Manual Tyre Changer Machine

Project title (የፕሮጀክቱ ርዕስ)

Design and manufacturing of manual tire changer

Prepared By: - Kidane Hailu (Bsc. In Mechanical

engineering)

Submitted to: - ________________

Submitted date: - 24/05/2013

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 Manual Tyre Changer Machine

1. Introduction (መግቢያ)

A car travels by tire. The tire rotates easily, allowing the car to move. A tire is a consumable
product. It changes at the end of its term. The used tire separated from the wheel disc/rim and
replaced or repaired. It is very difficult to separate the tire from the wheel disc, so a tool or machine
is needed.

A variety of methods, from simple to heavy mechanism, have been developed around the
world. These can be divided into two parts. Traditional mechanism and modern mechanism.
Traditional mechanism use tools such as hammer, rods, and wedges.

Traditional mechanism are very tedious, labour-intensive, time-consuming mechanisms

that do not protect the safety of tires and wheels. If it does not keep the tire and the wheel safe, the
tire will not keep its balance. Modern mechanism save time, energy, and the safety of tires and
wheels. Various modern mechanism have been developed around the world. These include
mechanical, hydraulically and electrical. In most of our country, tire mechanic use traditional
mechanism. This is because it is cheaper. This is outdated. Very few use hydraulically mechanism.
Most tire mechanics use traditional mechanism for two reasons.

1. Because it is cheap and modern mechanism is expensive.

2. by not adapting to technology or by not following along with the technology.

In general, this project study focuses on a cheap, time-consuming and labour-intensive

mechanically operated machine.

I junior instructor in bole manufacturing college under automotive department, would like to
introduce or begin this simple manual machine to Ethiopia by proposing a project to design and
manufacture a manual tire changer machine.

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2. The basis of the study (የጥናቱ መሰረት/ተነሳሽነት)

In most of our country, gourmets/ tire mechanic use the old/ unfashionable tire replacement
method. This outdated tire replacement system is a waste of energy and time and does not
ensure the safety of the tire and the wheel. For example, the tools used to change the tire are a
hammer, wedge and rod. Modern tire replacement systems are expensive.

Therefore, in order to improve this backward method, it was necessary to develop a time
and energy saving tire replacement method. The backwardness of the tire changer method and
the cost of modern tire replacement systems is the basis of the study.

3. The significance of the study (የጥናቱ አስፈላጊነት)

Advantages of developing or studying a tire replacement system:-
 Developing the ability to work on projects
 Transfers technology at the facility
 benefits Manufacturer of small and micro enterprises
 Reduces time, energy and money of the gourds/gomista’s.
4. Objectives of the study and questions to be answered (የጥናቱ አላማዎችና ጥናቱ
የሚመልሳቸው ጥያቄዎች)

The overall purpose of the project is to solve the problems of the community. In particular, it
facilitates the difficult work of Gomista for the beneficiaries of the project.

 Design and make a tire changer machine.

 Manufacture of mechanical tire changer
5. Project goal

My goal is to design and manufacture a cost effective working model, using knowledge and
skills and facilities of our very own country.

6. Objectives
 To design and manufacture manual tire changer mechanism
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 Manual Tyre Changer Machine

 To introduce labour and cost effective technology.

 To develop technology transformation in the college.
7. Why a manual tire changer machine?

Tire changer Remove worn tires from rims and remount them quickly and easily. This
manual tire changer requires no power hookups or pneumatic lines to operate and is suitable
for all tires from 8 in. to light truck tires. The tire changer features all-steel construction for
durability and specially designed to protect inner tubes.

8. Feasibility(አዋጭነት)

By using the manual 'tire-changer' equipment/ machine, the above mentioned difficult
associated with conventional method of tire changing can be eliminated and the entire
vulcanizing job can be completed with an single person using a minimum of physical effort in
less time compared to the conventional/traditional manual method. So that Tire chinger
machine is feasible.

9. The scope of the study (የጥናቱ ስፋት)

This project includes the analysis method of the study, the materials required for the study, the
cost analysis, the total cost of the project, drawing, modelling, and manufacturing.

10.Litrature review (ተዛማጅ ፅሁፎች)

A tire change is a type of automatic and manual with capability of changing tire from the wheel
either by mechanical or by hydraulics. It had been in use since the invented of car and gone through
various modifications since then, to apply its unique features to a modern day maintenance and
servicing needs.

There are a number of 'tire-changer' equipment/ machines of different designs with different
capacities available all over the world. But in Ethiopia, there are a very few to manufacture the
'tire-changer' equipment/ machines. The manufacturer was only fabricating automatic 'tire changer'

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with electrically operated motors which are very costly. Due to high cost of 'tire-changer'
equipment, most of the self-employed vulcanizing shops /units are not able to afford the same.

The designing and adding modification to the tire changer will be carried out in such a way that it
will best suit the manintance and servicing of vehicle organization’s needs.

The 'tire - changer' is the equipment/ machine used for demounting and mounting of tire from
and / or on to the rim/ disc of wheel of light motor vehicles(LMVs) to carry out or replacement of
tire or tube. The usage of the 'tire changer' equipment in Ethiopia is not popular due to high cost
but it is used in most of the other countries.

The manual-mechanical 'tire-changer' equipment has been considered for the research which
is used for tire changing of light motor vehicles. The people who use 'tire-changer' are the retailers
of new tires, tire-retreading works, vulcanizing shops and servicing stations.

In the manual mechanical method of tire-changing, people use spanners/ chisel(s), hammer(s)
and a lot of man power for demounting and mounting of tires. But this job requiring a minimum
two workers and the physical effort required for the job is very high in the conventional method,
the edge of the tire (called 'bead') usually gets spoiled due to rough handling of spanner/chisel(s)
with repeated hammering.

The manual mechanical 'tire-changer' equipment is considered for the (redesign) research.

11.Methodology of the study (የጥናቱ ስልት)


12.Project/study analysis (የፕሮጀክት / ጥናቱ ትንተና)

Tyre-changing operation consists of three main stages.

1. The first stage is 'bead' breaking. The edge of the tire will adhere very tightly to the wheel
rim or disc and hard due to high tension pressure of air and heat produced while running
of the automobile. To remove or break the adherence b/n the edge of tire and wheel rim or

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disc it requires a lot of force. The method of application force is different with different
types of tire changer machines from manual-pneumatic to manual-mechanical types.
2. The second stage of operation is fixing the tyre rim or disc on the table. the tire is firmly
fixed on the table.
3. The third stage of operation is demounting or mounting of tyre from and or on to the wheel
disc/rim as necessary.
 Designing and main parts of Manual-Mechanical Tyre-changer machine
(1.) Table:- Function
 Table is used to provide support for tire.
 The table is in round shape. it is a 6 mm thickness plate. A flat is welded
along with the edge of the table for reinforcement.
 450 x 450 x 6 mm M.S plate is taken. Make a central hole of 50 mm
diameter and a slot by using gas welding.
 The table is welded on to the hallow pipe (column).
 The tire along with the disc/ rim is placed on the table for carrying out
demounting and mounting operation(s) after firmly fixing it with fixing
mechanism.
(2.) Base:- function
 Base is used for rigid (stable) fixing of the machine and this is fixed on the
ground with the help of nuts and bolts.
 The 'base' is in square shape with 450mm length and 6 mm thickness.
 A square plate (300 x 300 x 6 mm) is recommended for base with four
foundation bolts (1 2.5 cm dia x 10 cm length) at four corners.
 Another square plate (150 x 150 x 6 mm) is recommended for fixing column
with the base plate.
 A 300 x 300 x 6 mm size M.S. plate is taken.
 A central hole of 107 mm diameter is made by using gas welding and four 12.5
mm diameter holes are made at four corners of the base plate by using drilling
machine.

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 Column is inserted into the 107 mm hole. Another 150 x 150 x 6 mm M.S.
plate is welded to this column pipe for reinforcement. Again this plate along
with the column is welded with the main base plate of 300 x 300 x 6 mm size.
 The whole 'tire-changer' equipment is fixed with the help of four standard
foundation bolts (100 x 12 mm).
(3.) Column:- function
 A M.S. pipe of 107 outer diameter having a thickness of 6 mm and a length of
650 mm is taken.
(4.) Hand tool
 It is used for rotating by hooking the duckbill arm during demounting and
mounting operations of the tire from and/or on to the wheel disc/rim. Length =
530 mm and dia =10mm.
(5.) Cone:-
 A M.S pipe of 60 mm diameter, 80 mm length with 9 mm thickness is taken.
(6.) Edge Press:- (scissor jack rotated either by handle manually or by motor )
 It is used for 'bead' breaking of the tire from the rim/ disc of the wheel.
 A 200 x 50 x 10 mm size M.S plate is taken Bend this plate or make a curved
shape with radius of 186 mm manually.
 Finishing of the plate is done by grinding.
 A M S. rod of 12 mm diameter of 375 mm length is welded at the middle of the
plate and the other end a welded to the G.I. pipe of 25 mm diameter of 225 mm
length at a distance of 150 mm (horizontal) from column at a height of 460 mm
from the base with the help of bolt and nut.
(7.) Duckbill:- function

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 It is used to remove the edge of the tyre from the disc or rim.

The material for all parts is taken as mild steel (MS.).

The allowable stresses assumed for mild steel during design are as given below.
ft = 2450 kg/cm2 (Tensile stress)
fc = 2450 kg/cm2 (Compressive stress)
fs = 1470 kg/cm2 (Shear stress)
E = 2100 x l o 3kg/cm2 (Modulus of elasticity)

1. Table:- proposed dimension dia= 107mm, thickness=6mm, length(sq.)= 450mm

The maximum load, we may assume acting on the Table is 173 Kg, ie.

 Maximum technical parameter of tire, assumed

 tire size =21x8-9

 rim size =6.00-9
 tyre weight = 40 Kg,
 diameter = 538mm
 width = 204mm

 Weight of Cone and Central Pivot Rod (approximately) = 13 Kg.

 Load when tool is manually operated = 120 Kg
 (A healthy man can apply a torque of 120 Kg.)

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 The formula for thickness is taken as below for plates whose edges freely supported with
distributed load
3𝐹(3+µ
t =√8𝜋 𝑓𝑡/𝑓𝑠) (shigley, 1983)

3𝑥173 𝑥(3+0.3)
=√ 8𝑥𝜋𝑥2450 /8

= 0.472cm = 5mm
Where p = 0.3 for Mild Steel, F = load applied = 173 Kg,
fs = Factor of Safety = 8

The available market size is 6 mm plate Hence a 6 mm square plate of 450 x 450 mm is taken for
Table which also enhances strength to avoid bending, ribs are provided at four corners of the plate
under the table supporting with column to give extra strength.

2. Column: - Column is a M.S Pipe of 107 mm external diameter of 650 mm length (height).

The maximum load acting assumed is 173 kg. The following Euler's formula may be applied to
calculate internal diameter of the pipe (column).

cπ2EA
Critical load, Fa =
(𝑙⁄𝑘)2

Where C = Constant = 0.25 for the above condition

E = Modulus of Elasticity= 2100 x 103 kg/cm
A = Cross sectional area of the column (pipe)

L = length of the column = 650 cm

k = least radius of gyration of the cross section
Here Factor of Safety assumed for the load = 8
F = factor of safety x maximum load (acting) = 8 x 173 = 1384 kg

(Because AK2 = I, moment of Inertia)

I = AK2 = where do = outer diameter of column (pipe)

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= 10.70cm.
di = inner diameter of column (pipe)

Solving the above equation, we get d= 9.56 cm = 96 mm

Hence for the column, a M.S. pipe of 107 mm outer diameter and 96 mm Inner diameter is taken
The length of the column is 650 mm (height).

3. Hand tool: - Tool is an important part of the 'tire-changer' equipment which requires
careful attention. It consists of solid rod of 1015 mm total length. The diameter of the solid
rod is 25 mm.
13.Project out line

November December January February march

Information gathering and preparation

Force analysis and material selection

2D sketches and dimension

CAD design and drawing

3D model and simulation

Purchasing the selected components

Manufacturing and assembly

Testing and evaluation

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14.Parts list

Part name Components Material Number Dimensions joining

type

1. Cone Pipe Mild 1 Do = 60 mm, L= 80

steel(M.S) mm, t = 9 mm
flat 4
M.S

2. Table Plate M.S 1 450 x 450 x 6 welding

mm(LxWxt), central
flate M.S. 4 hole dia = 50 mm

3. Column 1 pipe M.S. Do = 107mm,t = 6

mm, di = 96mm

L = 650 mm

4. Base Plate M.s 2 300 x 300 x 6mm welding

(12.5cm dia x 10 cm
length)

central hole dia =

107 mm

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 Manual Tyre Changer Machine

5. Edge press Plate M.s 1 200 x 50 x 10 mm

manual/handler
pipe G.I 2 Curved at R=186mm

rod M.s 3 H = 460 mm from

the base

6. scissor 1 Welding
jack/toggle and
jack bolts

7. duckbill 1 bolts

8. column 2 pipe G.I 1 Do = 86mm, L = welding

20mm,t= 6mm

9. column 3 Pipe G.I 1 Do = 80mm, L = welding

20mm,t= 6mm

10. outer sleeve pipe G.I 3 Do = 60mm, L =

pipe 15mm, t=6

11. inner sleeve pipe G.I 3 Do = 54 mm, L =

pipe 15mm, t=6

12. Hand tool pipe G.I 1 L= 530 mm and dia

=10mm.
Rod M.s 2

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13. 12v DC wiper 1

motor

14. wire meter 5m

15. push switch 1

16. Metal piece 1

17. Bolts bolt M.s 10

18. Nuts nut M.s 10

15.Cost analysis

Cost estimation
Item no. Specifications Cost in birr

1. plates 20 kg @ Etb 18/per kg 360

6 kg @ Etb 16/per kg 96
2. flats

9 kg @ Etb 16/per kg 144

3. shafts

4 kg @ Etb 15/per kg 60
4. rods

2.5 ft @ Etb 100/per ft 250

5. M.S black pipe

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2.5m @ Etb 50/per m 125

6. G.I. pipe

0.5 ft @ Etb 100/per ft 50

7. M.S pipe

3 kg @ Etb 45/per kg 135

8. EN 24 shafts

9. Bolts and nuts 40

10. duckbill 150

11. wiper motor 250

12. push switch 50

13. wire 50

14. scissor /toggle jack 250

Material cost 2010

15. Machining 700

16. finishing 500

16.drawing
a. part drawing

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Methodology:

High temperature polymeric materials will be used in this project for filling up packages.

Prior to that, selected polymers will be characterized to check their suitability for the

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