the safest
position i.e. (nearest floor) to it. This can be done by an emergency shutdown
button which when pressed stops the system instantly.

The emergency button when pressed will activate the alarms and another signal
gets automatically passed to the microcontroller when then stops the lift to its
safest mode.

Fire alarm and separate pump provisions.

Chances of fire as we have discussed are very less due to less friction and less
mechanical components. But still if there is any the fire alarm is provided which
will automatically stop the lift and open the doors to its safest floor and will also
activate the fire extinguishers.

Also if in any case if the hydraulic pump stops pumping fluid there is a
provision of a separate pump which will keep pumping fluid to the hydraulic
cylinder and the lift will keep on moving.

 Along with these basic safety requirements we can also use an RPM
transmitter to the shaft of hydraulic motor. An RPM transmitter transmits
a signal corresponding to the RPM of hydraulic motor to the
microcontroller and it thus regulates the excitation of DC motor
depending upon the return signal given by microcontroller. Finally it
helps in maintaining desired RPM in motor and generator operation,
reduces any chances of trouble shooting with the motor operation and
thus making our lift performance more smooth and our design safer.
Commissioning report:-
Commissioning is a process for achieving, verifying, and documenting the
performance of a facility to meet the operational criteria of the contract design
documents.  Its intent is to furnish the Owner with a high degree of assurance
that the equipment and systems have been installed in the prescribed manner
and will operate according to the performance guidelines.

Purpose: - Commissioning of a current sensor in hydraulic lift.

Model description:-
 High linearity and accuracy.
 Capable of switching 1.5 HP to 2.5 HP @ 120 v AC to @$) v AC.
 Operating range is 20 amps to 100 amps.
 Fast response and low temperature drift.
 Adjustable mounting bracket for installation flexibility.
 Override protection and current feedback control system.
 Visual indication for output status(LEDs)
 Hysteresis error +_20mv.
 Operating temperature -10degreeC+80degreeC
 Response time is < 5μs.

Price: $ 50 when ordered as part of a system.

Installation points to be checked:

Installation Points to be checked Complete Comments

Check whether the system is turn on.
Check whether the power supply is working.
Check whether all the wires are connected properly.
Check whether sensor pins are connected properly.
Check the output of the sensors.
Check the output of microcontroller
Check whether GSM modem is working
Replace the faulty components

I hereby undertake that the System referenced above has been commissioned by
me, in accordance with the prescribed commissioning report above and that I
am satisfied that all of the installation points specified have been correctly
followed / checked.

Tribhuvan Sharma.

10- oct- 2009

References:-
 www.freepatentsonline.com
 www.directindustry.com