Gujarat Technological University

A UDP
Project
Report On

“3 Wheel Drive Forklift for Industry Warehouse ”

in partially fulfillment for the award of the degree
of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING
SUBMITTED BY:

NAME ENROLLMENT NO.

Vikas Patel 170170119048
Kanak Gohil 170170119012

UNDER THE GUIDANCE OF:

Prof. Sanjayl B. Pipaliya

Head of Department:
Dr. Anand B. Dhruv
Vishwakarma Government Engineering College, Chandkheda (017)

Ahmadabad- 382424
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ACKNOWLEDGEMENT

We are very thankful to our project guide Prof. Sanjay B. Pipaliya, in Mechanical Engineering
Department VGEC, Chandkheda whose guidance and support has helped us for completing this
project work. Their belief in us has helped us to perform better than we could. They have been
great motivator and have encouraged us in our work.

We are also thankful to Prof. A.B.Dhruv, Head of Mechanical Engineering Department VGEC,
Chandkheda and all other faculty members of VGEC for providing necessary permission for
completing our work. Special regards to our colleagues for helping and supporting us during the
project work. We are very thankful to our parents for supporting us financially and mentally.

Lastly, We thanks who helped us in some or other way for carrying out this work.

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ABSTRACT

Forklifts are designed to handle and transport both raw materials and goods carefully and efficiently.
Fromtime to time these machines must be transported from one work site to another. A normal sit-
down forkliftwith the ability to lift 5,000 pounds will itself weigh as much as 9,000 pounds. The average
automobileweighs approximately. 4,000 pounds. Weighing in at more than two times the weight of the
average familyand automobile.

This paper presents research related to the choice of the criteria that can be used to fill the Gap
between the forklift’s minimum capacity and works maximum capacity To lift the objects from a placeto
another place in warehouse operation. The analysis had been done with the aim of exploring
therequirements of warehouses and construction sites. With some changes to forklift, we designed a
twowheeler forklift, This research paper gives an exact idea about how should be a two wheel forklift is
useful,safer and efficient in narrow passages working sites and how to design and contrast the two
wheel aisleforklift for such working places.

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Table of Contents

ACKNOWLEDGEMENT.....................................................................................2
ABSTRACT.............................................................................................................3
CHAPTER 1: INTRODUCTION..........................................................................5
1.1 PROJECT SUMMARY.....................................................................................6
1.2 PROJECT DETAILS.........................................................................................7
1.3 PROJECT SPECIFICATIONS........................................................................12
CHAPTER 2: MATERIAL, COMPONENTES AND CANVAS......................20
2.1 COMPONENTS & MATERIAL REQUIRED................................................21
2.2 AEIOU SUMMARY:.......................................................................................29
2.3 EMPATHY MAPPING CANVAS:.................................................................34
2.4 IDEATION CANVAS:....................................................................................35
2.5 PRODUCT DEVELOPMENT CANVAS:......................................................36
CHAPTER 3: DESIGN CALCULATION & IMPLIMENTATION.............37
3.1 DESIGN CALCULATION..............................................................................38
3.2 IMPLIMETATION..........................................................................................46
CHAPTER 4: SUMMARY...................................................................................49
4.1 SUMMARY.....................................................................................................50
REFERNCES.........................................................................................................52

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CHAPTER 1: INTRODUCTION

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INTRODUCTION

General the forklift can be defined as a tool capable of lifting load of tons. A forklift is a vehicle similar
toa small truck that has two metal forks on the front or side used to lift the load. The forklift operator
drives theforklift front until the forks push under the cargo, and can lift the cargo to the required height
in the air byusing the forks. The forks are usually made out of steel and can lift up to a few tons. Forklifts
are either powered by petrol or electricity. Electric forklifts relay on batteries to operate. Petrol forklifts
are heavy dutyand faster than electric forklifts, but they are difficult to maintain and operate so fuel cost
is higher. Electricforklifts are best for warehouse use because they do not produce noxious fumes and
noise like gas poweredmachines do. Some forklifts are meant to be used outdoors too. The majority of
rough terrain forklifts operateon petrol, and some use diesel or natural gas. Rough terrain forklifts have
the highest lifting and loadingcapacity and heavy-duty tires, making it possible to drive them on all
terrain. Forklifts plays revolutionaryrole in warehouse work of carry loads. They made it possible for
single person to move thousands ofkilograms at once. Well-maintained and safely operated forklifts
make lifting and transporting cargoinfinitely easier.

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LITERTURE SURVEY

★ The forklifts are the necessary part of

Today’s supply unit where it’s transporting goods from one placeto another in the
storage, loading or unloading good to the truck the forklift utilized .

★ The two-wheel hand operated forklift first appeared over one hundred years
ago. These original unitswere wrought-iron axle and cast-iron wheels which
enabled loads to be lifted and transported withoutmanual labour.

★ In the era of early 19th century the evolution to combine horizontal and
vertical motion resulted in the first hand operated forklift capable of lifting a few
inches of the ground. And with this the developmentof the forklift are on
FastTrack till today. In 1917 the company named Clark, started manufacturers
ofaxles, and created a truck called the truck tractor to move materials around
their factory in the variousunits of the plants. As visitors to the factory saw the
Truck tractor at work they are also interested touse truck tractor in their own
plants so they placed orders to Clark to build truck tractor for theircompanies.

★ After few years the first hydraulic powered lift was added to some trucks to
give them lifting power. In1923, company named Yale is the first company to use
forks that lifted loads off the ground and anelevated mast that could extend
beyond the height of the truck.

★ The Yale truck is considered to be the first forklift. After few developments
helped the forklift to increasein production including the introduction of the
standardized pallet in 1930s and World War II. Both ofthese developments

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increased production of forklifts and allowed distributors the means to

efficientlymove heavy loads in the factories. ‘Load centres’ represent the middle
of a forklift truck load, from frontto back.

★ It is easily calculated by measuring the load to be carried, and dividing by two

(providing the load isevenly distributed, and positioned to butt up to the forklift
backrest). The load centre is the distancefrom the face of the forks to the load’s
centre of gravity. Many forklifts are rated using a 24-inch load

Centre, which means that the load’s centre of

Gravity must be 24 inches or less from the face of theforks. Fig.1, the load centre
and finds its balance point.

★ The combined centre of gravity of the truck and load system shifts forward
outside the stability triangle,as the load’s moment is greater than the vehicle’s
moment, and the forklift

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FIG:- Stability Triangle

★ His design is intentional, rear-wheel steering allows the driver a larger degree of rotation
and precisionwhen control a load. The lifting controls consist of two levers, one for lifting the
fork up and down aswell as one for tilting the load back and forth. The lifting functionality works
as discussed above—forward moves up and backward moves down. The tilting functionality,
however, is slightly different.At the base of the masts are two sets of additional hydraulic
cylinders that attach to the base of thevehicle. When the tilt- handle is moved forward, fluid is
pumped into the chamber. This rise in pressure pushes the piston head and causes the masts to
lean away from the vehicle’s body.

★ When the tilt-handle is moved back, fluid is slowly released from this cylinder as fluid is
pumped intothe other pair of mast attached cylinders. When the pistons from the latter pair push
forward, the mastsare rocked back to the vehicle.

★ The first contribution toward scientific material handling instrumentality seems to possess
been the 2-wheel go cart. During this we tend to square measure move the fabric however not
carry it. In 1906, a political candidate of the Pennsylvania Railroad at Altoona, supplementary
accumulator power to a baggage wagon, it absolutely was the primary power truck. The primary
transportable elevator on recordwithin the Patent and Trademark Office Database was
engineered of wood in 1867, with upright,cantilever platform, and a hoist. One of the first efforts
to mix horizontal and vertical motion was in1887, once a crude truck capable of lifting its
platform some inches was build. This was most likely the primary application of the unit load
principle with skids. Then in 1909, once the primary all steel carrytruck appeared.
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★ In 1913 a truck appeared that supplementary wattage to advantage of combined vertical and
horizontalhandling ability. It took a kind of tiny crane mounted on a platform truck. The
introduction of hydraulic power and therefore the development of the primary electrical power
self propelled vehicle, beside theutilization of standardized pallets within the late Nineteen
Thirties.

★ In 1954, a British company named state capital Bagnall, currently a part of KION cluster,
developedwhat was claimed to be the primary slim aisle electrical reach truck. Throughout
Fifties to NineteenSixties, operator safety became a priority because of the increasing lifting
heights and capacities

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PROJECT SUMMARY

After market survey, we came to know the requirement of miniature forklift for
small scale industrieswho are not able to afford forklift available in the market.
So, we designed a forklift which is compact insize , economical for small scale
industries and can be used as an alternative for manual lifting.

★ Forklift is designed to move loads above hundreds of kilograms however if

necessary lifting capacityis reduce , a reduction in a number of required a smaller
structure and low power to drive forklift is possible, which bridged the gap
between the maximum possible lifting capacity of single labor and theforklift
capacity.

★ This would reduce the overall vehicle weight and dimension, a lower energy
is required for the liftingloads of mass 40-70 kilograms and fewer systems that
must work succession reliably thereby increasingoverall vehicle safety.

★ The objective of the project is to address this issue of reducing power

consumption and increasingefficiency of forklift with the lifting capacity 40-70
kilogram

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PROJECT DETAIL

★ Field of Use

The forklift are used to transfer material from one place to another place. These are
used in commercialareas like Industrial Workshops, warehouses, Car servicing
station, Institutes, Material handling andconstruction applications

★ CONSTRUCTION AND WORKING

The chassis is fictional from M.S sq. pipes. This can be finished by easy
fabrication, and to scale back theweight. The chassis is designed to require a static
load of 3kg.The rear wheel that holds the motor and is fastto the chassis. So, the
driving motors will simply accommodate below the chassis. The chassis
incorporateshole for attaching front globe wheel, and for attaching the raise
structure.It’s an oblong plate that is command between 2 vertical channels of M.S
sq. pipe that area unit unengaged to slide up and right down to raise andlower the
weight/load up to a desired limit with the assistance of hydraulic bottle jack that is
operated on footand it’s placed between the fork. 3 wheels area unit employed in
self-propelled vehicle and the two wheelsarea unit placed at front and the
remaining wheel area unit placed at the rear. The hydraulic device isemployed for
to raise the serious material by applying smaller force. It’s place at the front of the
self-propelledvehicle. The hydraulic jack could be a device used for lifting serious
hundreds by the appliance of a lot ofsmaller force. It’s supported Pascal’s law, that
states that intensity of pressure is transmitted equally altogetherdirections through
a mass of fluid at rest.

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CHAPTER 2: MATERIALS,
COMPONENTS AND CANVAS

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COMPONENTS REQUIRED:
★Wheel Axle & Supporting Frame

★Handle Rods

★Vehicle Motor

★Lifter Motor

★Lifter bearings

★Supporting Rods & Bearings

★Tires

★Shaft & Bearings

★Wires

★Mounts, Fixtures & Screws

★Supporting Frame

★Wheel Hub

COMPONENTS SPECIFICATION :
a)1 DC motor wheel

- Weight: 100 gm, rpm 60, Operating Voltage: 12V DC

b) Gearbox

- Shaft diameter: 6mm,No-load current = 60 mA(Max),Load current = 300

mA(Max)

c) Fork lifting motor

- 12 v power, 36nm torque,45

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d) Worm wheel gear

e) Battery :-

Features (12V , 7 amp)

1) Optimal Starting Power

2) Mountable in virtually any position
3) 15 times more . Vibration Resistance
4) Faster recharging

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f) MS plat :-

-1 mm thinness *1000mm *300mm

-Body mounting

g) MS angle:-

-3mm thinness

- L 10000mm

- W 25*25mm*3

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AEIOU SUMMARY

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EMPATHY MAPPING CANVAS

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IDEATION CANVAS

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PRODUCT DEVELOPMENT CANVAS

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CHAPTER 3:- DESIGN

CALCULATION AND
IMPLIMENTATION

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DESIGN CALCULATION

Design of Lead Screw–

★Mass carrying (m) = 250 Kg

★Length of screw = 1220 mm

★Factor of safety (FS)= 3

★Material = Mild steel {S_yt= 400N/Mm

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