TECHNICAL AND

VOCATIONAL TRAINING INSTITUTE

SATELLITE PROGRAM

DEPARTMENT OF AUTOMOTIVE TECHNOLOGY

This is on: Construction of Mechanically Operated Gear Box

Lifting Jack
A project proposal submitted to the department of automotive technology technical vocational
training institute in ethio-Italy polytechnic college dire-dawa in partial fulfillment the
requirement for the degree of B.S.C in A.T

NAME ID

YONAS ALEMAYEW ........................................... TTSE/ 023/11

ESKINDER HAILE ........................................... TTSE/ 034/11

KUMESA DENDENA ............................................ TTSE/ 040/11

ESAYAS AKILILU ............................................ TTSE/ 033/11

ABDI HASSEN ............................................ TTSE/ 003/11

FETIYA AHIMED ............................................ TTSE/ 035/11

ADVISOR: Mr. ABAY KEBEDE

August, 2022

Dire Dawa, Ethiopia

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 Table of Contents

1. Introduction..............................................................................................................................3

2. Value chain mapping and identifying the technology..............................................................6

2.1. ASIS..................................................................................................................................7

2.2. TO BE...............................................................................................................................8

2.3. GAPS................................................................................................................................9

2.4. Selecting the best technology............................................................................................9

3. Rationale and description......................................................................................................10

3.1. Cost.................................................................................................................................11

3.2. Time................................................................................................................................11

3.3. Scope...............................................................................................................................11

3.4. Quality.............................................................................................................................11

4. Objectives of the technology.................................................................................................11

5. Methodology..........................................................................................................................12

6. Work plan/time schedule.......................................................................................................14

7. Expected output.....................................................................................................................15

8. Benefits and beneficiaries of the results................................................................................15

9. Compatability of the project in addressing the competances...............................................15

10. Markebility of the technology............................................................................................16

11. Financial requirments.........................................................................................................16

References.....................................................................................................................................17

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List of table

1. 2.5. Selecting the best technology

2. 6.1. work plan / time schedule
3. 11.1.finacial requirment
List of figure

1. 1.1 mechanical operated lifting jack

2. 1.2 hydraulically operated lifting jack
3. 5.1 Design of mechanicaloperated gear box liftingjack
List of Abbreviation

1. RPM ......Revolution per minute

2. CATIA.... Computer aided three-dimensional interactive application
3. Etc …….already known
4. e.g …..Example
5. CAD ….design software

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1.Introduction

Often, a transmission has multiple gear ratios (or simply "gears") with the ability to
switch between them as the speed varies. This switching may be done manually (by the
operator) or automatically (by a control unit). Directional (forward and reverse) control may
also be provided. Single-ratio transmissions also exist, which simply change the speed and
torque (and sometimes direction) of motor output. Conventional gear/belt transmissions are
not the only mechanism for speed/torque adaptation. Alternative mechanisms include torque
converters and power transformation (e.g. diesel-electric transmission and hydraulic drive
system). Hybrid configurations also exist. Automatic transmissions use a valve body to shift
gears using fluid pressures in response to engine RPM, speed, and throttle input.

Often the term 5-speed transmission refers simply to the gearbox, that uses gears and
gear trains to provide speed and torque block conversions from a rotating power source to
another device.[1][2] The most common use is in motor vehicles, where the transmission
adapts the output of the internal combustion engine to the drive wheels. Such engines need to
operate at a relatively high rotational speed, which is inappropriate for starting, stopping, and
slower travel. In motor vehicles, the transmission generally is connected to the engine
crankshaft via a flywheel or clutch or fluid coupling, partly because internal combustion
engines cannot run below a particular speed. The output of the transmission is transmitted via
the driveshaft to one or more differentials, which drive the wheels. While a differential may
also provide gear reduction, its primary purpose is to permit the wheels at either end of an
axle to rotate at different speeds (essential to avoid wheel slippage on turns) as it changes the
direction of rotation.

Lifting jack are a device which lifts different device from the ground to the elevation of
some height. But our design is based on gear box lifting jack. Gear box lifting jack are a device
which lifts the gear box. Based on the operation this gear box is classified into two.

Those are:

 mechanical operated lifting jack

 hydraulically operated lifting jack

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 Mechanical operated lifting jack is a device work by a means of screw tread by driving by
the handle and this screw drives the lower coupling nut.in this device there is no any medium
that actuate during the proses.

Figure 1.1 mechanical operated lifting jack[3]

Hydraulically operated lifting jack are uses a liquid, which is incompressible, that is forced
into the cylinder by the pump plunger. Oil is used since it is self-lubricating and stable. When the
plunger pulls back, it draws out of the reservoir trough the suction check valve into the pump
chamber. When the plunger moves forward, it pushes the oil through the 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 in to
the cylinder. At this point the suction ball within the chamber is forced shut and oil pressure
builds in the cylinder.

Figure 1.2 hydraulically operated lifting jack[3]

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2. Value chain mapping and identifying the technology

2.1 Statement of the Problem

As we have noticed in our garages like Dre Dawa, most of th transmission maintenance service
is done by manual labor.

It is known that there are hydraulic lift jacks in our warehouse. Meanwhile, we cannot find them
easily in terms of cost. When they break down again, there is nothing convenient to repair and
restore easily. Especially, anyone who does not have knowledge about hydraulic lift jacks cannot
use them easily because once they start to open, they become difficult to control and pose a risk.

There are many problems in the shops of this country . Among this problems assembling and
disassembling of the gear box to and from the car is the major problem . Since the worker is
removing the gear box manually without the aid of any lifting system and technique. During this
process the workers hand and other body parts are in danger if the gear box is fail to their body
parts, since it is made of heavy and strong materials.The worker also lose the energy and time to
assemble and disassemble this gear box but by using this mechanical lifting jack the worker is
reduce such problem.

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 2.2 ASIS
Remove Disassembled Cleaning and Repairing installing on
Diagnosis the inspection
transmission the assemblin vehicle and checking
transmission
from vehicle transmission

Cleaning the
Driving test material
Disconect all Drain the Identity and Vehicle and
accessories transmission oil select repairing checked
all Visual Inspection part

Hearing sound
Remove Remove the Assembling Installing and
transmission transmission the connected all
bolt case cover transmission accessories

Remove
Remove Fill the oil
from vehicle
larger
man power
external part

Then start the

Remove small engin
part to gain
access

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 2.3 TO BE

Diagnosis the Remove Disassembled Cleaning and Repairing assemblin installing on Quality control
transmission transmission the inspection vehicle and
from vehicle transmission checking

Driving test Disconect Drain the Cleaning Identity and Vehicle and Check the
all transmission the select checked quality of
accessories oil material repairing services
all part against the
Hearing sound Keeping Assembling Installing standard
Remove Remove the
stethoscope transmission transmission orderly the and
bolt case cover transmission connected
using stand all
& sst tools accessories
Remove from Remove larger
vehicle lifting external part
Measuring the part Fill the oil
jack
using measuring
device
Tool card from engin z all Then start the
tool one place to other engin
place Visual
Inspection

Order as
remove

Disassemble
transitions
using sst

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 2.4 GAP

Diagnosis the Remove Disassembled Cleaning and Repairing installing on Quality control
transmission transmission from The inspection assemblin vehicle and
vehicle transmission checking

Hearing
Remove from Tool card from
sound Keeping Assembling Check the
vehicle lifting engin z all tool
stethoscop orderly the quality of
jack one place to
transmission services against
other place
using stand the standard
& sst tools

Disassemble Measuring
transitions the part
using sst using
measuring
device
Order as
remove

2.5 Selecting the best technology

Table 2.1 Selecting the best technology

Techno-ware Human-ware Info-ware Orgaware

Welding machine Skill gap of Documentation Different storage shops

Applying safety

Lethe machine Handling of Mentorship Working area layout

materials

Grinder Skill gap of Wastage disposal

Measurement method
device usage

Gear box lifting jack KAIZEN(5S)

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3.Rationale and description

A mechanical operated lifting jack is a device that uses lower manual force to lift heavy vehicle
transmission or gear box. It is used for lifting gear box and it facilitates the activities of workers
during assembling and disassembling of this gear box. By moving the handle of a small device,
an individual can lift a load weighing a specified load. A small initial force exerted on the handle
is transmitted to the screw and this screw transmits the manual force to the link and the gear box
is lifted up to the preferred height.

By manufacturing mechanically operated lift jack which is useful for saving extra man power
expended and as a result a single mechanic can perform his work task by the help of this jack.

The task of designing this project is to:

 Reduce risk
 Decrease loss of time and Minimizes number of persons and o Reducing labor forceThey will
lose much more time and their energy when loosening and fastening the transmission if they
don’t use this lifting jack.Generally, they should use this lifting jack to do their activity more
effectively & efficiently to be profitable.

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3.1Cost

Hydraulically lifting jack

-The cost is 27000 in the market of Now.

Mecanical lifting jack

 the cost of manual lifting jack 9,000 up to 15,000 that why we use theadvantage is cost and
durabilty ,strangth

3.2 Time

 Mechanical lifter jack is a material that we can easily find in the area, so it allows us to
finish our work in a short time.

3.3 Scope
It is known that there are different types of lifting jacks, and we intend to improve and solve
them up to the mechanical operating gear box lifting jack.
The scope of this project is restricted to the design and 3D modeling of mechanical operated
lifting jack by using solid work software

3.4 Quality

 Based on the strength of material we have learned, it has made us choose the material that
we have chosen in terms of weight bearing and quality.

4. Objectives of the technology

4.1generalobjective

 The general objective is to design the mechanical operated gear box lifting jack for heavy
duty vehicle.
4.2 Specific objective
The specific objective of the project is;

 To reduce human labor needed during disassembling of gear box

 To increase the efficiency of the company
 To increase work interest of company workers
. To increase the safety of workers

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 5. Methodology

5.1 Methods

Methods are the strategies processes or techniques utilized in the collection of data or
evidence for analysis in order to uncover new information or create better understanding of
atopic. This project performed various procedures to have final output.

Procedure of performing of project

Collecting information/data Literature review Material selection Prepare for work

Assemble lifter Jack

Install the component To be able to meet the separation

Check for functionality

 Methodology We use the following methodology to design this mechanically operated

transmission lift jack.
 Determinig the number of componts which are going to be bought and which are going to
be manufacture.
 Application of CATIA software for providing a detailed 2D and 3D drawingsmaterial
selection and simulation for the car jack.
 Manufacturing all needed componets at the workshop.
 Testing the project so is to check it

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 Design

Figure 5.1 mechanical operated lifting jack[5]

5.2. Material selection

The material selection is the major parameter for any design, since any property such as
mechanical property (malleability, ductility, strean, stress, elasticity, plasticity, etc. ), chemical
property (corrosion) are depend on the selected material i.e. the selected material must contain
the following characteristics[6]

Strength

 Durability
 match inability
 weld ability
 Corrosion resistance
 Availability of the material
 Suitability of the materials for the working conditions and
 The cost of the material
So to design our project we select the material called mild steel.since this material fulfills the
property that we have listed above relative to the other material.The available parameters for
mild steel are listed in the table below.

Used equipment - Bolt Handle, Nut,Caster, wheel ,Mild steel

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6.Work plan/time schedule

Table 6 1: Work plan/time schedule

September October November

N Tasks will be done W W W W W W W W W W W W
o 1 2 3 4 1 2 3 4 1 2 3 4
1 literature review and
Rawmaterialcollection
2 Based on the collected
raw
material selecting
appropriate material
and
starting work in the lab
3 Starting writing
document and
checking other
supplementary process
in the lab
4 Meeting and
communication
to adviser and other
lectures
5 Detail testing and the
quality of lifting jack
6 Data analysis and
report writing
7 Editing and correcting
of
errors
8 Final submission of
thesis to the
department
9 Presentation and
defense of the project

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7.Expected output

The result of this project shows that developmechanical operated gear box lifting jack

 Transfer to technology
 Increase the knowledge
 Study easy understand outcome
 Skill and confidence of trainees, the trainee
 Learning and increase ability to perform the system
 Functionality
 To reduce human labor needed during disassembling of gear box
 To increase the efficiency of the company
 To increase the safety of workers
 To increase work interest of company workers

8. Benefits and beneficiaries of the results

Economy:- Because mechanical operating lifter jacks are imported from foreign countries, it
eliminates the product that is imported at high cost

Student:- It makes it convenient for students to download components like Gearbox and learn
from anywhere while they are learning in the workshop.

Institute:- For the trainees who are trained in the institution, they will use it as a teaching
tool to create better things and improve tomorrow, and it will make the protest preferable.

9.Compatability of the project in addressing the competances

This project can be covering various topic or portions that are found in courses.

1. Bench work and basic workshop

2. Strength of material
3. Technical Drowning and 3D modeling CAD
4. Engineering material

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 5. Machine element
6. Auto motive under chassis operation and service one

10. Markebility of the technology

 Cost minimization
 Customer satisfactionsatisfaction
 From big to small, our project on automotive garages will be desirable because we have
designed them according to their capabilities and will reduce their time by half.

11.Financial requirments

Table 11.1 financial requirment

No Items Quantity Unit Total cost ( birr)

cost(birr)

1 Bolts 6 50 300

2 Nut 6 40 240

3 Steel 4 400 1600

4 Caster wheel 4 100 400

Service cost

Photo copy/print 2 3 240

total cost(birr) 2780

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References

[1] J. J. Uicker; G. R. Pennock; J. E. Shigley (2003). Theory of Machines and Mechanisms

(3rd ed.). New York: Oxford University Press. ISBN 9780195155983.

[2] B. Paul (1979). Kinematics and Dynamics of Planar Machinery. Prentice Hall.

[3] Different Types of Jacks | Metro Hydraulic". www.metrohydraulic.com. Archived from the original
on 2016-05-01. Retrieved 2016-02-05.

[4] [R. K. Bansal], [mar 25.2014]“Strength of materials 4th edition

[5] Cad portal. Retrieved July 7, 2017.SolidWorks2006OfficePremium(PDF).

[6] [R. K. Bansal], [mar 25.2014]“Strength of materials 4th edition

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