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Finalsubmissinformat Report 180705062058
Finalsubmissinformat Report 180705062058
Project Report
CERTIFICATE
This is to certify that the project entitled “Design and Fabrication of Wheel Changing kit”
has been submitted to the Department of Mechanical Engineering, Swami Keshvanand
Institute of Technology, Management and Gramothan (Rajasthan Technical University,
Kota) for the fulfillment of the requirement for the award of the degree of Bachelor of
Technology in “Mechanical Engineering” by following student of final year B.Tech.
(Mechanical Engineering).
i
DECLARATION
We, hereby declare that the discussion entitled “Design and Fabrication of Wheel Changing
Kit” being submitted by us towards the partial fulfillment of the degree of bachelor of
Technology, in the Department of Mechanical Engineering is a project work carried by us
under the supervision of Mr. Sudhanshu Chhajed, and have not been submitted anywhere
else.
Date:
(13ESKME036) (13ESKME010)
(13ESKME016) (13ESKME060)
ii
ACKNOWLEDGMENT
We like to share our sincere gratitude to all those who help us in completion of this project.
During the work we faced many challenges due to our lack of knowledge and experience
but these people help us to get over from all the difficulties and in final compilation of our
idea to a shaped sculpture.
We would like to thank Mr. Sudhanshu Chhajed sir for his governance and guidance,
because of which our whole team was able to learn the minute aspects of a project work.
We would also like to show our gratitude to our Project Coordinators Mr. Amit Bansal and
Mr. Ankit Agarwal for their continuous help and monitoring during the project work.
In the last we would like to thank the management of Swami Keshvanand Institute of
Technology, Management and Gramothan for providing us such an opportunity to learn
from these experiences.
All of our team is thankful to Mr. Narendra K. Banthiya Sir, Mr. Alok Mathur Sir, Mr.
Dheeraj Joshi sir and all the Faculties and Staff of Department of Mechanical Engineering,
SKIT, for their help and support towards this project and our team.
We are also thankful to our whole class and most of all to our parents who have inspired us
to face all the challenges and win all the hurdles in life.
iii
ABSTRACT
The efforts required in achieving the desired output can be effectively and economically be
decreased by the implementation of better designs. Power screws are used to convert rotary
motion into translator motion. A screw jack is an example of a power screw in which a
small force applied in a horizontal plane is used to raise or lower a large load. The principle
on which it works is similar to that of an inclined plane. The mechanical advantage of a
screw jack is the ratio of the load applied to the effort applied. The screw jack is operated
by turning a lead screw. The height of the jack is adjusted by turning a lead screw and this
adjustment can be done either manually or by integrating an electric motor.
Screw jack plays an important role in changing the wheel of an automobile, also a huge
amount of force is required in opening and tightening the nuts to fix the wheel. By the help
of this project we want to reduce both of these manual jobs, to a less complicated – more
efficient motor driven and Semi-Automatic Job.
The significance and purpose of this work is to provide a user friendly support for the
existing car jack in order to make the operation easier, safer and more reliable in order to
reduce health risks. The designed kit will also save time and requires less human energy to
operate.
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.Contents
CERTIFICATE ................................................................................................................ i
DECLARATION ............................................................................................................ ii
ABSTRACT................................................................................................................... iv
Chapter: 1........................................................................................................................ 1
Introduction ..................................................................................................................... 1
Chapter: 2........................................................................................................................ 5
Chapter 3......................................................................................................................... 8
3.1.3. Switches..................................................................................................... 9
v
3.3.2. Design of nut............................................................................................ 16
Chapter 4....................................................................................................................... 20
Chapter 5....................................................................................................................... 29
5.2. Discussion:...................................................................................................... 29
References..................................................................................................................... 33
vi
List of Figures
vii
List of Tables
viii
0
Chapter: 1
Introduction
Wheel changing is a tedious process that requires a lot of manual force to change the wheel,
when it get flat. In various scenarios it has been seen that people found themselves
physically incapable of doing such kind of job when it comes to one. Also, especially
women and people with senile disorders feel uncomfortable to do a job which requires a
lot of manual force.
Medical researches has shown that whenever a person is exposed in any scenario where
he/she has to show extensive muscle movements to meet external force/stress, then there is
a lot of chance that the muscles might get damaged or may be a serious injury can be
prevailed because of the process.
As an Engineer it is our duty to provide new technology to the society for the betterment
of them, but also it is our concerns too to seek the need of reduction of human efforts in the
places where health of a human is exposed to certain risks.
Screw Jack are the mechanical device that are used to lift or lower the weight with minimum
power requirement. A screw jack works on the principal of inclined plane motion of an
object where heavy amount of load can be moved from one location to another with
introduction of correct amount of torque and inclined angle.
In modern jacks, a lead screw is used to produce relative motion between two ends of a
closed linkage, in which one link is fixed while the other can move freely. This movement
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of the mechanism is been controlled with proper tuning of the threads in clockwise and
anti-clockwise motion.
In today’s world a screw jack is been used in all parts of the industry but the most common
application of a jack is found in automobile where it is been used in changing the wheel is
required. By the help of the screw jack a person can lift his car and change the wheel well
efficiently. Also it is a major point that the
Car jacks usually use toggle 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.
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 for makes it go
up.
When the screw lifts the load on the platform which placed above will also be raised.
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.
Torque multipliers are handheld, air driven, non-impacting torque delivery tools intended
to tighten and loosen nuts, bolts and threaded fasteners. The pressure is controlled using an
external air pressure regulator. Whilst in operation the reaction arm on a torque multiplier
rotates in the opposite direction to the output square drive and must be allowed to rest
squarely against a solid object or surface adjacent to the bolt to be tightened or loosened.
2
This reaction allows the torque to be applied. Once the required torque is achieved the tool
stalls and no further tightening is possible.
Known torque-responsive power screw drivers which are driven by electric motors or
pneumatically have a relatively high speed of rotation in order to obtain a short screwing
in time. Since the maximum moment of tension for the screw to be screwed requires a
determined torque, the driving power of the screw driver must likewise be made high in
accordance with the relatively high speed of rotation, although a high torque is required for
only a short time during the tightening of the screw, unless some shock action is utilized
for the purpose of producing this peak degree. The limitation of the degree of tightening of
the screw is usually effected by means of ratchet couplings or striking mechanism. When
screwing in expansion screws, this degree of tightening must be kept constant within very
narrow, since these screws, are stressed almost to their yield point during screwing in.
Torque-responsive screwing drivers having a shock effects are useless for this purpose. The
degree of
tightening achieved is greatly dependent on the number of blows applied, which however
cannot be kept constant because of the rapid succession of blows, while in addition the
power of the individual blow is variable within wide limits because of the indeterminable
reaction of work piece, screw and screwing tool on the striking operation. In addition, the
shock effect causes rapid wear on the striking surface, which results in a considerable
variation of the face of the blows and a relatively short life of the screwdriver. Torque-
responsive screwdrivers having striking mechanisms are impractical where accurate
tensioning of a screw is necessary. It has moreover been found that, at the high speeds used,
ratchet couplings also apply a powerful shock action and are therefore likewise unsuitable
for tightening expansion screws
During the study for the project, we got acknowledged to various scenarios, where, because
of manual wheel changing system a lot of people have been injured. Also, it is a
recognizable factor that people found themselves helpless when they are exposed to such
conditions. So, by this project we are aimed to reduce the human efforts in changing a
wheel.
3
The main objective of this project is to design a motorized screw jack. Other specific
objectives are-
To fabricate a cost effective Kit to operate Screw Jack available in the car (provided
by manufacturer), without any additional add-on to the jack.
This project includes Design and Fabrication of Wheel Changing Kit and
Study of all the possible categories (Based on load of vehicle) to lay an outline on the
modification of current kit for those cars.
Creating a safer mechanism to reduce human efforts in wheel changing.
1.7. Organization of Chapters
Chapter 1 – Introduction
Chapter 2 – Literature Review
Chapter 3 – Design Procedure
Chapter 4 – Fabrication and Testing
Chapter 5 – Result and Discussion
4
Chapter: 2
Literature Review
Rout ET. Al. [1] during the research found that mostly some difficult methods were
adopted in lifting the vehicles for reconditioning, repair and maintenance. Fabricated model
has mainly concentrated on this difficulty, and hence a suitable device must be designed,
such that the vehicle and heavy objects can be lifted from floor land without the application
of impact force. Such a jack should 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 4000-5000 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 motorized automated object lifting jack has resulted to prove to be
beneficial in lifting and lowering of heavy loads.
Pawar ET. Al. [2] during the research found that Available car jacks are typically manually
operated and therefore require more physical effort on the part of the user. Such jacks
creates difficulties for the elderly, handicapped, and women’s. Disadvantageous in bad
weather conditions. The low degree of safety leads to the cause of accident or sudden failure
in the jacks. The researchers proposed the design to be automated to reduce human effort
while operating jack. The design proposed include control system so that jacking can be
done from a position of safety. It was easily movable and other support surface is not
required. Thus, the design has been developed considering all the above requirements. This
is the beneficial in lifting and lowering of loads.
Yadav ET. AL. [3] stated that most of the present day resources of energy are limited and
irreplaceable and next generation will face acute energy crisis if alternate resources of
energy are not developed concurrently. They found that in today’s developing world, the
extent of automation is obviously the foremost focus of engineers. Screw jack is a device
which is used to lift and support a heavy load in automotive vehicles, such as a car. The
5
research successfully developed a solar operated push button type Screw Jack. During
Research they putted automated toggle screw jack is put under various force analysis so
that its performance criterion will not fail in operation. The result of the research are: A
mathematical model was framed to estimate the power requirement at various loading
conditions & the model worked effectively in wide range of loading conditions to estimate
the power requirement and experimentally validated.
Maniamramasamy ET. AL. [4]during the research pointed that the recent decades
maintenance in automobile engineering become a challenging task among the engineers,
so it is found that, saving economy has become the task of highest priority in our generation.
Design modification of existing product allows the work as much as easier than the
previous model. In their work, they fabricated a model of motorized screw jack to reduce
the power consumptions and to decrease the human effort. Result of the research was they
found that motorized power jack can be widely used in low cost automation in
manufacturing industries. By their model weight lifting is quick and effortless, which
reduces the physical fatigue (tiredness) felt by the worker.
Akinwonmi ET. AL. [5] designed a power screw by considering the problems associated
with Ergonomics - which is a fundamental concept of design process. The main advantages
of the modified design over the existing design are that the modified designed motorized
jack will save time, be faster and easier to operate and requires less human energy and
additional work to operate. There by effectively curb the problems associated with
Ergonomics - which is a fundamental concept of design process. The result after the project
was very effective and problems related to human body posture and health issues are
resolved.
Lucia et. al. [6] during their design of an impact wrench acknowledged the fact that the
wrench mechanism is a complex system and it requires a lot of manual power to tighten or
open the bolt. They in their model of the electronic impact wrench introduced an improved
design to reduce the manual heath and work risks and also to overcome the problem of
automation in the working.
On the basis of following we have inferred that the existing designs of designs of
automation in Screw Jack are requires to have alignment issues in transporting power form
6
motor to the lead screw and also we have acknowledge the fact that these designs contains
permanent fixtures of motor and screw jack arrangements. So for the design of our project
“Design and Fabrication of Wheel Changing Kit” we have noticed some issues that must
be answered for better mechanism.
7
Chapter 3
Design Procedure
3.1. Materials
3. Speed 10 RPM
The screw jack used in this project is a scissor 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.
8
Table 2. Description of Screw Jack
3.1.3. Switches
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.
[8]
Are used in order to connect the battery to the motor and the switch. A base for the entire
set-up has also been used. The motor is mounted on an inverted U shaped support frame.
External power supplies are used both with equipment with no other source of power and
with battery-powered equipment, where the supply, when plugged in, can sometimes
charge the battery in addition to powering the equipment.
Sockets are available in various depths or lengths, often divided by most manufacturers
into two categories of "standard" and "deep" according to the ANSI or DIN standard they
are made to and the tolerances allowed by those specifications for each length of socket.
Because the standards allow for some flexibility in tolerances, it is common to see two
manufacturers make deep sockets of the same size but with slightly different depths even
though both meet the same specification. Standard length, otherwise known as "shallow"
sockets, have a lower profile and allow a user to access nuts in narrow spaces. Deep sockets
are useful for turning nuts onto bolts when the bolt extends upwards into the socket (as in
the case of many bolted joints), a very typical example being exhaust clamp bolts on a car.
10
Figure 3. A set of Socket [10]
40% 65 %
80% Yield 95% Yield
Yield Yield
M 12
15 24 30 35
M 16 30 48 60 71
11
M 27 170 270 320 400
40% 65 % 80%
95% Yield
Yield Yield Yield
M 12
25 40 50 58
M 16 50 80 100 118
12
M 30 360 590 700 900
40% 65 %
80% Yield 95% Yield
Yield Yield
M 12
30 48 60 70
M 16 60 96 120 142
13
M 33 560 920 1120 1270
Figure 4. Nominal Diameters vs. Torque Requirement for tightening Bolts [12]
Given data:
Load = 5KN
For Medium Carbon Steel (35 mm 75) (screw)
σ = 100 MPa σ = 60 MPa
For phosphorus bronze (nut)
σ = 50 MPa σ = 40 MPa
3.2.1 Design of Screw
The main load on the *screw is when the jack is in the bottom most part.
14
In this part Cos θ = (100 - 15 110 )
Θ = 39.4
= 2
= 3.044 KN
= + ,
12+6=18mm
Helix Angle
α= ( ) =7.25°
Angle of Friction
ϕ= = (0.2) = 11.310
P= × tan(∝ +ϕ)
15
Torque
= = 45.19
Here Pitch p = 6
. ×
= = = 10.73
× × × × ×
To prevent moment of nuts beyond 200 mm, rings of 8mm thickness are provided on the
screw on both sides and fixed by set screw.
Let the operator apply a force of 50N to the end of spanner 1mm long
L= = 365.6
16
3.3.3. Design of pins in nuts
Pins are in double shear. If Is the diameter of pins then
√4 √4 × 3044
− = = = 6.96 ≈ 7
2 2 (40)
/2 = 1522
= 3
Moment of Inertia
= = 2.25
12
Least radius of Gyration
2.25
= = = 0.75
3
For buckling of links in essential plane, the ends are considered hinged, therefore using
RANKINE – GORDON formula,
× ×
= = =
[ ] .
.
F.O.S = 2
17
= F.O.S × F
300
=
+ 2.15
=4 , = 12
The link is considered to be fixed ends for buckling in a plane perpendicular to the vertical
plane
∴ = = 55
2
100 × 3
=
1 55
1+ [ ]
7500 0.75
100 × 3 × (4)
= 4643.9
1 55
1+
7500 0.75(4)
Knuckle pin
́
Shear stress in pin : =
( )
= = 276.31
( × . )
́
=
2
2500
= = 13.021
2 × 4 × 24
Nut Spanner :
Minimum torque required to remove nuts is approx. 140 Nm
= = 12 × 5 = 60
18
2 × 60
= ↔ =
60 2
60 × 60
= = 57.3
2 × × 10
= 7.5
= 12 × 7.5 = 90
×
= = 85.95
( )
It has been found that the coefficient of friction (μ) at the thread surface depends upon the
workmanship in cutting the threads and on the type of the lubricant. It is practically
independent of the load, rubbing velocity or materials. An average of 0.15 can be taken for
the coefficient of friction, when the screw is lubricated with mineral oil.
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.
19
Chapter 4
For the project following minor/major components are designed and fabricate specifically
to meet the project requirements
Linking-Section to link motor shaft and screw Jack: This section is used to link the
shaft of the motor to the screw jack. The purpose of this jack is to remove any permanent
linkage between the motor and the jack to improve the effectiveness of the motor and
to use the motor for various other functions.
20
Figure 7. Fabrication Process: Drilling of holes in the Linkage mechanism (Drilling Machine)
Name of the
S.N. Material Form (Shape) Quantity
component
1 Metal sheet GI Sheet 5mm Sheet 10x4 mm2
10mm dia and
Shaft support Hollow
2 Mild Steel 20 mm length
section cylinder
thickness 3 mm
Low carbon
3 Bolt Screw 40 mm length
steel
A nut opening socket system: the nut opening and tightening socket is specially
designed to improve the power transmission of the motor to the nut. This socket has an
open end to support different size of nut opening sockets and the opposite end to lock
this object to the shaft of the motor.
21
Figure 9. Design of Nut Opening and Tightening Socket
Figure 11. Fabrication Process: Grinding of a Pipe Socket for creating a base to weld the socket (Grinding
Machine)
22
Table 8. Bill of Material for the Nut opening socket
Name of the
S.N. Material Form (Shape) Quantity
component
High carbon
1 Socket Nut socket ½” dia
steel
Hollow 1” dia and 3”
2 Pipe Mild Steel
cylinder length
1” dia and
3 Base plate Mild Steel Circular disc
5mm thickness
10mm dia and
Hollow
4 Shaft support Mild Steel 20 mm length
Cylinder
thickness 3 mm
23
Figure 14. Fabrication Process: Extending the dimensions of the hole to attach the switch in the handle
(Horizontal Milling Machine)
Name of the
S.N. Material Form (Shape) Quantity
component
Hollow 1 ½” dia
1 T Mild Steel
Cylinder section
Hollow 1” dia and 9”
2 Pipe Mild Steel
cylinder length
Impact Wrench: The impact wrench is used to remove and tight the nuts in the wheel.
In general automobile, the nuts in a wheel are tighten with a huge force, order of more
24
than 250N.m. that much of force can’t be obtained by the use of general motor shaft
arrangement. For the development of force we use impact force arrangement. That
means we strike the nuts with huge impact so that it gets loose or tight.
Screw Jack and arrangement to support the C-Section: this type of arrangement is
very essential to support the C-Section for better transmission of power from the shaft
of motor to the screw threads of the jack.
25
Figure 18. Screw Jack design with Eye holes to support the C-Section
For the confirmation of the projects ability to sustain real life action, various type of tests
and experiments are designed and results are recorded to claim that the objectives of the
project works are achieved.
26
Figure 20. Testing of the project
27
2. Power Rating 100W
Remove the
Lower the screw jack
arrangement
28
Chapter 5
5.1. Results:
The project “Design and Fabrication of Automatic Wheel changing kit” has been fabricated
and final testing has been done using real world scenarios. In the testing mode, we have
applied the actual load of a Maruti Suzuki Alto. The jack has successfully uplifted the
automobile without any problem.
Expected
Weight of
S.N. Automobile Name Uptime Lower Time
the
Automobile
5.2. Discussion:
The project “Design and Fabrication of Wheel Changing Kit” is an automation of available
car jacks provided by the manufacturers, without any manufacturing updation of the design
of the project. Also, it is found that the project can work proficiently with the working
capacities of the Car Jack (Toggle/Scissor Jack). The project is not producing any extra
amount of thrust on the user and is cost effective as only some components are going to be
add-on to the existing design (with comparison to other electronic screw jacks [13]
available in the market).
The other part of the project i.e., Nut tightening and opening socket is been fabricated on
the design of an impact wrench and the mechanism is working under the real world scenario
with sufficient supply of driving torque to both open and tight the nuts to case the wheel.
29
The project is working by extruding power of the available Car Batteries and haven’t shown
any significant power depletion in the car battery.
Table 13. Bill of Material for the project including coast analysis
30
Car weight is more Use jack in prescribed
than limit limit
The Jack is not lifting the
1. No Electricity is
vehicle Check electric supply
available
5.6. Maintenance
31
Design and Febrication Of Wheel Changing Kit
02-08-2016 17-08-2016 01-09-2016 16-09-2016 01-10-2016 16-10-2016 31-10-2016 15-11-2016 30-11-2016 15-12-2016 30-12-2016 14-01-2017 29-01-2017 13-02-2017 28-02-2017 15-03-2017 30-03-2017 14-04-2017 29-04-2017
Project Stage II
Group Meeting with Project Guide
Literature Review
Submission of Literature Review
Design and Project Modification
Submission of New Title
Market Survey
Market Survey based on Internet and Shopping Sites
Market Survey in Local Area (Jaipur)
Submission of Market Survey Report and Bill of Material
Group Meeting with Project Guide
Design Modification
Material Procurment Process
Project Febrication Process
Submission of All Material to College
Fabrication Process Initiated
Modification and Project Completion
Project Fabrication Completed and Submission of Working Model
Acceptance of advice from faculties about modification
Project Remodification
Submission of Draft Report
32
References
[3] S. Yadav and M. L. Aggarwal, "Effect of Lifting Load on Solar Powered Screw
Jack Design In Automotive Vehicles," IJSRD - International Journal for Scientific
Research & Development, vol. 2, no. 10, pp. 234-237, 2014.
[7] "Ultimate Floor Jack Buying Guide," Floor Jack Shop, [Online]. Available:
https://www.floorjackshop.com/. [Accessed 31 November 2016].
33
[9] "Connecting a 6 Terminal Toggle Switch To a DC Motor," [Online]. Available:
https://www.12volt-travel.com/knowledgebase/connecting-a-6-terminal-toggle-
switch-to-a-dc-motor/. [Accessed 31 November 2016].
[12] Fastener Mart, Metric bolts, nut and screw tightening torques.
34