Design and Fabrication of Motorized Screw Jack For Four Wheelers

CHAPTER-1
INTRODUCTION

Our research survey in this regard revealed that in several automobile, mostly some
difficulties in lifting the vehicles for reconditioning, repair and maintenance. This fabricated
model has mainly concentrated on this difficulty, and hence a suitable device has been
designed, such that the vehicle and heavy objects can be lifted from floor land without the
application of 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 its essential
tools on automobile garages. The motorized screw jack has been developed to satisfy the
needs of small and medium automobiles, which are normally man powered with minimum
skilled labour. In most of the vehicles are lifted by using screw jack. This needs high man
power and skilled labour. In order to avoid all such disadvantages, the automated motorized
object lifting jack has been designed in such a way that it can be used to lift the vehicle very
smoothly without any impact force. The operation is made simple so that even unskilled man
can use it with easy. The dc motor is coupled with the lead screw by gear arrangement, the
lead screw rotation depends upon the rotation of dc motor. 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 essential part of the system although with
changing demands on physical input, the degree of mechanization is increased.

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NEED FOR AUTOMATION:

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

of these sources, mechanical form an attractive medium for low cost automation. The main
advantages of all pneumatic systems are economy and simplicity. Automation plays an
important role in mass production.

 To achieve mass production

 To reduce man power
 To increase the efficiency of the plant
 To reduce the work load
 To reduce the production cost
 To reduce the production time
 To reduce the material handling
 To reduce the fatigue of workers
 To achieve good product quality
 Less Maintenance

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

CHAPTER 2
LITERATURE SURVEY

Screw type mechanical jacks were very common for jeeps and trucks of World War
II vintage. For example, the World War II jeeps (Willys MB and Ford GPW) were issued the
"Jack, Automobile, Screw type, Capacity 1 1/2 ton", Ordnance part number 41-J-66. This
jacks, and similar jacks for trucks, were activated by using the lug wrench as a handle for the
jack's ratchet action to of the jack. The 41-J-66 jack was carried in the jeep's tool
compartment. Screw type jack's continued in use for small capacity requirements due to low
cost of production raise or lower it. A control tab is marked up/down and its position
determines the direction of movement and almost no maintenance. The virtues of using a
screw as a machine, essentially an inclined plane wound round a cylinder, was first
demonstrated by Archimedes in 200BC with his device used for pumping water.
There is evidence of the use of screws in the Ancient Roman world but it was the
great Leonardo da Vinci, in the late 1400s, who first demonstrated the use of a screw jack for
lifting loads. Leonardo‟s design used a threaded worm gear, supported on bearings, that
rotated by the turning of a worm shaft to drive a lifting screw to move the load - instantly
recognizable as the principle we use today. We can’t be sure of the intended application of
his invention, but it seems to have been relegated to the history books, along with the
helicopter and tank, for almost four centuries. It is not until the late 1800s that we have
evidence of the product being developed further.
With the industrial revolution of the late 18th and 19th centuries came the first use of
screws in machine tools, via English inventors such as John Wilkinson and Henry Maudsley
The most notable inventor in mechanical engineering from the early 1800s was undoubtedly
the mechanical genius Joseph Whitworth, who recognised the need for precision had become
as important in industry as the provision of power. While he would eventually have over 50
British patents with titles ranging from knitting machines to rifles, it was Whitworth’s work
on screw cutting machines, accurate measuring instruments and standards covering the angle
and pitch of screw threads that would most influence our industry today. Whitworth’s tools
had become internationally famous for their precision and quality and dominated the market
from the 1850s. Inspired young engineers began to put Whitworth’s machine tools to new
uses.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

During the early 1880s in Coaticook, a small town near Quebec, a 24- year-old
inventor named Frank Henry Sleeper designed a lifting jack. Like da Vinci’s jack, it was a
technological innovation because it was based on the principle of the ball bearing for
supporting a load and transferred rotary motion, through gearing and a screw, into linear
motion for moving the load. The device was efficient, reliable and easy to operate. It was
used in the construction of bridges, but mostly by the railroad industry, where it was able to
lift locomotives and railway cars. Local Coaticook industrialist, Arthur Osmore Norton,
spotted the potential for Sleeper’s design and in 1886 hired the young man and purchased the
patent. The Norton‟ jack was born. Over the coming years the famous “Norton” jacks were
manufactured at plants in Boston, Coaticook and Moline, Illinois. Meanwhile, in Alleghany
County near Pittsburgh in 1883, an enterprising Mississippi river boat captain named Josiah
Barrett had an idea for a ratchet jack that would pull barges together to form a „tow‟. The
idea was based on the familiar lever and fulcrum principle and he needed someone to
manufacture it. That person was Samuel Duff, proprietor of a local machine shop, together,
they created the Duff Manufacturing Company, which by 1890 had developed new
applications for the original “Barrett Jack” and extended the product line to seven models in
varying capacities.
Over the next 30 years the Duff Manufacturing Company became the largest
manufacturer of lifting jacks in the world, developing many new types of jack for various
applications including its own version of the ball bearing screw jack. It was only natural that
in 1928, The Duff Manufacturing Company Inc. merged with A.O. Norton to create the Duff-
Norton Manufacturing Company. Both companies had offered manually operated screw jacks
but the first new product manufactured under the joint venture was the air motor-operated
power jack that appeared in 1929. With the aid of the relatively new portable compressor
technology, users now could move and position loads without manual effort. The jack, used
predominantly in the railway industry, incorporated an air motor manufactured by The
Chicago Pneumatic Tool Company. There was clearly potential for using this technology for
other applications and only 10 years later, in 1940, the first worm gear screw jack, that is
instantly recognizable today, was offered by Duff-Norton, for adjusting the heights of truck
loading platforms and mill tables. With the ability to be used individually or linked
mechanically and driven by either air or electric motors or even manually, the first model had
a lifting capacity of 10 tons with raises of 2” or 4”. Since then the product has evolved to
push, pull, lift, lower and position loads of anything from a few kilos to hundreds of tonnes.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

One of the biggest single screw jacks made to date is a special Power Jacks E-Series
unit that is rated for 350 tonnes –even in earthquake conditions for the nuclear industry. More
recent developments have concentrated on improved efficiency and durability, resulting in
changes in both lead screw and gearbox design options for screw jacks. A screw jack that has
a built-in motor is now referred to as a linear actuator but is essentially still a screw jack.
Today, screw jacks can be linked mechanically or electronically and with them advances in
motion-control, loads can be positioned to within microns. Improvements in gear technology
together with the addition of precision ball screws and roller screws mean the applications for
screw jacks today are endless and a real alternative to hydraulics in terms of duty cycles and
speed at a time when industry demands cleaner, quieter and more reliable solutions. Screws
Application is used in the elevation of vehicles or objects.
The operation of the screw jack is such that it comprises a handle for driving a bolt
element (Lead Screw) manually so as to adjust the height of the Jack to elevate a vehicle or
the object. The operation of the jack manually makes it difficult for most women and the
elderly to operate since much effort is needed to drive the screw jack which results in low
linear speed and time consuming. These presently available jacks further require the operator
to remain in prolonged bent or squatting position to operate the jack. Doing work in a bent or
squatting position for a period of time is not ergonomic to human body. It will give back ache
problem in due of time. Suppose car jacks must be easy to use by women or whoever had
problem with the tyres along the road. The objective of this paper is therefore to modify the
existing design of car jack by incorporating an electric motor into the existing screw jack to
make the operation easier, safer faster and more reliable.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

CHAPTER- 3

MANUFACTURING PROCESS

Manufacturing processes are the steps through which raw materials are transformed
into a final product. The manufacturing process begins with the creation of the materials from
which the design is made. These materials are then modified through manufacturing
processes to become the required part. Manufacturing processes can include treating (such as
heat treating or coating), machining, or reshaping the material. The manufacturing process
also includes tests and checks for quality assurance during or after the manufacturing, and
planning the production process prior to manufacturing.

Fig. 3.1 Manufacturing process

3.1 SAWING
Cold saws are saws that make use of a circular saw blade to cut through various types
of metal, including sheet metal. The name of the saw has to do with the action that takes
place during the cutting process, which manages to keep both the metal and the blade from
becoming too hot. A cold saw is powered with electricity and is usually a stationary type
of saw machine rather than a portable type of saw.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

Fig. 3.2 Sawing cutting machine

The circular saw blades used with a cold saw are often constructed of high speed
steel. Steel blades of this type are resistant to wear even under daily usage. The end result is
that it is possible to complete a number of cutting projects before there is a need to replace
the blade. High speed steel blades are especially useful when the saws are used for cutting
through thicker sections of metal.

Along with the high speed steel blades, a cold saw may also be equipped with a blade
that is tipped with tungsten carbide. This type of blade construction also helps to resist wear
and tear. One major difference is that tungsten tipped blades can be re-sharpened from time to
time, extending the life of the blade. This type of blade is a good fit for use with sheet metal
and other metallic components that are relatively thin in design.

3.2 WELDING

Welding is used for making permanent joints. It is used in the manufacture of

automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks,
furniture, boilers, general repair work and ship building.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

OPERATION

Several welding processes are based on heating with an electric arc, only a few are
considered here, starting with the oldest, simple arc welding, also known as shielded metal
arc welding (SMAW) or stick welding.In this process an electrical machine (which may be
DC or AC, but nowadays is usually AC) supplies current to an electrode holder which carries
an electrode which is normally coated with a mixture of chemicals or flux. An earth cable
connects the work piece to the welding machine to provide a return path for the current. The
weld is initiated by tapping ('striking') the tip of the electrode against the work piece which
initiates an electric arc. The high temperature generated (about 6000oC) almost instantly
produces a molten pool and the end of the electrode continuously melts into this pool and
forms the joint.

Fig. 3.3 Welding process

The operator needs to control the gap between the electrode tip and the work piece
while moving the electrode along the joint.
In the shielded metal arc welding process (SMAW) the 'stick' electrode is covered
with an extruded coating of flux. The heat of the arc melts the flux which generates a gaseous
shield to keep air away from the molten pool and also flux ingredients react with unwanted
impurities such as surface oxides, creating a slag which floats to the surface of the weld pool.
This forms a crust which protects the weld while it is cooling. When the weld is cold the slag
is chipped off.
The SMAW process cannot be used on steel thinner than about 3mm and being a
discontinuous process it is only suitable for manual operation. It is very widely used in

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

jobbing shops and for onsite steel construction work. A wide range of electrode materials and
coatings are available enabling the process to be applied to most steels, heat resisting alloys
and many types of cast iron.

3.3 ASSEMBLY
An assembly line is a manufacturing process (most of the time called a progressive
assembly) in which parts (usually interchangeable parts) are added as the semi-finished
assembly moves from work station to work station where the parts are added in sequence
until the final assembly is produced. By mechanically moving the parts to the assembly work
and moving the semi-finished assembly from work station to work station, a finished product
can be assembled much faster and with much less labor than by having workers carry parts to
a stationary piece for assembly.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

CHAPTER-4

COMPONENTS AND DESCRIPTION

The main components of a project is

 Screw Jack
 D.C motor
 Battery
 Frame
 Switch

4.1 Screw Jack

Screw jack consists of piston and piston rod with plate. The Plate is fixed at the end
of the piston rod, which is used to lift the vehicle from the ground level.The screw jack have
a load lifting capacity of 2 tons. It is a double step screw jack. In the first rotation of screw
30mm of 1st step will come out, further 40mm of 2nd step will comes out. About 200mm of
lift can produced by using this screw jack.

Fig. 4.1 Screw jack

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

4.2 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.The motor used is 12v, 90w, 60rpm permanent magnet DC gear motor.

Fig. 4.2 DC Motor

DC Motor Theory
 There are two conditions necessary to produce a force on a conductor:- The conductor
must be carrying current.- The conductor must be within a magnetic field.
 The right-hand rule for motors states that when the forefinger is pointed in
thedirection of the magnetic field lines, and the center finger is pointed in
thedirection of current flow, the thumb will point in the direction of motion.
 The function of torque in a DC motor is to provide the mechanical output
todrive the piece of equipment that the DC motor is attached to.
 Torque is developed in a DC motor by the armature (current-carrying conductor)being
present in the motor field (magnetic field).CEMF is developed in a DC motor by the
armature (conductor) rotating (relativemotion) in the field of the motor (magnetic
field).
 The function of the voltage that is developed in a DC motor (CEMF) opposes
theapplied voltage and results in the lowering of armature current.
 The speed of a DC motor may be changed by using resistors to vary the fieldcurrent
and, therefore, the field strength.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

4.3 Battery
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 (H₂SO₄). 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. Of
the different types of secondary cells, the lead-acid type has the highest output voltage, which
allows fewer cells for a specified battery voltage.

Fig. 4.3 Battery

4.4 Frame
Mild steel rods were used to create the frame. The frame have the capacity carry the
weight of jack, motor, battery, ect.. Welding, sawing, and other machining operations done to
create such a structure.

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

Fig. 4.4 Frame of the design

4.5 Switch
10A, 250V switch is used.

Fig. 4.5 Switch

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

CHAPTER-5
DESIGN CONSIDERATIONS

The load on the screw is the load which is to be lifted W, twisting moment M,
between the screw threads and force F at the handle to rotate the screw. The load W is
compressive in nature and induces the compressive stress in the screw. It may also lead the
screw to buckle. The load F produces bending and it is maximum, when the screw is at its
maximum lift. The screw also experiences twisting moment due to F, the shear stress is also
induced in the screw due to the twisting moment between the threads of screw and nut.
Step I: -Problem Specification
It is required to design an object lifting jack for supporting the machine parts during
their repair and maintenance. It should be a general purpose jack with a load carrying
capacity of 3 KN and a maximum lifting height of 0.2m. The jack is so operated by means of
a D.C motor.
Step II Selection of Materials
The frame of the object lifting jack has complex shape. It is subjected to compressive
stress. Mild steel is selected as the material for the frame. Mild steel is cheap and it can be
given any complex shape without involving costly machining operations. Mild steelhas
higher compressive strength compared with steel. Therefore, it is technically and
economically advantageous to use mild steelfor the frame.(ii) The screw is subjected to
torsional moment, compressive force and bending moment. From strength consideration,
EN8 is selected as material for screw. (iii) There is a relative motion between the screw and
the nut, which results in friction. The friction causes wear at the contacting surfaces. When
the same material is used for these two components, the surfaces of both components get
worn out, requiring replacement. This is undesirable. The size and shape of the screw make it
costly compared with the nut. The material used for the nut is stainless steel.
Step III Design of object lifting jack
The object lifting jack is an intermittently use device and wear of threads is not an
important consideration. Therefore, instead of trapezoidal threads, the screw is provided with
square threads. Square threads have higher efficiency and provision can be made for self-
locking arrangement. When the condition of self-locking isfulfilled, the load itself will not
turn the screw and descend down, unless an effort in the reverse direction is applied.

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5.1 BASIC DESIGN OF SHAFT

 The stepped shaft shown in the figure is to rotate at 900 rpm as it transmits 7000 Nm
torque from a turbine to a generator and this is the only loading case on the shaft. The
material specified in the design is A 284 Steel (grade C) and design factor is given as
2. Determine/evaluate following cases for the shaft.

5.1.1 a) Maximum shear stress on the shaft

Parameter Symbol Value Unit

Maximum shear stress τmax 285.206 MPa

Angle of twist θ 4.085 Degree

Power requirement P 659.734 kW

Polar moment of inertia J 613592.312 mm^4

Table 5.1 Result of shear stress testing

5.1.2 b) Principal stresses on the shaft

RESULTS

Parameter Symbol Value Unit

Maximum principal stress σmax 357

MPa
Minimum principal stress σmin -357

Table 5.2 Results of principal stress

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Design and Fabrication of Motorized Screw Jack For Four Wheelers

5.1.3 c) Material yield criteria for selected material and occurred stresses.

RESULTS
Parameter Condition to be met for safe design Status

MSS theory (σmax-σmin) <Sy/n 714<102.5 Nok

DE theory (σmax²-σmax*σmin+σmin²)^0.5<Sy/n 618.3 < 102.5 Nok

Table 5.3 Material selected

5.2DESIGN OF SPUR GEAR

Speed in gear box:
Measured Specifications:
N1 D2
=
N2 D1
Where,
N1 = Motor speed in RPM = 60 RPM
N2 = Output speed
D2 = Diameter of the big gear wheel
= 200 mm
D1 = Diameter of the small gear wheel
= 25 mm
D1
∴ N2 = x N1
D2
25
= x60
200
= 7.5 rpm

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Design and Fabrication of Motorized Screw Jack For Four Wheelers
5.3DESIGN OF GEAR WHEEL
SPUR GEAR:
Pressure angle (α)
Pitch (p)
Power (P)
Number of teeth on pinion (z1)
Number of teeth on gear (z2)
Centre distance (a)
Face width (b)
Addendum dia. of pinion (da1)
Addendum dia. of gear (da2)
Dedendum dia. of pinion (df1)
Dedendum dia. of gear (df2)
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AACET, Thodupuzha
= 14½°
= 3 mm
= 90 w
= 12
= 96
𝐷1+𝐷2
=
2
25+200
=
2
= 112.5 mm
= 10*M
= 10x1
= 10 mm
= D1+2*ha
= 25+(2*1*M)
= 25+ (2*1*1)
= 27 mm
= D2+2*ha
= 200+ (2*1*M)
= 200+ (2*1*1)
= 202 mm
= D1-2*hf
= 25- (2*1.157*M)
= 25- (2*1.157*1)
= 22.69 mm
= D2- 2*hf
= 200- (2*1.157*M)
= 200- (2*1.157*1)
= 197.69 mm
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Design and Fabrication of Motorized Screw Jack For Four Wheelers

9.55∗106 ∗𝑃∗𝐶𝑠
Transmitted force (Ft) =
𝑁1∗𝑅1
9.55∗106 ∗90∗1.5
=
60∗12.5
= 1719 N
Torque = Ft*R1
= 1719*12.5
= 21487.5 Nm

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CHAPTER-6

WORKING PRINCIPLE

STEP 1
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 driven 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 object moving jack moves the lead screw
upwards, so that the vehicle lifts from the ground. The vehicle is lifted by using the lifting
platform at the top of the jack. The motor draws power supply from the battery. The lifting
and uplifting is done by changing the battery supply to the motor.
STEP 2
When switch is on, the circuit is completed and from battery power is transferred to
the motor that is connected to the roller. Now the roller starts moving. Now controlling the
two number of switch which is connected to the two motors at the base the whole set-up is
adjusted below the body which is being lifted.
STEP 3
Now pressing the switch to the circuit which is connected to the motor that is coupled
to the lead screw, the circuit is completed and voltage from the battery is pass to the motor.
When tapping the switch to the positive pole, positive voltage is supplied to the d.c motor
moves in clockwise direction and lead screw moves in downward direction.
STEP 4
When tapping the switch to the negative pole, negative voltage is supplied to the d.c
motor moves in anticlockwise direction and lead screw moves in upward direction.
STEP 5
Now when the lead screw moves to the maximum limit, the limit switch at the upper
end gets activated and the circuit gets cut-off. When the lead screw moves to the minimum
limit, the limit switch at the bottom end gets activated and the circuit gets cut-off.

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CHAPTER-7
ADVANTAGES AND DISADVANTAGES

The motorized screw jack have so many advantages. The cost of product depends on
the weight to be lifted, so disadvantages also exist.

ADVANTAGES

 The loaded light vehicles can be easily.

 Checking and cleaning are easy, because of the main parts are screwed.
 Handling is easy
 No Manual power
 Easy to Repair.
 Replacement of parts are easy

DISADVANTAGES
 Cost of the equipment is high when compared to ordinary hand jack.
 Care must be taken for the handling the equipment such as proper wiring
connection, battery charging checkup, etc.

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CHAPTER-8

APPLICATIONS

The screw jack has wide varieties of application. The system can be used for any kind
lifting operations.

1. It is very much useful in auto-garage. This motorized screw jack is used for lifting
the vehicles.
2. Thus it can be useful for the following types of vehicles in future;
 Maruti,
 Ambassador,
 Fiat,
 Mahindra

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CHAPTER-9

CONCLUSION

The “Design and fabrication of motorized screw jack for a four wheeler” was
successfully completed as per the designed specification.

The trial performance of this device provides to be successful, with case of operation
and safety, hence the results has given a clear indication of its commercial viability. The cost
analysis has shown its economic feasibility and we are under the impression that it can be
further reduced, when produced on a mass scale.

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REFERENCES
 International Journal of Advanced Research (2015), Volume 3, Issue 3, 1279-1282,
RESEARCH ARTICLE REMOTE CONTROLLED SCREW JACK TO LIFT THE
VEHICLE Journal homepage http://www.journalijar.com.

 International Journal of Scientific Engineering and Applied Science (IJSEAS) ‐

Volume‐1, Issue‐3, June 2015 , ISSN: 2395‐3470 ANALYSIS AND FABRICATION
OF REMOTE CONTROL LIFTING JACK. Journal homepage
:http://www.ijseas.com .

 TJ. Prabhu “Design of transmission elements” Mani offset Chennai.1999.

 Dr. sandhu singh “Machine design”Khanna Publishers,Delhi.1997.

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